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Brushless DC Motors | Gearmotors
Brushless DC motors, also known as BLDC or EC motors, are the workhorses of the modern world. Here's why they're perfect for your high-quality machines:
- Built to Last: Low-wear design keeps these motors running strong for years, with minimal maintenance needed. You'll spend less time tinkering and more time getting things done.
- Powerhouse Performance: These motors deliver high efficiency, meaning they get the most out of every ounce of energy. Plus, their impressive dynamic acceleration provides quick starts and smooth operation.
- Built Tough: They're designed to handle whatever you throw at them, making them ideal for even the most demanding applications.
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Specifications
| Applied Voltage | 6 / 12 / 24 / 48 / 60 / 325 | VDC |
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| Nominal power | 10 - 1995 | W |
| Nominal torque | 0,017 - 5,25 | Nm |
| Nominal speed | 2860 - 13160 | rpm |
Control. Performance. Simplicity.
The BG Series brushless DC motors with integrated drives are your solution for powerful performance
The BG Series brushless DC motors with integrated drives are your solution for powerful performance
- Precise control: Speed, position, current - you're in charge.
- Customize it: Add encoders, brakes, gearboxes for the perfect fit.
- Control your way: Bus, I/O, or standalone - it's up to you.
- Built tough: High IP protection keeps dirt and water out
- Built smart: Inherent overload protection keeps your motor safe
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Function Overview
Brushless DC motors - 4 stages of functionalities Feedback dCore dGo dMove dPro Sensorless (✔) - - - Hall sensors ✔ ✔ ✔ ✔ High resolution encoder (✔) - - ✔ Controller dCore dGo dMove dPro Block commutation - ✔ ✔ (✔) Sinusodial commutation /
vector control- - - ✔ Speed (open loop) - ✔ (✔) (✔) Speed/ torque (closed loop) - - ✔ ✔ Position - - ✔ ✔ Complex motion profiles - - - ✔ Features dCore dGo dMove dPro Programmable / Stand-alone-operation/ Motion Apps - - - ✔ Robust isolation of bus - - - (✔) Ballast circuit parameterizable - - (✔) ✔ Safe Torque Off - - - (✔) Brake output - - (✔) ✔ Quick start commands - - ✔ ✔ Interface dCore dGo dMove dPro Digital and analogue I/Os - (✔) ✔ ✔ Field Bus (CANopen) - - (✔) (✔) Industrial Ethernet (Profinet, EtherCAT,...) - - - (✔) SSI - - - (✔) Replaces previous versions Hall KI SI, CI (low res.) SI, CI, PI, MI, EC (high res.) ✔ = Standard, (✔) = Optional / on request
Downloads Series
Operating Manuals
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Product Datasheets
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FAQ's
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Flyer
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What is a brushless DC motor? What is the difference between BLDC, EC motor and synchronous motor?Brushless DC motors (short: BLDC for brushless DC, also called EC motors) are designed like a three-phase synchronous machine with excitation by permanent magnets.
The three-phase winding is driven by a suitable circuit in such a way that it generates a rotating magnetic field which pulls the permanently excited rotor along with it.
EC motors of Dunkermotoren are commutated and controlled by a mostly integrated electronic to which a DC direct voltage is applied. BLDC motors are also similar to classic DC motors in their overload behaviour. -
What is the difference between dCore / dGo / dMove and dPro?dCore: Brushless DC motors BG series with integrated Hall sensors for rotor position detection
dGo: Brushless DC motors BG series with integrated commutation electronics
dMove: Brushless DC motors BG series with integrated control electronics
dPro: Brushless DC motors BG series with integrated control electronics and integrated high-resolution encoder Further information can be found in a comprehensive overview in catalogues and on the website. -
What are the advantages and disadvantages of brushed and brushless motors?Brushed DC motors from Dunkermotoren are robust, cost-efficient and easy to commission. Due to the wear of the carbon brushes, their service life is limited. Depending on the design and application, the service life is typically between 1000 and 8000 hours.
Brushless DC motors, also known as EC motors, are electronically commutated and have a significantly longer service life and lower interference radiation due to not having carbon brushes. The service life is usually limited by the ball bearings and is several 10000 hours, depending on the application. In addition, the motors have an even higher power density and dynamics, easy to implement protective functions and very good controllability.
