In today’s rapidly evolving industrial sector, conveyors play a pivotal role in streamlining operations across various industries, from packaging and warehousing to manufacturing and distribution. While a variety of motor types can be employed in conveyor systems, brushless motors stand out as a top choice due to their numerous benefits. This article explores several compelling reasons why brushless motors should be considered essential for conveyor applications. Conveyors are tasked with moving materials, products, and goods efficiently, and the choice of motor can significantly impact performance and operational efficiency. Brushless motors offer distinct advantages over other motor types, making them a prime candidate for conveyor systems. **Types of Motors Commonly Used in Conveyors** Conveyor systems often utilize different motor types based on the specific needs of the application. Fixed-speed conveyors frequently rely on AC induction motors, which are cost-effective and user-friendly. However, these motors usually require gearheads to adjust speed, whereas brushless motors can achieve the desired speed without them. For variable-speed conveyors, VFD-driven AC induction motors are standard, providing flexibility in speed control. On the other hand, brushless motors offer superior speed regulation and a smaller footprint, making them ideal for space-constrained environments. Servo motors, while offering even higher performance, come at a premium. Indexing conveyors, which demand precise stopping and holding torque, typically use stepper motors for their high accuracy. However, servo motors may be preferred in cases where heat generation and limited duty cycles are concerns. **The Case for Brushless Motors** Brushless motors are generally smaller and lighter than other motor types used in variable-speed applications due to their innovative design. For instance, the absence of brushes in brushless motors makes them more compact than brushed motors. Additionally, brushless motors are shorter than servo motors because they typically employ hall-effect sensor feedback rather than encoder feedback. Compared to AC induction motors, the most commonly used motor type in conveyor applications, brushless motors are smaller due to their greater efficiency, cooler operating temperatures, and the use of permanent magnets. Unlike AC motors, which rely on electromagnetic induction, brushless motors use permanent magnets in their rotors and electromagnets in their stators to generate rotation, minimizing energy losses. **Brushless Motors vs Other Speed Control Systems** When contrasted with VFD-driven AC induction motors, brushless motors excel with built-in closed-loop feedback and constant torque output. A brushless motor driver continuously monitors and adjusts the motor’s speed and torque according to feedback from the motor, ensuring consistent performance even under varying loads. Conversely, the speed of an AC motor can fluctuate due to open-loop operation and load changes. The significant advantage of brushless motors lies in their compact size and weight. In comparison to brushed DC motors, brushless motors are more expensive because they require closed-loop feedback and a dedicated driver for winding commutation. Brushed motors, on the other hand, use brushes and a commutator, requiring only a variable voltage for speed control. Brushless motors are more efficient, draw less power, and are smaller in size. Moreover, brushless motors eliminate the need for regular brush and commutator maintenance, a substantial benefit. When pitted against servo motors, brushless motors provide a simpler solution in applications where servo motors might be oversized or over-engineered. Although brushless motors share a similar design and operation with servo motors, their typical hall-effect sensor feedback simplifies control methods and drive circuitry. This streamlined design keeps costs down for conveyor applications that don’t require the highest speeds, tightest speed regulation, or the peak torque offered by servo motors. For less demanding conveyor applications, the decision between brushless and servo motors may ultimately hinge on the functionality provided by the driver. Brushless motors are structurally similar to stepper motors, except that one uses a radially magnetized rotor and the other an axially magnetized rotor. Both operate using power and phase excitation controlled by a dedicated driver. However, the key difference lies in the lower number of poles and the lack of holding torque in brushless motors, which means they cannot match the stop accuracy of stepper motors. Therefore, stepper motors are recommended for positioning applications with limited duty cycles, such as indexing conveyors, while brushless motors, designed for continuous operation, are better suited for variable-speed conveyors. The table below provides a summary of the differences between AC motors, brushless motors, and servo motors. Additional speed control comparison details are available. To further enhance their compactness, Oriental Motor’s latest brushless motors incorporate an optimized magnetic design with high-performance magnetic steel sheets and permanent magnets. Closed-loop speed regulation for Oriental Motor’s brushless motors is rated at ±0.2% for motors with hall-effect sensors and up to ±0.05% for motors with encoders. With a small overrun ranging from approximately ±0.1 to ±0.4 revolutions depending on RPM and load inertia, brushless motors can also handle some indexing conveyors, although start/stop frequency and accuracy must be tested. **Product Series Recommendations by Conveyor Type** Oriental Motor offers AC-input brushless motor systems tailored for specific conveyor types, including single-axis, modular, low-profile conveyors and packaging/labeling conveyors. For single-axis modular low-profile conveyors with basic speed control requirements, the BMU Series brushless motor paired with a dedicated variable speed driver is recommended. The BMU Series is designed for quick installation on single-axis, modular conveyors, thanks to its compact size and ease of use. The small motor and driver size help reduce the overall footprint of the conveyor. The dedicated driver includes built-in features such as load factor and speed limits. For conveyors with advanced requirements, such as those used in packaging and labeling, the BLE2 Series brushless motor and dedicated variable speed driver are recommended. Up to 16 speeds can be set via the control panel, external potentiometer, external analog voltage, or MEXE02 data setting software. An HMI can output an analog voltage to control two drives simultaneously, along with issuing commands to each driver via I/O. The driver includes functions such as load factor, torque-limiting, and speed teaching. **Summary** Brushless motors’ high efficiency, small footprint, and tight speed regulation meet the design demands of compact variable-speed conveyors. While brushless motors offer numerous advantages over VFD-driven AC motors, they can also replace brushed DC motors and even servo motors in certain applications. Although brushless motor design is similar across many manufacturers, Oriental Motor’s brushless motors are offered in various frame sizes rather than longer stack lengths. Dedicated drivers ensure optimal motor performance and add enhanced capabilities such as speed teaching and torque limiting. Say goodbye to oversizing. Contact our team today for a motor sizing consultation to find the perfectly matched brushless motor and driver for your conveyors. We understand engineers love charts. Here’s a comparison of our two most popular AC-input brushless motor systems. Feel free to reach out to our team for additional motor options tailored to meet specific application requirements, such as battery compatibility or multi-axis network control.

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