Design and Conversion of a BLDC Motor to a Variable Reluctance Stepper Motor

This paper presents the conversion of a conventional Brushless DC (BLDC) motor into a Variable Reluctance Stepper Motor (VRSM) aimed at reducing reliance on rare-earth permanent magnets while lowering manufacturing cost and improving robustness. The proposed approach is particularly suited for electric vehicle (EV) and industrial drive applications where reliability and ease of maintenance are critical. The conversion process involves redesigning the stator and rotor geometry, performing detailed winding calculations, and fabricating the motor using laminated silicon steel. Electromagnetic performance, including flux distribution, torque characteristics, and thermal behavior, was evaluated using ANSYS Maxwell and RMxprt. A dedicated drive system was developed employing an Arduino Uno micro- controller and IR2110 gate drive integrated circuits to achieve appropriate phase excitation, sequential switching, and speed control. The experimental validation of the prototype confirmed that the design performed reliably under standard operating conditions. These results demonstrate that the proposed VRSM is a fully functional and effective alternative to conventional BLDC motors. By eliminating the need for rare-earth materials, it provides a dependable, low-cost solution perfectly suited for light electric vehicles and industrial applications.