Further information on this issue can be found in the corresponding white paper on the Dunkermotoren website (section "Knowledge")
Where Our BLDC Motors Are Used
Our Brushless DC (BLDC) motors with integrated controllers and gearmotors are versatile and reliable, making them ideal for a wide range of applications across various industries. Here are some detailed examples of where and how our BLDC motors are utilized:
Automated Guided Vehicles (AGVs)
BLDC motors are crucial in AGVs for their precise control and reliability. They ensure smooth and efficient movement of these vehicles in warehouses and manufacturing facilities, enhancing productivity and safety. AGVs equipped with BLDC motors can autonomously transport goods, navigate obstacles, and communicate with other systems to optimize material handling processes, reducing labor costs and improving operational efficiency.
Conveyor Systems
BLDC motors enhance conveyor systems by offering precise speed control and high efficiency. They are ideal for transporting materials smoothly and reliably, reducing maintenance and improving overall system performance. For instance, in a warehouse setting, BLDC motors power the conveyors that move goods from storage areas to shipping docks. Their ability to operate at variable speeds allows for the efficient handling of different types of products, optimizing workflow and reducing energy consumption.
Packaging Lines
BLDC motors are essential in packaging lines for their precise control and high efficiency. They enable smooth and accurate product handling, ensuring high-speed operations and reducing bottlenecks. For example, BLDC motors drive the conveyor belts that transport products through various stages of packaging, from filling to sealing. Their ability to maintain consistent speed and torque ensures that each package is handled with precision, reducing errors and increasing throughput.
Outdoor Cleaning Robots
BLDC motors are used in outdoor cleaning robots for their high-power density and efficiency. These motors enable precise control and quick movements, making them ideal for tasks such as lawn mowing, leaf blowing, and snow removal. For example, a robotic lawn mower equipped with BLDC motors can navigate complex terrains, adjust its cutting height, and operate for extended periods on a single battery charge, providing reliable and efficient lawn maintenance.
Checkweighers
In checkweigher systems, BLDC motors provide reliable and precise control for weighing products on conveyor belts. These motors are used to drive the belts that move products across the weighing sensors. The high torque and efficiency of BLDC motors ensure accurate measurements and consistent performance, which is crucial for maintaining product quality and compliance with weight regulations.
Robotic Lawn Equipment
BLDC motors are widely used in robotic lawn equipment such as mowers and leaf blowers. Their high torque and efficiency make them ideal for demanding outdoor applications, providing reliable performance and extended battery life. For instance, a robotic mower with BLDC motors can efficiently cut grass, avoid obstacles, and return to its charging station autonomously, ensuring a well-maintained lawn with minimal human intervention.
Our BLDC motors are used in even more diverse applications, including Access systems, Laboratory equipment and Vending machines.
Learn more: See our industry overview
Industries
Learn more: See our industry overview
Industries
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Step-by-Step Guide - How to Select the Right Brushless DC Motor
How to Select the Right Brushless DC Motor for Your Application
Choosing the right Brushless DC (BLDC) motor for your application involves considering several key factors to ensure optimal performance and efficiency. Here’s a guide to help you make the best choice:
1. Determine the Load Requirements
- Torque: Identify the torque requirements of your application. Consider both the continuous torque and peak torque. Our BLDC motors offer high torque suitable for various applications.
- Speed: Determine the speed at which the motor needs to operate. BLDC motors are ideal for applications requiring precise control at various speeds.
- Combination: Define your operating points and review the motor performance curves. Ensure your operating points are within the motor's capabilities.
2. Select the Appropriate Size
- Motor Sizes: Choose the appropriate motor size based on your space constraints and torque requirements. Larger motors generally provide higher torque but may have different speed characteristics.
- Compact Design: Ensure the motor fits within the physical dimensions of your application. Our BLDC motors are designed to offer high torque in a compact form factor.
3. Consider the Motor Specifications
- Voltage Rating: Ensure the motor's operational voltage range matches your power supply to avoid performance issues
- Current Rating: This indicates how much current the motor can handle before overheating. It's crucial to match this with your system's needs to prevent overloading
- Electronic Speed Controllers (ESC) and Feedback Sensors: These components are vital for precise control and monitoring of the motor's performance
4. Evaluate the Environmental Conditions
- Temperature: Ensure the motor can operate within the temperature range of your application. Consider any additional cooling requirements.
