Proposal of Brushless Motor to Meet Today's Automation and Energy Saving Requirements
The need for automation is accelerating these days, from production facilities to everyday life. Motors are indispensable for automation. Meanwhile, worldwide efforts to achieve carbon neutrality are in full swing, and there is an urgent need for energy saving and high efficiency measures in various fields.
Under such circumstances, highly efficient and compact brushless motors (PM motors and circuits) are attracting attention as key components for automation. Oriental Motor's brushless motors have been used in many devices and equipment. Here are the strengths of our motors that contribute to problem solving.
Oriental Motor Brushless Motor
What are brushless motors?
Brushless motors are speed control motors that use circuits (drivers and inverters) to control motors that use permanent magnets for the rotors. They are characterized by high efficiency and are significantly smaller than induction motors used for power, contributing to energy saving and resource saving.
Generally, brushless motors and PM motors are associated with large motors such as spindle motors and motors for car power units, but Oriental Motor offers products with intermediate sizes ranging from 15 W to 400 W. They are widely used in various automatic machines including production equipment because of its high speed stability due to the optimum control by the hall sensor mounted on the motor and the dedicated circuit (driver).
History of Brushless Motor Development
Oriental Motor started developing brushless motors in the early 1980s. Initially, it was an outer rotor type with DC input, but AC input and inner rotor types were developed while responding to market demands. Since around 2000, it has become possible to control torque and position, and it has evolved to achieve performance comparable to servo motors. In recent years, both motors and drivers have become increasingly compact and are widely used to drive conveyors and transfer robots. We have always developed products that meet market needs and maintained a stable supply and our products have been widely accepted in the market for many years.
Product Strengths
Energy Saving and Resource Saving Design That Contributes to Carbon Neutrality
High Efficiency Equivalent to IE4*
Brushless motors with built-in permanent magnets have higher efficiency than three-phase motors (induction motors). For example, the BMU Series 200 W has a motor/driver efficiency of 86 %, which exceeds the IE4 standard value of 75.8 % and meets the energy saving requirements.
- *This efficiency class is specified by the international standard IEC 60034-30-1 and applies to induction motors of 120 W or more. The efficiency values in IE 4 are for 50 Hz, 4-pole machines at rated output power. The efficiency values for brushless motors are for rated torque at rated speed.
Compact and Lightweight Design
Brushless motors with built-in permanent magnets are slim and high-powered. For example, compared to a three-phase induction motor of frame size of 90 mm, their total length is 84.6 mm shorter. This contributes to equipment downsizing and the use of fewer natural resources.
Design and Manufacturing Features
Highly Efficient Design With Reduced Loss
Copper loss and iron loss are reduced by winding a thick copper wire around the stator without gaps and optimizing the material, thickness, and shape of the magnetic steel sheet. A compact and power-saving design is realized.
Rotor Design and Driver Control That Achieve Low Vibration and Low Noise
The motor is designed to reduce the cogging torque that causes uneven rotation and shipped with the rotor balanced and inspected.
The driver realizes smooth operation by driving with a sine wave. Motor parameters are reflected in the control for optimal operation.
High Reliability and Long Life
Longer life than before. In addition, some models that specialize in equipment integration use bearings with high heat resistance. Creep-resistant structure with rubber parts (O-rings) inserted around the outer circumference of the bearing to resist eccentric loads is also incorporated. The dedicated gearhead is also highly strong and can be used for a long time with a rated life of 10000 hours*1.
- *1
- Depends on the type and output of the gearhead
Watertight and Dust-Resistant Design That Can be Washed With Water
Watertight and dust-resistant types that are resistant to water and dusty environments are also available. Sealing parts prevent water from entering inside the motor and it is IP67-compliant, including the connector part. Stainless steel material is used for the output shaft and screws, and a special coating is applied to the entire surface to prevent rusting.
Availability
Global Support Overseas Standards
Products are available in voltage specifications of single-phase 100 VAC/200 VAC system, three-phase 200 VAC system and DC input, allowing use in major countries around the world. Each Series is UL/CSA Standards certified, EN Standards compliant, and has the CE Marking.
Adoption Results
Adoption Results
Oriental Motor's brushless motors have many advantages such as speed stability, small size and high output, and low noise. It has been employed in a wide range of applications where these characteristics can be utilized. In addition, replacing the drive shafts of AC motors and inverters with high efficiency brushless motors will reduce CO2 emissions, save energy, and save resources.
Here are some actual adoption results along with the main reasons why they were adopted.
AGV
- Battery-Powered
- Stable During Both High and Low Speeds
- Low Heat Generation Even With 24-Hour Operation
- CANopen Compatible (BLV Series R type)
Medical Inspection and Analysis Equipment
- Low Vibration With Smooth Startup and Shutdown Contributes to the Improved Specifications of the Equipment
- Low Noise and Improved Equipment Quietness
- Global Compatibility in One Model
Pump
- Longer Equipment Life Due to the Use of High-Temperature Resistant Bearings
- Anti-creep Structure Withstands Applications Prone to Eccentric Loads
- Low Heat Generation Prevents Specimen Alteration
Security Gates/Automatic Doors
- Compact Design That Fits Inside the Enclosure
- Fast and Smooth Opening and Closing is Possible
- Stable Speed Even With Load Fluctuations Due to Wind
Sushi Making Robot
- Utilizing the Torque Limiting Function Allows for Delicate Force Adjustment
- Compact and Lightweight Equipment Achieved
- Global Compatibility in One Model
Agitator
- Stable Speed Even With Load Fluctuations
- Continuous Operation is Possible With Low Heat Generation
- Fewer Failures Than Conventional Models Due to the Anti-creep Structure
Product Line
Brushless Motor Product Line
A huge variety of motors are available, from types that offer easy speed adjustment with a dial to those that offer position control and network control. Select the motor that best suits your application.
DC Input
BLV Series R Type
Can be set to low speed operation of just 1 r/min, achieving smooth drive. Since it’s compatible with battery drive, it supports the development of even more compact devices.
BLH Series
This is a high torque and low noise brushless motor that uses a compact 24 VDC board type driver.
AC input
BMU Series
Equipped with a digital display panel and a setting dial, it is easy to operate with a rotate-and-push. The wiring to connect the motor and driver is easy.
BLE2 Series
Speed switching by I/O from a host controller, speed setting using external DC voltage as well as setting and commanding via a PC is possible.