Why Brushless Motors Make Sense for Conveyors
Pressure Reactor,Stainless Steel Pressure Vessel,Stainless Steel Mixing Vessel,Tower Reactor Jiangsu Taigoo New Material Co. Ltd. , https://www.spun-castings.com
June 03 03:19:10, 2025
In today’s fast-paced industrial environment, conveyors play a vital role in moving materials, products, and goods across various sectors, including packaging, warehousing, and distribution. While different types of motors can be utilized for conveyor systems, this article will outline why brushless motors should be considered a top choice for conveyor applications.
Conveyors rely on different types of motors depending on their purpose and operational needs. For fixed-speed conveyors where space is not a concern, AC induction motors are often selected due to their affordability and ease of use. However, gearheads are frequently needed to reduce speed. Brushed and brushless motors can achieve this without gearheads.
Variable-speed conveyors, on the other hand, often require multiple speed settings. VFD-driven AC induction motors are commonly used in these scenarios. In contrast, brushless motors provide excellent speed regulation and take up less space, while servo motors deliver even higher performance. Indexing conveyors, which demand precise stopping points and holding torque, usually opt for stepper motors for their high stop accuracy. Servo motors might be considered in situations where heat generation and limited duty cycles could pose issues.
Brushless motors, however, can be employed across all conveyor types. They are particularly effective in start/stop conveyors where stop accuracy or holding torque is not a necessity. Moreover, they offer numerous advantages that make them an ideal fit for many conveyor applications at a competitive price point.
One compelling reason to choose brushless motors is their compactness and lightweight design. Compared to brushed motors, brushless motors are smaller because they don’t have brushes. Additionally, they are shorter than servo motors, thanks to the use of hall-effect sensor feedback rather than encoder feedback. These advantages are even more pronounced when comparing brushless motors to AC induction motors, which are the most widely used motors in conveyor applications.
Brushless motors can be made smaller than AC induction motors because they are more efficient, run cooler, and utilize permanent magnets. Their rotor consists of permanent magnets, while the stator uses electromagnets to generate rotation. This eliminates the energy losses associated with electromagnetic induction in AC motors.
A comparison between brushless and AC motors reveals significant differences in efficiency and size. Brushless motors operate more efficiently and consume less power, making them a greener alternative. The accompanying images illustrate the stark contrast in size between the two types of motors.
When compared to VFD-driven AC induction motors, brushless motors excel with their built-in closed-loop feedback and constant torque output. A brushless motor driver continuously monitors and adjusts the motor’s speed and torque based on feedback, ensuring consistent performance despite load fluctuations. In contrast, AC motors may experience inconsistent speed due to open-loop operation and load changes. The size and weight advantage of brushless motors are also noteworthy.
Compared to brushed DC motors, brushless motors are pricier as they require closed-loop feedback and a dedicated driver for winding commutation. Brushed motors use brushes and a commutator, so no driver is needed for commutation other than a variable voltage to control speed. Brushless motors are also more efficient, draw less power, and are smaller in size. Additionally, they eliminate the need for regular brush and commutator maintenance, a significant benefit.
When compared to servo motors, brushless motors provide a simpler solution in applications where servo motors might be oversized or over-engineered. Both brushless and servo motors share similar designs and operations, but brushless motors typically use hall-effect sensor feedback, simplifying the control method and drive circuitry. This simpler design helps keep costs down for conveyor applications that don’t require the highest speeds, tightest speed regulation, or the peak torque offered by servo motors. For less demanding conveyor applications, the decision between brushless and servo motors might hinge on the features offered by the driver.
Brushless motors are structurally similar to stepper motors, except one uses a radially magnetized rotor and the other an axially magnetized rotor. Power and phase excitation are provided by a dedicated driver, but that’s where the similarities end. The lower number of poles and lack of holding torque mean brushless motors don’t offer the same stop accuracy as stepper motors. Therefore, stepper motors are recommended for positioning applications with limited duty cycles, such as indexing conveyors, while brushless motors are better suited for continuous running variable-speed conveyors.
The table below summarizes the differences between AC motors, brushless motors, and servo motors. Additional speed control comparison information is available.
Here’s a video comparing the power consumption and CO2 emissions of a 6W AC induction motor versus a 30W brushless motor on a conveyor. The results are quite striking.
To further reduce its size, Oriental Motor’s latest brushless motors incorporate an optimized magnetic design with high-performance magnetic steel sheets and permanent magnets. Closed-loop speed regulation for Oriental Motor’s brushless motors is rated at ±0.2% for motors with hall-effect sensors and up to ±0.05% for motors with encoders. With a small overrun ranging from approximately ±0.1 to ±0.4 revolutions depending on RPM and load inertia, brushless motors can also handle some indexing conveyors. However, start/stop frequency and accuracy must be tested.
Oriental Motor’s brushless motors come in various frame sizes for wattages ranging from 30W to 400W, offering different AC-input driver options. Oversizing can be avoided without sacrificing performance. A variety of gear options are available for even the smallest frame sizes, ensuring proper sizing for any requirement.
Unlike other manufacturers who tend to maintain the same frame size and increase motor length, Oriental Motor offers multiple frame sizes for different wattages. This allows for more flexibility and optimal motor selection.
For single-axis, modular, low-profile conveyors with basic speed control requirements, the BMU Series brushless motor and its dedicated variable speed driver are recommended. The BMU Series is ideal for quick installation due to its compact size and user-friendly front digital panel. Easy wiring and speed setting make it perfect for these conveyors. The dedicated driver includes built-in functions such as load factor and speed limits.
For conveyors with advanced requirements, such as those in packaging and labeling, the BLE2 Series brushless motor and its dedicated variable speed driver are recommended. Up to 16 speeds can be set via the control panel, external potentiometer, external analog voltage, or MEXE02 data setting software. An HMI can output an analog voltage to control two drives simultaneously and send commands to each driver via I/O. The driver includes functions such as load factor, torque-limiting, and speed teaching.
Brushless motors offer high efficiency, a small footprint, and tight speed regulation, meeting the design requirements of compact variable-speed conveyors. While brushless motors offer many advantages over VFD-driven AC motors, they can also replace brushed DC motors and even servo motors in certain applications.
While brushless motor design is similar among many manufacturers, Oriental Motor’s brushless motors are offered in multiple frame sizes rather than longer stack lengths. Dedicated drivers guarantee motor performance and add enhanced capabilities such as speed teaching and torque limiting.
Avoid oversizing by contacting our team for a motor sizing consultation today to find the perfectly sized brushless motor and driver for your conveyors.
We know how engineers like charts. Here’s a comparison of our two most popular AC-input brushless motor systems. Feel free to reach out to our team for additional motor options tailored to meet specific application requirements, like battery compatibility or multi-axis network control.