- Protection: Assess the need for IP protection against dust and moisture. Our BLDC motors can be customized with various IP ratings to suit different environments.
5. Integration with Gearboxes and Encoders
- Gearboxes: Determine if your application requires additional torque or speed reduction. Our BLDC motors can be paired with high-quality gearboxes for enhanced performance.
- Encoders: For applications requiring precise feedback, consider integrating high-resolution encoders.
6. Control and Drive Requirements
- Controllers: When selecting the right controller for a BLDC motor, it's important to ensure compatibility with industrial communication protocols such as EtherNet/IP, EtherCAT, CANopen, and PROFINET to facilitate seamless integration and efficient real-time control in your automation system.
- Power Supply: Ensure the motor and controller are compatible with your power supply specifications.
7. Customization Options
- Tailored Solutions: Consider any specific customization needs, such as shaft modifications, cable lengths, connectors, or additional features. Our technical team can provide tailored solutions to meet your exact requirements.
8. Consult with Experts
- Free Consultation: Take advantage of our free consultation service to discuss your specific needs with our experts. They can help you select the right BLDC motor and configure it for your application.
Benefits of Brushless DC Motors
1. Precise Positioning and Control
BLDC motors excel in providing accurate positioning and control, making them ideal for applications where precision is crucial. They offer smooth and responsive control, allowing for exact rotation and movement. For example, in packaging lines, BLDC motors ensure precise product handling and positioning, reducing errors and increasing efficiency.
2. High Torque and Efficiency
Unlike traditional motors, BLDC motors provide high torque across a wide range of speeds. This ensures optimal performance without the need for additional gearboxes, enhancing efficiency and reducing complexity. In conveyor systems, BLDC motors maintain consistent speed and torque, ensuring smooth material transport.
3. Reliability and Durability
BLDC motors are highly reliable due to their brushless design, which minimizes mechanical wear and tear. This results in a longer operational lifespan and reduced maintenance requirements. In outdoor cleaning robots, BLDC motors withstand harsh environments and provide reliable performance.
4. Cost-Effectiveness
BLDC motors are generally more affordable in the long run due to their efficiency and reduced maintenance needs. Their integrated controllers further streamline the design process, reducing overall system costs. In checkweigher systems, BLDC motors offer precise control and high efficiency, ensuring accurate measurements and consistent performance.
5. Flexibility in Control
BLDC motors offer excellent speed and torque control and can be easily integrated with various control systems. Their versatility makes them suitable for a wide range of applications, from robotic lawn equipment to automated guided vehicles (AGVs).
BLDC Motors vs. Other Motor Types
When selecting a motor for your application, it's important to understand the differences between BLDC motors and other common motor types, such as Stepper motors and DC motors. Here's a detailed comparison to help you make an informed decision:BLDC Motors vs. Brushed Motors
- Efficiency: BLDC motors are more efficient due to the absence of brushes, which reduces friction and energy loss. Brushed motors, while simpler and cost-effective, have lower efficiency because of the energy lost in brush friction.
- Maintenance: BLDC motors require less maintenance as they don't have brushes that wear out. Brushed motors need regular maintenance to replace brushes
- Lifespan: BLDC motors generally have a longer lifespan due to fewer moving parts. Brushed motors have a shorter lifespan because of brush wear.
- Applications: BLDC motors are used in high-efficiency applications like electric vehicles and robotics. Brushed motors are often found in low-cost applications such as household appliances and power tools.
BLDC Motors vs. Stepper Motors
- Precision: Stepper motors excel in applications requiring precise positioning and repeatability, such as CNC machines and 3D printers. BLDC motors offer precise speed control but are less suited for applications requiring exact positioning.
- Torque: BLDC motors provide higher torque at higher speeds, making them suitable for dynamic applications. Stepper motors deliver high torque at low speeds but can lose torque at higher speeds.
- Control: Stepper motors operate in open-loop systems, which can be simpler but less efficient. BLDC motors typically use closed-loop systems for better efficiency and control.
