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A brushless DC motor is a motor without brushes and commutators, which changes the direction of the current through electronic commutation, thereby driving the motor to rotate.
A DC brush motor is a rotating electrical machine with a brush device inside, which can convert DC electrical energy into mechanical energy.
BLDC motor | DC brushed motor | |
Cost | No carbon brushes, lower maintenance costs, and slightly higher purchase costs | There are carbon brushes, which are more expensive to maintain and slightly less expensive to purchase |
Life | The wear is small and the service life is long, generally in 5000-20000h | The wear is large, the electric spark is short, and the service life is short, generally in 800-1200h |
Install | Higher technical content, higher installation control conditions | The control circuit is relatively simple |
Efficiency | Electronic steering technology, high precision control efficiency, wide range of speed regulation | Through large-scale voltage adjustment, the speed regulation range is wide and smooth |
Noise | Low noise, about 35DB | Due to the use of brushes,the noise is high,at 40-45DB. |
Expend | Mechatronics, high efficiency and energy saving | The loss is large. |
Application | Industrial automation, robots, drones, energy-saving inverter home appliances, new energy vehicles, etc. | Electric bicycles, household appliances, electric drills, chainsaws, rotating display stands, etc. |
You may be discouraged by its slightly higher purchase price, but think about it from another angle: a slightly higher price is more energy-efficient, longer life, less noisy, and because there are no brushes, it directly greatly reduces the maintenance cost, and directly increases the use value of the products it is equipped with, that is, 1≥5.
Therefore, in general, brushless DC is an advanced and improved version of the motor with brushed DC, which is more suitable for the needs of modern society, family needs and industrial needs.
In this way, it is a fairly hassle-free and cost-effective deal.
Due to the different demand scenarios and matching products, BG has customized brushless motors for Duojia Company, and our engineers have one-on-one detailed communication from dimensional drawings to samples, and do our best to meet the needs of customers.
In April 2023, our colleague Anna visited the U.S. to meet with the client. They revealed a new vacuum cleaner project requiring a dual-voltage AC motor, capable of automatically switching between 110V and 230V. At first, the idea seemed impossible—creating an AC motor with such flexibility was unprecedented in our industry.
But Mark, ever the visionary, said, “Anna, let’s work some magic. Let’s be the first in the industry to achieve this.”
When Anna returned to China, she immediately gathered our technical team to brainstorm this challenge. After 10 days of intense research by our mechanical and electrical engineers, we realized this idea might actually be feasible.
We quickly launched the project, using the client’s detailed 3D vacuum cleaner designs to tailor our motor. The dual voltage requirement, coupled with the need for overload protection and compact sizing, presented a significant challenge. But our technical and software teams collaborated closely, and after three months of relentless effort, we successfully developed the solution.
This is the spirit of BG Motor. When our clients present a challenge, we go the extra mile to meet their needs.
The client approached us through Google in 2019 and they are a creative agency. Their goal was to create a convenient portable coffee maker for their customers. At the time, the market was full of larger coffee makers, and they were more expensive. The customer wanted to develop a simple coffee maker for people who love coffee and care about the quality of life to take with them, and they wanted the new coffee maker to taste better and not waste coffee. The motor is one of the core components of the machine, and customers expect us to work with them to develop a motor that meets their needs.
In the initial phase, we started by providing two solutions to our customers. The first solution is a DC brush motor, which can fully meet the customer's parameter requirements. However, the solution was quickly rejected by the customer due to the DC power supply. We also provide the second solution for the customer, using the high-speed AC motor gearbox model, which can meet the requirements of the AC power supply, and the motor parameters will fully meet the customer's needs. Smaller size, more convenient, in line with the customer's complete design.
After 4 repeated sample tests, the product quality fully met the requirements. Now we have officially entered the cooperation period!
BG motor's delivery is very fast! They were very responsive when we asked questions. The motor is stable and of high quality. In a few of our experiments, it was very good at working. Although it took more time in the initial sample phase, it was great to work with them in the follow-up samples. It's perfect! Thank you for all the support you have given us!
-Mr.Nace (Chief Technical Engineer)
3. AGV trolley
The client approached us through Google in 2014. They are manufacturers of commercial warehouse robots. The customer expects the warehouse robot to work stably under the premise of fully satisfying the work. The motor is one of the important core components of the machine. Customers expect us to work with them to develop motors that meet their needs.
Difficulty：
1. There is very little space reserved for the motor inside the customer's robot. In the case of small motor diameters, the motor needs to meet the customer's requirements for high power (800W) and high torque (100Nm).
2. Motor products need to meet the requirements of high service life and no sparks during operation
3. The protection level of the motor needs to reach IP68
Solution:
1. We use brushless planetary geared motors. On the premise of satisfying the customer's data, we reopened the motor housing and internal main components to ensure that the motor can fully meet the internal dimensions of the product, and the motor protection level can reach IP68
2. Because customers are worried about product life and sparks, we use brushless planetary geared motors to ensure the life of the motor and ensure that there will be no sparks when the motor is running
Centrifuges are widely used in the medical industry, mainly for blood fractionation, DNA research/immunohematology labs, laboratories, research laboratories, etc. It is an ideal product for serum, plasma and radioimmunology in medical biochemical laboratories, and is a must-have for blood bank equipment, laboratories, blood banks, medical schools and various hospital medical research institutions. In recent years, the scale of the medical centrifuge market has been expanding, and the future development potential is quite large. It's a good medical device industry.
Difficulty:
The required motor data are: rated voltage: 120V AC, rated power: 500W, rated speed: 15000rpm
Motor size: The maximum motor diameter must be controlled within 78mm
The technical difficulty of this type of motor lies in the service life and resonance of the motor. The service life at high speed is a test of each component; The resonance problem inside the centrifuge is also a very big test.
When the temperature of the motor is too high and the speed of the motor is too fast, it must be considered whether the motor will demagnetize after long-term operation;
Solution:
The motor products have undergone strict dynamic balance tests to ensure that the motor remains in a relatively stable state during operation and reduce the possibility of loose screws. In addition, the bearings are replaced with high-quality bearings to improve the stability of the product.
Intensive discussions with the customer, a two-week detailed discussion of the centrifuge interior, installation and resonance issues, and after repeated computer tests and sample tests, the motor finally met the customer's requirements
In order to ensure the high-speed operation of the motor, all materials are made of materials with high insulation grade to ensure good high-temperature resistance at high speed and prevent demagnetization during long-term operation.
In addition, BG motors has more products and more application scenarios, welcome to contact our engineers or visit our website at any time.(https://china-bgmotor.com/)
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