There's no denying that brushless DC motors are among the most impressive innovations in motor technology. They offer superior efficiency, power, and torque, while significantly reducing noise, electromagnetic interference (EMI), and vibration. Additionally, they extend battery life, improve motor longevity, allow for higher speeds, and deliver a more refined performance. These benefits make them not only functional but also exciting—offering users a sense of innovation, fun, and even a bit of admiration from others. This list has made me increasingly hopeful and inspired, almost like I'm on the path to achieving my dreams (see Figure 1). But of course, results may vary.
Figure 1: Brushless DC: Supporters of Hope and Dreams
What makes brushless DC motor drives truly engaging is the variety of control algorithms you can implement. Whether it’s sensor-based or sensorless, trapezoidal or sinusoidal control, or even field-oriented control (FOC), there are countless options—like how many ways you can cook an egg. In reality, though, only about ten are truly distinct, with others just being minor variations. But I won’t dive into those details right now. Instead, I want to focus on “Step Zeroâ€â€”designing the hardware for your motor drive system. At this point, you can still walk away. Figure 2 captures my perspective on this process.
Figure 2: Comfort decreases linearly with voltage levels and analog content
For those who stayed with me, many brushless DC motor systems are designed with high power and efficiency in mind. That usually means using discrete MOSFETs controlled by a microcontroller (MCU) through a gate driver. Before you even test out 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 the bridge between the MCU’s logic domain and the power domain of the MOSFET and the motor. There are two main architectures for this: discrete gate drivers and integrated gate drivers. Each has its own set of advantages and trade-offs. Discrete solutions offer the highest voltage support and optimal performance, but require more components and often lack built-in protection. Integrated solutions, like the DRV8320, provide a more compact and tailored approach, with added features such as gate drive power, sense amplifiers, and integrated passives. If you skipped earlier sections, take a look at Table 1 below.
Table 1: Discrete gate drivers and integrated gate drivers; the table provides more detailed insights than the paragraph!
In Part 2 of this series, I’ll go deeper by creating and demonstrating the schematic and layout differences between discrete and integrated gate drivers, showing how each affects the overall design and performance. Stay tuned for a hands-on look at real-world implementation challenges and solutions.
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