Gearhead Selection for Brushless Motors

A motor becomes a gear motor when a gearhead is assembled with a motor. The gearhead case consists of a series of gears that can multiply a motor's torque but also reduce its speed by the same ratio. The gearhead also has an output shaft where the load attaches to.

Similar to a belt-and-pulley mechanism, where one pulley runs slower than the other due to the difference in the two pulley diameters, a gearhead's output shaft runs slower than the motor pinion shaft by the factor of its gear ratio. The advantage is that the gearhead is more rigid and can house a series of gears in a much smaller footprint than a belt-and-pulley mechanism.

In this article, I'll cover the types of gearheads offered for brushless gear motors and how to select one.

Topics covered:

• About Brushless Motors
• Gear Selection for Brushless Motors
• Motor Sizing Example - Belt Conveyor
• Summary

First, here's a little background about brushless motors. A brushless motor is a type of closed-loop DC motor that is continuous-duty rated and commutates its windings with a dedicated driver. Due to their compact size, lightweight, speed regulation, and high efficiency, brushless motors are ideal as drive solutions for variable speed material handling applications, such as conveyors or an AGV/AMR. The lack of holding torque makes them less than ideal for positioning applications.

High Speed Stability

With closed-loop speed regulation by hall-effector sensors or encoder, the dedicated driver for a brushless motor constantly monitors the motor speed and changes the applied voltage to adjust the actual speed of the motor closer to the set speed. Even with load fluctuations, the motor speed will only fluctuate ±0.2% at most (±0.05% with encoder equipped brushless motors).

For applications such as pinch belt conveyors where two belt speeds have to be synchronized, brushless motors present a more reliable speed control solution than VFD/inverter-controlled AC induction motors, which run open-loop.

Space Saving

The compact yet powerful brushless DC motor incorporates permanent magnets in the rotor. Compared with an AC induction motor with a frame size of 3.54 in. (90 mm), a brushless DC motor of the same specifications is 62% shorter. With a much shorter length, a brushless motor is also 62% lighter than an AC induction motor of the same frame size.

The compact motor structure is helpful when downsizing equipment or reducing the load on an AGV/AMR.

Energy Saving

Brushless DC (BLDC) motors, which incorporate permanent magnets in the rotor, generate little secondary loss from the rotor. Compared to AC induction motors, brushless motors can have up to 66% less loss. At an output power of 1/6 HP (90 W), for example, the power consumption of the BMU Series brushless DC motor is approximately 26% less than that of a VFD/inverter-controlled AC motor. In the same frame size, a brushless motor can output 1.3 times more power than an AC induction motor.

Brushless motors consume much less power when compared to AC induction motors due to their design.

Since brushless motors can run at 3,000 to 4,000 RPM, the gearheads paired with these motors must be quiet even at high speeds, and they also must have high permissible torque and long life to make the most of the high performance motor's characteristics. Our lineup of gearheads for brushless motors includes several parallel shaft gearheads (GFS, JV, JB), parallel shaft gearheads with centered output shaft (CS), hollow shaft right-angle gearheads (JH), and hollow shaft flat gearheads (FR).

By attaching a gearhead to a motor, you can: Increase torque Reduce speed Reduce speed fluctuations Reduce vibrations Reduce overrun Increase axial load Increase radial load

For other advantages of geared motors, please read this article.

Here's the standard gearhead lineup for our brushless gear motors. We split the lineup into 2 categories: long life and high torque.

Each gearhead type has specific applications based on the required torque, speed, and space constraints. For instance, parallel shaft gearheads are ideal for applications requiring compact designs, while right-angle gearheads are suitable for installations where space is limited and the motor needs to be positioned perpendicularly to the output shaft.

Additionally, it's important to consider the environmental conditions the gearhead will be exposed to, such as temperature, humidity, and potential exposure to dust or chemicals. These factors can significantly impact the longevity and performance of the gearhead over time.

Choosing the right gearhead involves a balance between cost, performance, and reliability. It's always recommended to consult with technical experts or refer to detailed product specifications before making a final decision. This ensures that the selected gearhead not only meets the current requirements but also provides room for future expansion or modifications without requiring a complete system overhaul.

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