Designing Smaller and Lighter Equipment by Using Brushless Motors

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As the demand for energy-efficient solutions continues to grow, the adoption of brushless motors is becoming increasingly popular. Replacing traditional AC motors with brushless ones presents several key benefits, especially in terms of enhancing the design of lightweight and compact equipment. Brushless motors are far more power-efficient than AC induction motors, meaning a smaller brushless motor can perform the same tasks as a larger AC motor. This efficiency advantage makes brushless motors an essential consideration during the motor selection process for new designs.

One of the most compelling applications of brushless motors is in conveyor systems. Consider a typical grip conveyor with two belts on either side, each driven by an AC induction motor. While AC motors are reliable, they are less efficient in terms of power-to-torque conversion. This inefficiency requires the use of larger and heavier motors, which can pose significant challenges during installation and handling.

Challenge: Reducing Conveyor Mass for Easier Handling and Installation

Conventional Equipment: A grip conveyor with two AC gear motors driving belts on both sides. Typically, an inverter (VFD) is used for speed control.

Problems with Conventional Equipment:

  • Bulkier AC motors are cumbersome to handle and install.
  • Additional support frames are often required.
  • The use of two motors significantly increases the overall motor mass.

Solution: BMU Series Brushless Gear Motor + AC Input Driver

The solution lies in replacing the AC motors with the compact and highly efficient BMU Series brushless gear motors. These motors are designed to minimize size and weight, reducing the protrusion of the motors above the conveyor and making the system easier to manage. By opting for brushless motors, we eliminate the need for a support frame, which can add unnecessary weight and cost to the system.

Grip conveyor with BLDC motors Advantages of the BMU Series:

  • Higher efficiency compared to AC motors.
  • Smaller and lighter motors for easier handling.
  • Simpler installation and maintenance processes.
  • Compatible with the same input voltage for the driver.
  • IP66-rated motors for enhanced durability.

  Oriental Motor AC Induction Motor BMU Series
Output Power 90 W (1/8 HP) 60 W (1/12 HP)
Frame Size â–¡ 90 mm (3.54") â–¡ 80 mm (3.15")
Gear Type Parallel Shaft Parallel Shaft
Gear Ratio 9:1 30:1
Permissible Torque 4.2 N·m (37 lb-in) 5.2 N·m (46 lb-in)
Mass 4.7 kg (10 lbs) 1.4 kg (3 lbs)

Result: The total mass was reduced by 6.6 kg (3.3 kg per unit), significantly simplifying the handling and installation process.

Feedback control in brushless motors provides superior speed regulation compared to AC induction motors. Stay tuned for the next post, where we will explore how to synchronize the speeds of the two belts effectively.

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