Brushless DC motors are truly impressive, and there's a solid reason to believe they're one of the most advanced motor technologies available. They offer higher efficiency, greater power output, and improved torque, while simultaneously reducing noise, electromagnetic interference (EMI), and vibration. Additionally, they extend battery life, reduce motor wear, allow for faster speeds, and deliver more reliable performance. These advantages make them not only functional but also fun to work with—bringing joy, excitement, and even new friends into the mix. This list has inspired me to dream bigger and push further, as shown in Figure 1. But of course, results may vary.
Figure 1: Brushless DC: Supporters of Hope and Dreams
What makes brushless DC motor drives so fascinating is the flexibility of their control algorithms. You can choose between sensor-based or sensorless operation, trapezoidal or sinusoidal control, and even field-oriented control (FOC) or simple commutation. The options are almost endless—like how many ways you can cook an egg—but in reality, only a few methods are fundamentally different. Others just tweak the same core idea. However, I won’t dive into that right now. Instead, I want to focus on "Step Zero"—designing the hardware for your motor drive system. At this point, it’s easy to walk away. Figure 2 captures my perspective on this stage.
Figure 2: Comfort decreases linearly with voltage levels and analog content
For those who stayed, many brushless DC motor systems are built with high power and efficiency in mind. That usually means using a discrete MOSFET controlled by a microcontroller (MCU). Before you can test the most advanced speed loop algorithm, you’re essentially connecting the MCU’s intelligence to the raw current-driving capability of the MOSFET. The gate driver acts as a bridge between the MCU’s logic domain and the MOSFET and motor’s power domain. There are two main architectures for this: discrete gate drivers and integrated gate drivers. Each has its own set of pros and cons. Discrete drivers offer the highest voltage support and best performance, but require more components and lack built-in protection. Integrated drivers provide a more compact, tailored solution but don't match the performance of discrete options in high-voltage applications. Some integrated drivers, like the DRV8320, go beyond basic functionality by including features such as gate drive power, sense amplifiers, power devices, and even integrated gate drive passives. If you skipped the earlier part, take a look at Table 1 below.
Table 1: Discrete vs. Integrated Gate Drivers – the details here are even more comprehensive than the previous explanation!
In Part 2 of this series, I’ll build and demonstrate the schematic and layout differences between discrete and integrated gate drivers, testing my skills in circuit design and PCB layout. Stay tuned!
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