- Applications: Stepper motors are ideal for applications needing precise control, like printers and medical devices. BLDC motors are used in applications requiring high efficiency and power, such as drones and AGV´s
BLDC Motors vs. AC Motors
- Efficiency: BLDC motors are generally more efficient than AC motors, especially in variable speed applications. AC motors can be less efficient due to higher energy losses in certain conditions
- Control: BLDC motors offer better speed and torque control, making them suitable for applications requiring precise control. AC motors are simpler and often used in applications where precise control is less critical.
- Maintenance: Both BLDC and AC motors have low maintenance requirements, but BLDC motors may have an edge due to fewer moving parts
- Applications: AC motors are widely used in industrial applications like pumps, fans, and compressors. BLDC motors are preferred in applications requiring high efficiency and compact size, such as electric vehicles and consumer electronics.
Comparison of Motor Types
| Motor Type | Advantages | Disadvantages | Typical Applications |
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| BLDC Motors |
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| Brushed Motors |
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| Stepper Motors |
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| AC Motors |
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FAQ´s on Brushless Motors
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What is a brushless DC motor?
A brushless DC motor (BLDC motor) is an electric motor that operates on direct current (DC) electricity but does not use brushes for commutation. Instead, it uses an electronic controller to switch the current in the motor windings, producing a rotating magnetic field that the rotor follows. The main components of a BLDC motor include:
- Stator: The stationary part of the motor that contains the windings.
- • Rotor: The rotating part of the motor that contains permanent magnets.
- • Electronic Controller: Manages the current flow to the windings, ensuring the magnetic fields rotate and drive the rotor.
This design eliminates the need for brushes, reducing wear and tear and increasing efficiency. BLDC motors are also known as EC motors (electrically commutated motors) or servomotors. -
How does a BLDC motor works?A brushless DC motor operates using an electronic controller instead of brushes and a commutator. The electronic controller supplies current to the stator windings in a specific sequence, creating a rotating magnetic field. The stator is the stationary part of the motor that contains the windings, while the rotor is the rotating part that contains permanent magnets.
When the electronic controller sends pulses of current to the stator windings, it generates a rotating magnetic field. The permanent magnets on the rotor are attracted to this rotating magnetic field, causing the rotor to turn. The controller continuously adjusts the current to maintain the rotation, providing precise control over the motor's speed and torque.
This method eliminates the need for brushes, reducing wear and tear and increasing efficiency. The electronic controller allows for precise control of the motor, making BLDC motors highly efficient and reliable. -
Where are BLDC motors used?Brushless DC motors from Dunkermotoren are used in various applications due to their high efficiency, low maintenance, and precise control. Common uses include:
- Warehouse Automation: Automated storage and retrieval systems (AS/RS) and conveyor systems.
- Material Handling: Packaging machinery and labeling equipment.
- Food & Beverage: Processing equipment and automated dispensing systems.
- Machinery: CNC machines and industrial robots.
- Agriculture: Automated feeding systems and irrigation equipment.
- Building Automation: Smart blinds, automated doors, and HVAC systems.
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What are the advantages of an integrated controller?Motors with integrated controllers offer several key advantages. First, they save space by combining the motor and controller into a single unit, reducing the overall size and footprint of the system. This integration also simplifies wiring, as fewer cables are needed, which makes installation easier and reduces potential points of failure.
Additionally, integrated systems can optimize performance and reduce energy consumption, leading to improved efficiency. With fewer components and connections, the system is less prone to failures and electrical noise, enhancing reliability. Integrated controllers often come with user-friendly interfaces and software, making configuration and control straightforward.
Another benefit is that electromagnetic interference (EMI) is easier to manage. The controller is firmly connected to the motor, ensuring a perfect fit. Moreover, no additional space is needed for the controller in the control cabinet, further saving space and simplifying the setup. -
How are they controlled?Brushless motors from us are easily commissioned, parameterized, and controlled via the Drive Assistant 5 tool from Dunkermotoren. This commissioning and configuration tool is designed for dPro and dMove motors, as well as external controllers in IO mode, with interfaces such as EtherCAT, PROFINET, EtherNet/IP or CANopen. It supports devices with MotionCode and allows for monitoring the CAN bus.
Once motors are parameterized, they can operate stand-alone. Up to 14 different speeds, positions, ramps, and currents can be assigned to digital inputs, providing flexibility in control. Direct parameter access is possible, and the status of all relevant motor parameters can be displayed. The tool offers a wide range of tuning options and is compatible with all dMove and dPro motors and external controllers.
