Hi!
I require your help regarding a problem I’m encountering.
I am planing to create BLDC motor for a project i am planing.
I have some knowledge about BLDC design but i am wondering do i really have to concern about core saturation in Stator. I don’t need to have a good efficiency for my project but need to achieve maximum torque as possible.
can you please help me to understand about core saturation and effect , on motor performance?
I’m no motor designer, but I can offer a bit of information.
Core saturation is a bad thing.
Any core placed inside an inductance (other than air or vacuum) can saturate. In effect, it “fills up” with a magnetic field and can not hold any more. Most cores (not all!) are intended to INCREASE the inductance and make the field stronger. But if the core saturates, it no longer increases the inductance and it can not hold any more magnetic field. What happens then is the inductance drops to approximately the same as if there were no core (it “disappears”) which causes the current to rise much faster while the magnetic field climbs very little. That lower inductance / higher current will cause a rapid, excessive current draw from the control electronics and power supply, and excessive heating in the core and windings, possibly either burning out the windings or demagnetizing the permanent magnets. And, of course, wasted power and possible damage to the controller.
So, the short answer is, “YES” You need to consider core saturation."
EDIT: BTW, it’s easy enough to test for core saturation if you have an oscilloscope. Put a small (~1 ohm) resistor in series with the winding and put the scope probe across it. You are now measuring the current throguh the winding. Watch the waveform. It should be approximately a triangle wave and smooth. If at some point the current jumps rapidly that is the point of core saturation.
Thank you for your answer… I got a little bit of understand,I will search for more details about what you have mentioned. Thank you again 
