How Brushless Motors Can Meet Today's Automation and Energy Saving Requirements

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The need for automation is accelerating, from production facilities to everyday life. Motors are indispensable for automation. Meanwhile, worldwide efforts to achieve carbon neutrality are in full swing, and there is a growing need for energy saving and high efficiency measures in various fields. Discover how compact, high-efficiency brushless permanent magnet (PM) motors can advance automation while supporting energy savings and carbon-neutrality goals.

What Are Brushless PM Motors?

Brushless PM motors are a type of DC motor that uses permanent magnets for their rotors. Since permanent magnets reduce efficiency losses and enable synchronous operation, brushless PM motors are ideal for variable speed applications, such as conveyors and mobile robots. Driving circuits , such as drivers or inverters, are necessary to control the motor's phase excitation based on their feedback. Therefore, their speed is regulated to a fraction of a percentage of set speed even with load fluctuations. They are characterized by high efficiency and are significantly smaller than AC induction motors of the same wattage, contributing to energy saving and resource saving.

Generally, brushless motors and PM motors are associated with large motors such as spindle motors and motors for car power units, but Oriental Motor offers products with intermediate sizes ranging from 15 W to 750 W. They are widely used in various automatic machines and production equipment because of its high speed stability due to the feedback control by the hall sensor mounted on the motor and the dedicated circuit (driver).

Market wattage positioning of OM brushless motors

History of Brushless Motor Development

Oriental Motor started developing brushless motors in the early 1980s. Initially, it was an outer rotor type with DC input, but AC input and inner rotor types were developed while responding to market demands. Since around 2000, it has become possible to control torque and position, and it has evolved to achieve performance comparable to servo motors. In recent years, both motors and drivers have become increasingly compact and are widely used to drive conveyors and transfer robots. We have always developed products that meet market needs and maintained a stable supply, and our products have been widely accepted in the market for many years.

Features of Brushless PM Motors

✅ Energy Saving and Resource Saving Design That Contributes to Carbon Neutrality

High Efficiency Equivalent to IE4^*

Compact and Lightweight Design

Brushless motors with built-in permanent magnets have higher efficiency than three-phase motors (induction motors). For example, the BMU Series 200 W has a motor/driver efficiency of 86 %, which exceeds the IE4 standard value of 75.8 % and meets the energy saving requirements.

*This efficiency class is specified by the international standard IEC 60034-30-1 and applies to induction motors of 120 W or more. The efficiency values in IE 4 are for 50 Hz, 4-pole machines at rated output power. The efficiency values for brushless motors are for rated torque at rated speed.

Brushless motors with built-in permanent magnets are slim and high-powered. For example, compared to a three-phase induction motor of frame size 90 mm, their total length is 84.6 mm shorter. This contributes to equipment downsizing and the use of fewer natural resources.

✅ Design and Manufacturing Features

Highly Efficient Design		Low Vibration and Low Noise

Copper loss and iron loss are reduced by winding a thick copper wire around the stator without any gaps and optimizing the material, thickness, and shape of the magnetic steel sheet.		The motor is designed to reduce the cogging torque that causes uneven rotation and ships with the rotor balanced and inspected. The driver achieves smooth operation by driving with a sine wave method. Motor parameters are reflected in the control for optimal operation.
High Reliability and Long Life		Watertight and Dust-Resistant

Longer life than before. In addition, some models that specialize in equipment integration use bearings with high heat resistance. Creep-resistant structure with rubber parts (O-rings) inserted around the outer circumference of the bearing to resist eccentric loads is also incorporated. The dedicated gearhead is also highly strong and can be used for a long time with a rated life of 10000 hours^1. 1 Depends on the type and output of the gearhead		Watertight and dust-resistant types that are resistant to water and dusty environments are also available. Sealing parts prevent water from entering inside the motor and it is IP67-compliant, including the connector part. Stainless steel material is used for the output shaft and screws, and a special coating is applied to the entire surface to prevent rusting.

✅ Global Safety Standards

Products are available in voltage specifications of single-phase 100 VAC/200 VAC system, three-phase 200 VAC system and DC input, allowing use in major countries around the world. Each Series is UL/CSA Standards certified, EN Standards compliant, and has the CE Marking.

What Can Brushless PM Motors Be Used For?

Oriental Motor's brushless motors have many advantages, such as speed stability, small size, high output, low noise, and less heat. They have been employed in a wide range of applications where these characteristics can be utilized. In addition, replacing AC motors with high efficiency brushless motors will reduce CO₂emissions, save energy, and save resources.

Here are some actual adoption results along with the main reasons why they were adopted.

AGV/AMR/Mobile Robots	Medical Inspection and Analysis Equipment

Battery-Powered Stable During Both High and Low Speeds Low Heat Generation Even With 24-Hour Operation CANopen Compatible (BLV Series R type)	Low Vibration With Smooth Startup and Shutdown Contributes to the Improved Specifications of the Equipment Low Noise and Improved Equipment Quietness Global Compatibility in One Model
Pumps	Security Gates/Automatic Doors

Longer Equipment Life Due to the Use of High-Temperature Resistant Bearings Anti-creep Structure Withstands Applications Prone to Eccentric Loads Low Heat Generation Prevents Specimen Alteration	Compact Design That Fits Inside the Enclosure Fast and Smooth Opening and Closing is Possible Stable Speed Even With Load Fluctuations Due to Wind
Sushi Making Robots	Agitators

Utilizing the Torque Limiting Function Allows for Delicate Force Adjustment Compact and Lightweight Equipment Achieved Global Compatibility in One Model	Stable Speed Even With Load Fluctuations Continuous Operation is Possible With Low Heat Generation Fewer Failures Than Conventional Models Due to the Anti-creep Structure