Gearhead Selection for Brushless Motors

Gearheads are essential components in optimizing motor performance. Each type of gear provides specific features and characteristics, and the gear ratio adjusts the motor’s output torque and speed. By carefully choosing the appropriate gear type and ratio, engineers can fine-tune motor performance to perfectly match application requirements. When a gearhead is combined with a motor, it forms a gear motor. The gearhead housing contains a series of gears that amplify the motor's torque while simultaneously reducing its speed proportionally. The gearhead also features an output shaft where the load is attached. Similar to a belt-and-pulley system, where one pulley turns slower than the other due to differences in diameter, the gearhead's output shaft rotates slower than the motor pinion shaft by the gear ratio factor. The advantage of using a gearhead over a belt-and-pulley system is that it is more robust and can fit multiple gears within a much smaller space. In this article, we’ll explore the various types of gearheads available for brushless gear motors and how to select the best one for your needs. ### Topics Covered: - About Brushless Motors - Gear Selection for Brushless Motors - Motor Sizing Example – Belt Conveyor - Summary #### About Brushless Motors A brushless motor is a type of closed-loop DC motor that is designed for continuous duty and uses a dedicated driver to commutate its windings. Due to their compact size, light weight, precise speed regulation, and high efficiency, brushless motors are excellent choices for variable-speed material handling applications like conveyors or automated guided vehicles (AGVs/AMRs). However, their lack of holding torque makes them less suitable for positioning applications. ##### High-Speed Stability With closed-loop speed regulation via hall-effect sensors or encoders, the dedicated driver ensures the brushless motor maintains its speed with minimal fluctuation—only ±0.2% deviation at most (or ±0.05% with an encoder-equipped motor). This makes brushless motors a more reliable option for applications like pinch belt conveyors, where synchronization of two belt speeds is critical. For example, consider a pinch belt conveyor. Unlike VFD-controlled AC induction motors that operate open-loop, brushless motors provide a more dependable speed control solution, ensuring consistent operation even under varying loads. ![High-Speed Stability](http://bsg-i.nbxc.com/blog/ec0d346508d0169a584282966fd90173.jpg) ##### Space-Saving Design Brushless DC motors are compact and powerful, incorporating permanent magnets in the rotor. Compared to AC induction motors with a frame size of 3.54 inches (90 mm), a brushless DC motor of similar specifications is 62% shorter and 62% lighter. This compact design is advantageous when downsizing equipment or reducing the load on AGVs/AMRs. ![Compact Size of Brushless Motors](http://bsg-i.nbxc.com/blog/4e92088f689ea4e300fee151b1545cce.jpg) ##### Energy Efficiency Brushless DC (BLDC) motors, featuring permanent magnets in the rotor, generate minimal secondary losses from the rotor. Compared to AC induction motors, brushless motors can achieve up to 66% less energy loss. For instance, at an output power of 1/6 HP (90 W), the power consumption of the BMU Series brushless DC motor is approximately 26% lower than that of a VFD-controlled AC motor. In the same frame size, a brushless motor can produce 1.3 times more power than an AC induction motor. Brushless motors are significantly more energy-efficient compared to AC induction motors due to their design. ![Energy Savings of Brushless Motors](http://bsg-i.nbxc.com/blog/cba10e558cab3afb776f4dc36743c1eb.jpg) Since brushless motors typically operate at speeds ranging from 3,000 to 4,000 RPM, the accompanying gearheads need to remain quiet at high speeds and possess high permissible torque and long lifespans to maximize the motor’s performance. Our gearhead lineup for brushless motors includes several 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). ### Advantages of Adding a Gearhead By attaching a gearhead to a motor, you can: - Increase torque - Reduce speed - Minimize speed fluctuations - Decrease vibrations - Limit overrun - Enhance axial load capacity - Improve radial load capacity For additional benefits of geared motors, refer to this article. ### Important Considerations When Selecting Gearheads When choosing gearheads, pay close attention to the rotation direction of the gearhead shaft. Certain gearheads reverse the shaft rotation depending on the gear ratio. ### II. Gear Selection Here’s the standard gearhead lineup for our brushless gear motors. We’ve categorized the lineup into two groups: long-life and high-torque options. By combining the right gearhead with a brushless motor, you can significantly enhance performance while maintaining reliability and efficiency. Understanding the nuances of each gearhead type will help you make the best decision for your application. This concludes our overview of gearhead selection for brushless motors. If you have any questions or need further assistance, feel free to reach out!

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