Brushless Motors (BLDC Motors)

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Why choose ISL for your brushless dc motor needs?

BLDC motors have come a long way in the last 15 years. Today, they are suitable for many different fields and uses. However, that does not mean every motor is created equally.

ISL has decades of experience designing and manufacturing electronic component solutions. We continue to improve capabilities with our unique, value-added brushless DC and brushless gear motors.

Our ability to expertly optimize various aspects of our motors means you can get a solution based on your specific requirements at a very competitive cost. If your looking for a simple controller, we have BLDC motor controllers available.

BLDC Motor Controllers

It’s not just our expertise you’ll enjoy, you also get stable lead times when you choose to use ISL components. We carefully coordinate with our customer’s production schedule and manufacturing facilities to ensure you get fully integrated logistical support. You’ll never be left in the dark with ISL.

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 permanent magnets attached to the motor rotor. These types of 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.

Most of these motors are equipped with a simple hall-effect sensor, which determines the rotor position. Alternatively, they may be sensorless. A brushless motor that is sensorless typically infers the rotor position by measuring the back-EMF (electromotive force) in the undriven stator coils.

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. 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 Principles of a BLDC Motor

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 bldc 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. Read our intuitive design note to learn how small gear motors operate.

High Power in a 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 motor more efficiently and at higher speeds than were previously thought possible. This has led 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 motors in more applications than 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 motor or brushless gear motor is fully enclosed, unlike brushed motors that can have vent holes for cooling purposes. Since brushless motors produce 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, like the brushed motor counterpart, they will have more than double the service life, depending on the duty cycle.

Types of BLDC Motors

Brushless DC motors can be classified by design, such as inrunner or outrunner rotor models. Other specific types of motors that fall within the BLDC family would be a Stepper motor or a three-phase BLDC motor.

Stepper motors are synchronous brushless DC motors which utilize digital input and output for precise motion control. This type of motor is most widely selected for its superb speed control, repeatable movements, and precision. Hybrid stepper motors will come in a variety of NEMA sizes and various step angles.

Meanwhile, the multi-pole BLDC motors have low current consumption and are suitable for use in a wide range of applications. Depending on the internal design, a motor can have anywhere from two to eight or more poles. The amount of poles in the windings are what dictates the motors output speed. The more poles, the slower the motor and higher the peak torque.

A coreless brushless DC motor is a good option if you want something with higher power and less weight, that operates across a wide speed range. Slotless BLDC motors have their own unique design in that the motor coils are wound and formed into a cylindrical shape which largely eliminates cogging.

ISL Products continues to be a leading manufacturer in the dc motor market. Our team of engineers can assist at any stage in your design process.

How to choose a BLDC motor

Choosing a brushless DC (BLDC) motor can be a complex process, as there are many factors to consider. Here are a few key points to keep in mind when making your selection:

• Power and torque: Consider the power and torque requirements of your application. BLDC motors are rated by their power output, typically measured in watts. Make sure to choose one that can provide the necessary power and torque for your application.
• Speed and control: BLDC motors typically have a wide speed range and can be controlled by utilizing a controller and PWM (pulse-width modulation) to achieve precise speed control. Consider your application’s speed range and control requirements when selecting a motor.
• Efficiency: BLDC motors are generally more efficient than their brushed DC counterparts. Look for something with a high-efficiency rating to minimize energy losses and prolong battery life.
• Size and weight: BLDC offerings come in a range of sizes and weights. Consider the space constraints and weight requirements of your application when selecting the best option.
• Environmental factors: Some motors are rated for specific environmental conditions, such as temperature range and humidity. Make sure the motor you choose is suitable for the environment in which it will be used.
• Cost: Motor prices can vary. While it is important to consider cost, it is also critical to choose a motor that works well for your application.

Benefits of working with ISL Products on your next brushless motor project

There is no doubt that BLDC motors are an ideal option for many. They have excellent precision control, rotational speeds, and position control. In addition, they are quieter than brushed DC motors and very compact. If you are looking for something with superior longevity that won’t tie up time or resources with maintenance requirements, then a brushless DC motor is hard to beat.

Plus, with ISL Products, you get customized care. With so many variable parameters, it can be hard to know if you are choosing the right motor for your specific application needs. Our team can assist with this.

Don’t hesitate to get in touch with any questions you may have. We are on hand to help at every stage, from ensuring you select the perfect brushless DC motor to offering solutions to unique problems and providing reliable lead times so you get your motor when you need it.