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Designing Smaller and Lighter Equipment by Using Brushless Motors
With the increasing popularity of efficient brushless motors, replacing traditional AC motors offers numerous benefits. In this blog post, we'll explore one key advantage: the ability to create lighter and more compact equipment. Brushless motors are significantly more power-efficient than AC induction motors, meaning a smaller brushless motor can perform the same task as a larger AC motor. As efficiency becomes a top priority in modern design, it's essential to consider brushless motors during the selection process.
An excellent example of this is a grip conveyor system that uses two AC induction motors to drive belts on either side. However, AC motors aren't the most efficient when it comes to converting power into torque. This inefficiency often requires larger and heavier motors than necessary.
**CHALLENGE:**
Reduce conveyor mass for easier handling and installation.
Conventional setup: A grip conveyor with two belts driven by two AC gear motors. An inverter (VFD) is typically used for speed control.
**Problems with Conventional Equipment:**
- Larger AC motors are bulky and heavy, making them difficult to handle and install.
- Additional support frames are often required.
- The use of two motors increases the overall weight significantly.
**SOLUTION:** BMU Series brushless gear motor + AC input driver
By replacing the AC motors with the compact and high-performance BMU Series brushless gear motor, we can reduce both the size and weight of the conveyor. A heavier motor would require extra support structures, which add to the cost and complexity of the system. With the BMU Series, the motor protrusion is minimized, and the overall weight is significantly reduced.
[Image: Grip conveyor with BLDC motors]
Using the BMU Series brushless motor and AC input driver provides several advantages:
- More efficient than AC motors
- Lighter and more compact design
- Easier installation and maintenance
- Compatible with the same input voltage
- IP66 rating for the motor and quick disconnect cable
Here's a comparison between the Oriental Motor AC Induction Motor and the BMU Series:
| Feature | Oriental Motor AC Induction Motor | BMU Series |
|----------------------|-----------------------------------|--------------------|
| Output Power | 90 W (1/8 HP) | 60 W (1/12 HP) |
| Frame Size | 90 mm (3.54") | 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)**, making the conveyor much easier to handle and install.
Watch how easy it is to operate a BMU Series brushless motor and driver.
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Brushless motors also provide better speed regulation due to their feedback control system. In our next post, we’ll show you how to synchronize the speeds of the two belts for optimal performance.