How to Select Brushless Motors                Image Credit: Aerotech, Inc.; Bodine Electric Company; Crouzet What are Brushless Motors? Brushless motors are synchronous electric motors that have a magnetically (AC induction) or electronically (DC) controlled commutation system instead of a brush-based mechanical commutation system.   Brushed motors are used in many applications, but have an important disadvantage in...
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Q & A on Brushless Motors

We asked our users for their input on Brushless Motors. Here are the results of 146 users familiar with Brushless Motors.

Who Took Our Poll? | Design Trends | Applications and Use | Features | Buying Advice |

Who Took Our Poll?Top

Design TrendsTop

Q:
What new technologies are influencing brushless motor design?
21 answers
Answers:
Segmented stator design and switch over from NdFeB to Ferrite wherever possible because of price and availability constraints of NdFeB motors.
~Partha R, CEO, Navsari, India
Designs to use less magnetic material, high torque- lower speed applications, and switched reluctance motors and their control.
~Engineer, Tucson, AZ
Small turbines, power semiconductor switches with high voltage capability, regenerative braking(e-bike), robotics
~Faculty/Staff, Chennai, India
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Q:
From your perspective, which companies are creating the most innovative brushless motors?
19 answers
Answers:
Motorpower company, Shenzhen Tianxing Brushless Motor Manufacturing Co., Minebea
~Faculty/Staff, Chennai, India
Thingap, Kollmorgen, a UK company I can't think of now.
~Lead Systems Engineer, Bedford, MA
I don't know which factories are working on this subject.
~Engineering, Design, Izmir, Turkey
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Applications and UseTop

Q:
What are some of the applications you have used brushless motors for?
33 answers
Answers:
I used DC brushless motor made for vacuum application to drive a rotating disk which also spins in vacuum, and the type of the motor is VS-R63, which is manufactured by Empire Magnetics. inc. The rotating disk is used as a chopper.
~Ping Wang, Research & Development, Beijng, China
The Gemini Electric Motor & Generator will become the industry standard once the improved performance is acknowledged. It can be used for all applications that use an electric motor.
~John Ettridge, Inventor / Managing Director, Dover Gardens, Australia
We used our motors inside the rear wheel of the "FIAT " we manufacture these motors and used with the "KELLY" drivers. The motors was 72 volts 3 phase and app. 8 kw
~Engineering, Design, Izmir, Turkey
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Q:
Please share with us any “non-standard” applications that brushless motors have been used for.
14 answers
Answers:
I bought a vacuum DC brushless motor and used it in vacuum. As I have known that few companies can manufacture the brushless motor for vacuum applications, and I think there are wide foreground for specialized motors in various extreme environments.
~Ping Wang, Research & Development, Beijng, China
Brushless motor used as brake in a wire tensioner dragged by the load and used also in position control mode to supply the wire of a well defined quantity.
~Carlo D., Project Manager, Florence, Italy
That is a subjective question. For below 2kW rating, all so called "non-standard applications" can be addressed with BLDC motors.
~Partha R, CEO, Navsari, India
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Q:
Do you know of any disastrous mistakes that occurred due to the incorrect usage of brushless motors?
10 answers
Answers:
I have personally not come across. However, in a sensorless BLDC motor application for elevators or hermetically sealed compressors, the direction of rotation has to be well oriented.
~Partha R, CEO, Navsari, India
Only a disastrous control issue when I learned that the motor I selected did not respond well to spikes in the AC power and required a contactor to reset the motor.
~Frank Lembo, Director of Engineering, Mississauga, Canada
The electronic controller can be destroyed and need replacing ( it is not worth repairing ) and a replacement can take days or week to obtain.
~John Ettridge, Inventor / Managing Director, Dover Gardens, Australia
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FeaturesTop

Q:
What would your design or feature "wish list" be for this product?
26 answers
Answers:
- Structurally sound (reduce structural work on surrounding mounts) - Integrated brake/clutch or ease of mounting this to the motor - Associated amplifier that can handle load, reverse current (braking), etc.
~Lead Systems Engineer, Bedford, MA
The Gemini Electric Motor & Generator is the only electric motor that when put under load reduces the current draw to match the r.p.m.
~John Ettridge, Inventor / Managing Director, Dover Gardens, Australia
Less expensive, more different Manufacturers, less electronic play tools, only one speed 2 directions.
~Engineering, Design, Hofheim, Germany
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Buying AdviceTop

Q:
Do you have any advice for people relative to buying or using brushless motors?
14 answers
Answers:
Choose the right motor for the intended application. Cost and performance will determine the motor you select, so do your home work, as to what is available.
~John Ettridge, Inventor / Managing Director, Dover Gardens, Australia
Be careful of selecting the right speed/torque performance which most engineers are not familiar or aware of its' limitations. Choose the right make.
~LC N, Engineering, Design, NA, Singapore
Look at the differences between motors from different manufacturers and be aware you are comparing like features.
~Frank Lembo, Director of Engineering, Mississauga, Canada
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Q:
Is there any advice you want to share with users to help them avoid common errors in selection or usage of brushless motors?
9 answers
Answers:
It can be very easy to damage or destroy an electronic controller, even by connecting the positive to negative terminals, or putting too much current to the controller. Some controllers only use low currents to work the controller, even though the controller can handle large currents to the motor.
~John Ettridge, Inventor / Managing Director, Dover Gardens, Australia
Temperature effects must be considered. Rotor heating due to asynchronous fluxes that are not desired, but always to some extent present, can affect the bearing temperature and reduce the efficiency..
~Ralph C, Chief engineer, Albany, NY
Get the minute details on how the motor interfaces with controls and safety devices before you buy them so you can compare the total cost of the motor.
~Frank Lembo, Director of Engineering, Mississauga, Canada
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