Industrial Application of Brushless Motors

Brushless motors are some of the most preferred motors for different industrial applications because of their high energy efficiency.  Since they do not have brushes that have to rub against anything, little energy is lost and can run on your batteries for up to 50% longer than standard models. They rely on a dedicated driver circuit that helps to monitor feedback from the motor and further employ transistors to excite stator poles to move the rotor. If you have an industrial facility or are planning to start one, here are the main applications to consider for brushless motors. 

What are Brushless Motors?

Brushless motors operate on the same principle of magnetic repulsion and attraction that is used in brushed motors, but the magnetic field of the stator is moved by electronic commutation. They are designed with permanent magnets, while the stator comes with windings (phases). While they can be designed with varying types of windings (phases), the commonest is the three-phase brushless motor. The windings are usually connected in either “delta” or “star (wye)” configuration, as shown below: 

Industrial Application of Brushless Motors 

Now that you know how brushless motors work, here are the common industrial applications: 

• Industrial Automation and Robotics

Removing the brushes in a brushless motor does more than cutting down the noise. In addition, it makes it possible for motors to handle more peak current and rotate faster compared to that of average speeds. This means that the brushless motors are able to do the same task as brushed models but faster. The increased speed plus less risk of sparking makes them a perfect pick for industrial automation applications. This is why they are the preferred motors for the service robots, battle bots, prosthetic limbs, and rovers. When thinking of automation, make sure also to buy and install programmable logic controllers.

• Manufacturing 

In performance-driven businesses, brushless motors are used for building and running next-generation machines. Because they can run for a longer period, up to ten years, without requiring upkeep, they are preferred for applications such as actuation systems, motor control and positioning for manufacturing fields. Other applications that use brushless motors include power generation, steel production, HVAC systems, and machining tools.  

• Marine Applications 

One of the main applications of brushless motors in marine–related industries is in drones. Notably, the original drone modes were heavy, large, and expensive. The adoption of brushless motors made it easier to make lighter and more effective drones that can be used with greater efficiency. For example, drones with IP rating of, say 66 or more, can be used to safely run underwater, making it possible to power diver propulsion vehicles, tank cleaners, and jet skis. 

How to Select a Good Brushless Motor for Industrial Operations 

Once you understand the main industrial applications of brushless motors, the next question is: “How do you select the right one for your facility?”. Here are some useful tips to consider: 

• Understand where the brushless motor will be used. Are you planning to buy a brushless motor to use in material handling equipment, machining tools or drones?
• Motor size: Brushless motors are named based on their sizes, and you should determine the preferred one well before placing your order. Common sizes are 1806, 2205, and 2207.
• Motor Speed and revolution per minute rating: The speed of the motor you select should be in line with the recommended rating of the equipment under consideration. 
• Arc magnets: The arc gap between the permanent magnets fixed on the stator is crucial in determining the motor power. Consider going for the brushless motor that has a very small space, preferably less 1mm, for better performance. 

As you can see, brushless motors have many applications in industrial settings. Remember to start by selecting the brushless motor based on the rating of your machine or application. In addition, you need to maintain your equipment and entire facility in top condition for better performance of brushless motors.