Drive Assistant 5 also includes an extensive oscilloscope function and supports commissioning and service for EtherCAT and PROFINET motors (dPro EC and dPro PN) directly via Ethernet. Additional features include a Python scripting function, a CAN monitor, and automatic device search and detection for CANopen, EtherCAT, and PROFINET devices.
This comprehensive tool ensures that our brushless motors are easy to set up, configure, and control, making them highly efficient and user-friendly. -
Where are motor with integrated controller used?Motors with integrated controllers from Dunkermotoren are utilized in a variety of applications due to their compact size, efficiency, high dynamic and ease of integration:
- Industrial Automation: Employed in conveyor systems, robotic arms, and CNC machines for precise control and automation.
- Warehouse Automation: Integrated into automated storage and retrieval systems (AS/RS) and conveyor systems.
- Material Handling: Used in packaging machinery and labeling equipment.
- Food & Beverage: Incorporated into processing equipment and automated dispensing systems.
- Machinery: Essential for CNC machines and industrial robots.
- Agriculture: Implemented in automated feeding systems and irrigation equipment.
- Building Automation: Key components in smart blinds, automated doors, and HVAC systems.
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What are the advantage of motor for external controller?Brushless DC motors with external controllers, often equipped with Hall sensors, offer several advantages. These motors have higher efficiency due to the elimination of brush friction, which reduces energy loss. Hall sensors detect the rotor's position, allowing for smooth and precise control, especially at low speeds and during startup. Without brushes, there is less wear and tear, leading to a longer operational life and reduced maintenance.
The design allows for a more compact motor, which is beneficial in applications where space is limited. The absence of brushes also reduces noise, making these motors suitable for noise-sensitive applications. They support a wide range of motor speeds, providing flexibility for various applications.
Additionally, these motors are modular, allowing the controller to be chosen freely and making the overall system generally shorter. Suitable controllers can be selected for different motor sizes, and the less complex basis components mean that the controller can be changed without changing the motor.
These advantages make brushless DC motors ideal for applications such as cordless power tools, air conditioners, automated doors, and various automotive systems. -
Where are motors for external controller used?Brushless DC motors with external controllers, often equipped with Hall sensors, are used in a variety of applications due to their high efficiency, smooth operation, and reliability. Here are some typical uses:
Home Appliances
- Air Conditioners and Refrigerators: For efficient and quiet operation.
- Washing Machines: Enabling direct-drive systems that eliminate the need for belts and gearboxes.
- Electric Fans: Providing quiet and precise speed control.
Automotive Industry
- Electric Vehicles: Powering main drive motors and auxiliary systems.
- Automated Doors: Ensuring reliable and smooth operation.
Industrial Equipment
- Cordless Power Tools: Such as drills and saws, for high efficiency and durability.
- Conveyor Belts: Providing reliable and efficient movement in manufacturing processes.
Consumer Electronics
- Drones: Offering high power-to-weight ratio for longer flight times and better maneuverability.
- Hard Drives and Printers: Enabling precise control and high-speed operation.
Precision Devices
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Medical Equipment: Used in devices requiring precise and reliable motor control.
These motors are ideal for applications requiring high dynamics and precision, such as automation, machinery, material handling, agriculture, and access gate
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What is a servo motor?Generally, a servomotoris understood as a motor that has at least one control unit or can provide feedback on its rotational or linear position. "Servomotor" does not describe a specific motor type, but rather servo motors of different types. Permanently excited synchronous motors (BG series at Dunkermotoren), asynchronous motors and brushed DC motors (GR series at Dunkermotoren) are widely used as servo motors.
Further information on this issue can be found in the corresponding White Paper on the Dunkermotoren website (section "Knowledge"). -
What is a brushless DC motor? What is the difference between BLDC and synchronous motor?Brushless DC motors (abbreviation BLDC for brushless DC, also called EC motors) are designed like a three-phase synchronous machine with excitation by permanent magnets. The three-phase winding is controlled by a suitable circuit in such a way that it generates a rotating magnetic field which pulls the permanently excited rotor along with it. EC motors of Dunkermotoren are commutated and controlled by a mostly integrated electronic to which a DC direct voltage is applied.
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