This paper presents the cost reduction design of a brushless DC motor (BLDCM) considering twelve step control. The twelve step control can improve the output of the motor using the conventional six step control. Weight reduction can be effectively achieved by reducing rotor, stator and magnet through optimization of BLDCM using a response surface method (RSM). The BLDCM volume was decreased by about 45%, while satisfying basic performance requirements and improving efficiency. Original and optimized motors were built and tested. Experimental results are compared in terms of output power and efficiency.
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