This paper describes the concept of a multilayer brushless DC motor which is suitable for use on unmanned aerial vehicles (UAVs) and capable of carrying a heavy payload. The paper deals with a unique multilayer structure, using three standard stators placed in parallel with a single rotor body, to increase the torque even under low-speed conditions. In this solution, nine inner windings can use different star/delta interconnections to optimize the performance of the BLDC motor on demand. The proposed multilayer BLDC motor solution utilizes the main advantages of BLDC motors, ensuring highly reliable operation, and thus enabling a BLDC motor to be applied to UAVs. This paper gives an overview of the design, assumes an extension with an electronic inner winding switching capability, and provides practical details about realization, testing, and experimental verification. Practical measurements and obtained data are utilized to confirm the approach.

Nowadays, one of the most promising areas in the motor industry is the production of BLDC motors, which are used in a wide range of applications and products—from power tools to electrical vehicles. The windings of BLDC motors are connected according to the Delta or Star circuits. However, such circuits (Delta or Star) do not allow dynamically changing the parameters of the BLDC motor during operation and thus reducing the overall motor efficiency. This paper deals with and proposes an electronic switch of the BLDC motor windings, which brings an advantage in having a capability of dynamically switching the windings during operation and thus increasing the efficiency of the BLDC motor performance.