Gearhead Selection for Brushless Motors

Gearheads are essential components for optimizing motor performance. They come in various types, each offering unique features and characteristics. The gear ratio plays a critical role in altering the motor’s output torque and speed. By selecting the appropriate gear type and ratio, engineers can fine-tune motor performance to meet specific application requirements. A motor transforms into a gear motor once a gearhead is attached. The gearhead casing houses a series of gears that amplify the motor's torque while reducing its speed proportionally. The output shaft of the gearhead is where the load is connected. Much like a belt-and-pulley system, where one pulley rotates slower than the other based on diameter differences, a gearhead’s output shaft spins slower than the motor pinion shaft according to its gear ratio. The benefit of a gearhead lies in its rigidity and ability to accommodate multiple gears within a compact space, surpassing the functionality of a belt-and-pulley system. In this article, I’ll discuss the different types of gearheads available for brushless gear motors and guide you through the selection process. **Topics Covered:** - Understanding Brushless Motors - Selecting Gearheads for Brushless Motors - Motor Sizing Example – Belt Conveyor - Conclusion --- ### **Understanding Brushless Motors** Brushless motors are a type of closed-loop DC motor designed for continuous duty cycles. These motors use a dedicated driver to manage winding commutation. Their compact size, lightweight construction, and high efficiency make them ideal for variable-speed applications like conveyors or autonomous guided vehicles (AGVs/AMRs). However, their lack of holding torque limits their suitability for precise positioning tasks. #### **High-Speed Stability** Equipped with hall-effect sensors or encoders, the dedicated driver continuously monitors the motor’s speed. It adjusts the applied voltage to keep the motor's actual speed close to the setpoint, ensuring fluctuations remain minimal (±0.2%, or ±0.05% with encoders). This closed-loop regulation makes brushless motors more reliable than open-loop systems like VFD-controlled AC induction motors—especially in applications requiring synchronized belt speeds. ![High-Speed Stability](http://bsg-i.nbxc.com/blog/ec0d346508d0169a584282966fd90173.jpg) --- #### **Space-Saving Design** The compact yet powerful brushless DC motor utilizes permanent magnets in its rotor. For example, a brushless DC motor with the same specifications as a 3.54-inch (90mm) AC induction motor is 62% shorter and 62% lighter. This design advantage helps in downsizing equipment or reducing the load on AGVs/AMRs. ![Compact Size](http://bsg-i.nbxc.com/blog/4e92088f689ea4e300fee151b1545cce.jpg) --- #### **Energy Efficiency** Brushless DC (BLDC) motors generate minimal secondary losses due to their permanent magnet rotor design. Compared to AC induction motors, BLDC motors can achieve up to 66% lower energy losses. For instance, at 1/6 HP (90W), the BMU Series brushless DC motor consumes approximately 26% less power than a VFD-controlled AC motor. Additionally, within the same frame size, a brushless motor can deliver 1.3 times more power than an AC induction motor. ![Energy Savings](http://bsg-i.nbxc.com/blog/cba10e558cab3afb776f4dc36743c1eb.jpg) --- ### **Gearheads for Brushless Motors** Given that brushless motors operate at speeds ranging from 3,000 to 4,000 RPM, their accompanying gearheads need to remain quiet at high speeds while providing high permissible torque and long service life. Our gearhead lineup for brushless motors includes parallel shaft gearheads (GFS, JV, JB), parallel shaft gearheads with centered output shaft (CS), hollow shaft right-angle gearheads (JH), and hollow shaft flat gearheads (FR). **Benefits of Using Gearheads:** - Increase torque - Reduce speed - Minimize speed fluctuations - Suppress vibrations - Decrease overrun - Support higher axial and radial loads ![Torque vs. Gear Ratio](http://bsg-i.nbxc.com/blog/15b1d2ea39506a29e71ff137bd132394.jpg) **Important Note:** When choosing gearheads, always check the rotation direction of the gearhead shaft, as some models reverse the shaft orientation depending on the gear ratio. --- ### **Selecting the Right Gearhead** Our standard gearhead offerings for brushless motors fall into two primary categories: long-life and high-torque options. These gearheads ensure smooth operation across a wide range of applications, maximizing the potential of brushless motors. By combining a brushless motor with the right gearhead, you can create a highly efficient and reliable system tailored to your specific needs. Whether you're designing a conveyor system or integrating motors into an AGV, selecting the appropriate gearhead is key to achieving optimal performance. --- ### **Conclusion** Brushless motors and their complementary gearheads offer a powerful combination for modern industrial applications. With their compact design, energy efficiency, and precision control, they provide significant advantages over traditional AC induction motors. By understanding the gearhead options available and making informed selections, engineers can unlock the full potential of brushless motor technology. If you have any questions about selecting the right gearhead for your project, feel free to reach out. Let’s work together to optimize your motor-driven systems!

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