Brushless Motors (BLDC Motors)

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How Do Brushless DC Motors Function?

A BLDC motor is a synchronous, electronically commutated motor that has a stator winding fitted with electromagnets and a series of magnets attached to the motor rotor. Brushless dc motors offer longevity and low maintenance since there are no brushes within the internal construction. The lack of brushes means low acoustic noise as well as electrical noise and with an overall robust design.

A brushless motor or bldc gear motor is controlled by a motor driver or electronic controller that allows them to provide precise rotation control of motor positioning, while delivering optimal motor speed and maximum torque. A brushless dc electric motor typically comes equipped with hall-effect sensors or an internal motor driver (sensorless BLDC motor). The accurate control of a ISL bldc motor results in reduced power consumption and less heat generation, creating a more efficient solution. In some cases, you may request to have a parallel shaft added to the rear of the motor for an added electromechanical brake or encoder. If you have any questions regarding motor speed controllers, please contact our engineering team. We have standard controllers designed for three-phase motors. Custom options are available as well, upon request.

Working Principle of BLDC Motor

A Brushless DC Gear Motor Provides More Torque

For increased output torque capabilities, consider using gearmotors. A brushless gear motor can be the perfect solution to your next project. Due to the high power and permissible torque of our brushless dc gear motors, we typically use planetary gearboxes. Our gearboxes are constructed with either ball bearings or sintered bearings. You can find an ISL planetary gear motor being utilized in all sorts of industrial and medical applications. A spur gear motor is another available option, but we typically only recommend those for lower torque applications. Let our engineers know your output torque requirements and we will provide a suitable gear reducer for continuous operations.

Compact Design

A small brushless DC motor is significantly more powerful now than one made 10 or 15 years ago. This is due to improvements in manufacturing techniques as well as improvements in electronic motion control circuits. These circuits and controllers can now drive a small brushless DC motor more efficiently and at higher speeds than were previously thought possible. This has lead to an increase in their use, as they take over roles traditionally reserved for brushed motors and AC motors, such as the drive motors inside mobile robots.

As BLDC motor integration moves forward, engineers are utilizing small brushless DC motors in more applications that ever thought before. It is obvious that these motors work great in robotic applications, but you may be more surprised to learn that they are also great for industrial applications like mixing fluids and powders.

The average small brushless DC motor or brushless gear motor is fully enclosed, unlike brushed motors that can have vent holes for cooling purposes. Since brushless motors produces less heat and have no wearing materials they can be completely closed, dissipating heat through the casing of the motor. This also means that a brushless gear motor produces no waste or “brush dust”, making them ideal for clean room applications. In fact, one of the first major adopters of brushless motors were PC manufacturers who demanded cleanliness for enclosed computers. Flat motors were used in hard drives for many years.

When compared to a standard electric dc motor, liked the brushed motor counterpart, brushless motors will have more than double the service life, depending on the duty cycle.

Specific types of motors that fall into the BLDC family are Stepper motors, 3-phase motors and 2-pole brushless direct current motors. ISL Products continues to be a leading manufacturer in the brushless dc motor market. Our team of engineers can assist at any stage in your design process. If your looking for a simple controller, we have BLDC motor controllers available. We also offer coreless or slotless motors in a brushless motor construction.

As leaders in dc motor solutions, we are able to offer stable lead times. By coordinating our customers production schedules with our manufacturing facility, we are able to provide fully integrated logistical support.