In today's fast-paced industrial environment, conveyors play a vital role in moving materials and products efficiently across various sectors such as packaging, warehousing, and distribution. While multiple types of motors can be used for conveyor systems, brushless motors stand out as a top choice due to their efficiency, compact size, and reliability.
This article explores why brushless motors are ideal for conveyor applications and compares them with other motor types like AC induction, brushed DC, servo, and stepper motors. It also provides recommendations on suitable product series based on different conveyor types.
**Types of Motors Used for Conveyors**
- **Fixed-Speed Conveyors**: AC induction motors are commonly used due to their cost-effectiveness. However, they often require gearheads to reduce speed. Brushless and brushed motors can achieve lower speeds without the need for gearheads.
- **Variable-Speed Conveyors**: VFD-driven AC induction motors are typical choices. Brushless motors offer better speed regulation and a smaller footprint, while servo motors provide even higher performance.
- **Indexing Conveyors**: Stepper motors are often chosen for their high accuracy in stopping. Servo motors can be considered when heat generation or limited duty cycles are concerns.
Brushless motors are versatile and can be used in all types of conveyors, including start/stop systems if stop accuracy is not required. Their advantages include higher efficiency, smaller size, and lower maintenance compared to other motor types.
**The Case for Brushless Motors**
Brushless motors are generally more compact and lighter than other variable-speed motors. They are more efficient, run cooler, and use permanent magnets in their rotor. This design eliminates the losses associated with electromagnetic induction found in AC motors. Compared to AC induction motors, brushless motors can be made significantly smaller and more efficient.
**Brushless Motors vs Other Speed Control Systems**
- **VFD-Driven AC Induction Motors**: Brushless motors have built-in closed-loop feedback and constant torque output, ensuring consistent performance despite load fluctuations. Their compact size is a major advantage.
- **Brushed DC Motors**: While cheaper, brushed motors require regular maintenance due to brushes and commutators. Brushless motors are more efficient, draw less power, and are smaller in size.
- **Servo Motors**: Brushless motors offer a simpler solution for applications where servo motors might be oversized. They use hall-effect sensors for feedback, which simplifies control and reduces costs.
- **Stepper Motors**: Although steppers offer high accuracy, they lack holding torque and are not suitable for continuous operation. Brushless motors are ideal for variable-speed conveyors that require continuous running.
**Recommended Product Series by Conveyor Type**
- **Single-Axis Modular Low-Profile Conveyors**: The BMU Series brushless motor and dedicated variable speed driver are recommended for basic speed control requirements. They are compact, easy to install, and come with built-in functions like load factor and speed limits.
- **Packaging and Labeling Conveyors**: The BLE2 Series brushless motor and driver are ideal for advanced control needs. They support up to 16 speed settings and offer features like torque limiting and speed teaching.
**Summary**
Brushless motors offer high efficiency, compact size, and tight speed regulation, making them an excellent choice for variable-speed conveyors. They outperform AC induction motors and can replace brushed DC and servo motors in certain applications. Oriental Motor’s brushless motors are available in various frame sizes, ensuring optimal performance without oversizing. Dedicated drivers add enhanced capabilities like speed teaching and torque limiting.
For engineers looking for reliable and efficient solutions, brushless motors are a smart choice. Contact our team for a motor sizing consultation to find the perfect brushless motor and driver for your conveyor system. We also offer tailored options for specific applications, such as battery compatibility or multi-axis network control.
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