Gearhead Selection for Brushless Motors
Wenzhou Huaze Machinery Co.,Ltd , https://www.multihz.com
June 06 05:11:47, 2025
Gearheads are essential components in optimizing motor performance. They come in various types, each offering unique features and characteristics. The gear ratio not only multiplies torque but also reduces the motor's speed accordingly. By carefully choosing the right gear type and ratio, engineers can tailor the motor’s performance to meet specific application needs.
When a gearhead is attached to a motor, it transforms the motor into what is known as a gear motor. The gearhead housing contains a series of gears that increase torque while simultaneously decreasing the motor's speed proportionally. This setup allows the gearhead to provide mechanical support to the motor's output shaft, which connects directly to the load.
Compared to belt-and-pulley systems, gearheads offer superior rigidity and can fit more gears within a smaller footprint. This makes them ideal for applications requiring precise speed control and efficient torque transfer.
In this article, I’ll discuss the different types of gearheads available for brushless gear motors and guide you through the selection process.
### Topics Covered:
- Introduction to Brushless Motors
- Gear Selection for Brushless Motors
- Motor Sizing Example - Belt Conveyor
- Summary
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### **Introduction to Brushless Motors**
Brushless motors are a type of DC motor designed for continuous operation. Unlike traditional motors, they use electronic controllers instead of brushes to switch current direction. This design provides several advantages:
#### High-Speed Stability
Brushless motors maintain consistent speed even under varying loads thanks to closed-loop speed regulation. Hall-effect sensors or encoders monitor and adjust motor speed, ensuring fluctuations remain minimal—typically within ±0.2%. Motors equipped with encoders can achieve even tighter control, with fluctuations as low as ±0.05%.
This level of precision is particularly beneficial for applications like conveyor belts, where maintaining synchronized speeds is critical.
#### Space-Saving Design
Brushless motors are compact and lightweight, making them perfect for applications where space is limited. For instance, a brushless motor of equivalent power to an AC induction motor is 62% shorter and weighs 62% less. This reduction in size and weight is especially advantageous in mobile robotics and automated guided vehicles (AGVs).
#### Energy Efficiency
Brushless motors operate with significantly lower losses compared to AC induction motors. Permanent magnets in the rotor eliminate secondary losses, leading to energy savings of up to 66%. At an output power of 1/6 HP (90 W), the BMU Series brushless motor consumes 26% less energy than a VFD-controlled AC motor.
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### **Gear Selection for Brushless Motors**
When pairing a gearhead with a brushless motor, consider factors such as noise levels, permissible torque, and expected lifespan. Our product line includes parallel shaft gearheads (GFS, JV, JB), parallel shaft gearheads with centered output shaft (CS), hollow shaft right-angle gearheads (JH), and hollow shaft flat gearheads (FR).
Each type offers distinct benefits:
- **Parallel Shaft Gearheads**: Provide robust performance with high torque density.
- **Centered Output Shaft Gearheads**: Ideal for applications requiring precise alignment.
- **Right-Angle Gearheads**: Useful for compact designs where space is constrained.
- **Flat Gearheads**: Offer versatility in mounting configurations.
When selecting a gearhead, always verify the rotation direction, as some models reverse shaft rotation depending on the gear ratio.
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### **Motor Sizing Example: Belt Conveyor**
Let’s consider a typical belt conveyor application. To calculate the required motor and gearhead combination:
1. Determine the conveyor’s load capacity and desired speed.
2. Calculate the necessary torque based on friction coefficients and load distribution.
3. Select a brushless motor capable of delivering the required torque at the target speed.
4. Choose a compatible gearhead to match the motor's output to the conveyor’s requirements.
For instance, if the conveyor requires 10 Nm of torque at 30 RPM, a GFS gearhead with a 10:1 ratio paired with a BMU motor would suffice.
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### **Conclusion**
Brushless motors and their associated gearheads represent a powerful combination for modern industrial applications. By understanding the nuances of gear selection and motor sizing, engineers can build systems that are both efficient and reliable. Whether you’re designing a conveyor system or automating an AGV, brushless motors paired with the right gearhead can deliver exceptional performance tailored to your needs.
Feel free to reach out if you need further guidance or assistance with your specific application!