AC induction motors are the workhorses that power many types of conveyors to transport materials. However, there's a smaller but mightier type of motor that can help enhance the design and performance of conveyors for many industries.
What's covered?
Benefits of Brushless DC "BLDC" Motors
AC induction motors uses AC power and generate its rotating magnetic field differently than brushless DC motors and thus offer different characteristics in speed, torque, stop accuracy, and efficiency. These differences in characteristics result in several advantages for brushless DC motors.
Read on as we explain exactly how these differences in characteristics apply to different conveyors.
Due to higher efficiency, brushless DC motors can be much smaller than AC induction motors. In the same 90 mm frame size, a 120 W brushless DC motor can be 62% shorter in length than a 90 W AC induction motor.
AC induction motors typically run without closed-loop feedback, so their speed can be up to 20% slower as the load increases until it exceeds the pull-out speed torque curve. With inverters or VFDs, the speed regulation is improved to 10% (reference value). Brushless DC motors require closed-loop feedback from encoders or hall-effect sensors to work, so they offer higher speed stability at +/-0.2% even under changing load conditions.
With its high efficiency characteristics, brushless DC motors consume 26% less power (42 W vs 31 W) and output more watts of power. Brushless DC motors also help release less carbon dioxide to the atmostphere to help with carbon neutrality. For more efficiency comparisons, please watch the video below.
Watertight, dust-resistant motors with IP67 rating and optional H1 food-grade grease can be suitable for applications that come into contact with food. Read this case study to learn how a vegetable producer used brushless DC motors to improve production effciency and reduce costs.
So...what does this mean for conveyors? Let us explain.
👍 Save Space and Reduce Weight
Application Example: Belt Conveyor
Challenge: Accommodate limited installation space, minimize the protrusion on the side of the conveyor
By replacing a parallel shaft AC induction gear motor with a right-angle brushless DC gear motor, the overall protrusion on the side of the conveyor is reduced by 123 mm.
Application Example: Chain Conveyor
Challenge: Heavy motors make it difficult to assemble and maintain a conveyor.
For maintenance and replacements, it's much easier to handle a 4.2 kg (9.26 lbs) brushless DC gear motor than an 8 kg (17.64 lbs) AC induction gear motor. That's almost half the weight.
Application Example: Integrating a Belt Conveyor into Smaller Equipment
Challenge: Fitting a belt conveyor inside a small space
With brushless DC gear motors, the belt conveyor has less protrusion and takes up less space than AC induction gear motors (even with parallel shaft gearhead). In the example below, the conveyor protrusion is reduced by 43 mm.
👍 Stabilize the Speed
Application Example: Side Conveyor
Challenge: Varying speeds between the left and right conveyor belts lead to inconsistent positioning of prints and labels
Since AC motor speed can be affected by load fluctuations, the speeds of the two belts on a dual belt pinch conveyor can vary, which causes the bottle labels to be oriented in different positions. This can create inconsistency in printing and labeling.
Application Example: Belt Conveyorr and Connecting Conveyance
Challenge: Speed discrepancies in the delivery section caused by changes in load disrupt the flow of parts
Since AC induction motor speed varies by fluctuations in load, speed discrepancies can be created where the speeds of different belt conveyors do not match. This can cause disruption in the flow of the parts on the belt.
Future-Proof Your Conveyor Systems with Advanced Motor Technology
Upgrading to brushless DC motors enhances conveyor efficiency, reliability, and adaptability. Whether you need a more compact design, precise speed control, or energy savings, BLDC motors provide the cutting-edge solution for modern material handling challenges.
Interested in upgrading your AC induction motors and VFD? Our helpful team of technical support engineers can help you find the most suitable solution for your application.
New Product: BLS Series
|
*750 W type coming soon in 2025. For 200 W (1/4 HP) and 400 W (1/2 HP) types, please see BMU Series, BLE2 Series, BLE Series, BX2 Series, or BLV Series R Type.