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In today's world of advanced technology, the adoption of brushless DC motors is gaining significant traction due to their efficiency and versatility. These motors offer numerous benefits over traditional AC induction motors, particularly when it comes to creating lighter and more compact equipment. Brushless motors are significantly more energy-efficient, which allows them to perform tasks typically handled by larger AC motors but with a smaller footprint. As a result, they are increasingly being considered in the design phase of new machinery.

Grip conveyor with AC motors

 

 

 

A prime example of where this transition can make a difference is in grip conveyors, which typically use two AC induction motors to drive two belts on either side. AC motors are not the most efficient in terms of power-to-torque conversion, so they tend to be bulkier and heavier than necessary. This poses challenges in terms of handling and installation.

 

 

 

  CHALLENGE  Reducing the overall mass of the conveyor for easier handling and setup

Conventional Equipment: A grip conveyor with two belts on each side driven by two AC gear motors. An inverter (VFD) is usually used for speed control (not shown).

Problems with Conventional Equipment: 

  • Large AC motors are cumbersome and difficult to handle and install.
  • Additional support frames are often required.
  • Using two motors increases the overall mass, making the difference more noticeable.

 SOLUTION  BMU Series brushless gear motor + AC input driver

By integrating compact and highly efficient brushless motors like the BMU Series brushless gear motor + AC input driver hbspt.cta._relativeUrls=true;hbspt.cta.load(2284573, '6ce59757-26df-45b3-80fa-959e4d5d0fef', {"useNewLoader":"true","region":"na1"}); , we can significantly reduce the size and mass of the motors on the grip conveyor. Heavier motors often necessitate additional support structures, adding to the conveyor’s weight, cost, and complexity during installation. By replacing AC motors with compact and efficient brushless motors, we can minimize the motor protrusion above the conveyor surface and decrease the overall motor mass.

Grip conveyor with BLDC motorsBMU motor and driver hbspt.cta._relativeUrls=true;hbspt.cta.load(2284573, 'a816e257-31b5-492b-8c37-f9a7df180729', {"useNewLoader":"true","region":"na1"});

Advantages of the BMU Series:

  • Higher efficiency compared to AC motors
  • Lightweight and compact design
  • Easier to install and maintain
  • Compatible with existing AC input voltages
  • IP66-rated motor with quick-disconnect cables
  Oriental Motor AC Induction Motor  BMU Series
Output Power 90 W (1/8 HP) 60 W (1/12 HP)
Frame Size â–¡ 90 mm (3.54") â–¡ 80 mm (3.15")
Gear Type Parallel Shaft Parallel Shaft
Gear Ratio 9:1 30:1
Permissible Torque  4.2 N·m (37 lb-in)  5.2 N·m (46 lb-in) 
Mass 4.7 kg (10 lbs)  1.4 kg (3 lbs)

RESULT: The total mass was reduced by 6.6 kg (3.3 kg per unit).

Watch hbspt.cta._relativeUrls=true;hbspt.cta.load(2284573, '14dae4d7-30ed-4249-8880-670076efc108', {"useNewLoader":"true","region":"na1"}); how easy it is to operate a BMU Series brushless motor and driver

Brushless motors also provide superior speed regulation thanks to feedback control systems, which surpass the capabilities of AC induction motors. To learn more about synchronizing the two belt speeds, read our next post.

 

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