High Torque BLDC Motor

High Torque BLDC Motor

High torque BLDC motor combines speed and power requirements with a small frame in motion control applications. In addition, their design allows them to operate at higher torque densities than comparable-sized motors.

24V working voltage provides plenty of power, and the integral controller offers flexibility in system integration. 0-5V analog input signal facilitates speed modulation.

Efficiency

High efficiency BLDC motors convert electrical energy into mechanical power with less waste, reducing energy consumption and operating costs. They can run at lower speeds and generate less noise, making them perfect for products that require quiet operation. They also have fewer moving parts than brushed DC motors, making them more durable and extending their lifespan.

These factors make them a popular choice for electric vehicles, where their high torque capabilities High torque BLDC motor provide more power with a smaller battery size. They are also increasingly used in robotics and industrial applications, where they can provide the strength and precision required for intricate tasks.

Unlike other motor types, BLDC motors don’t suffer from iron losses or copper losses in the core windings. However, they still experience hysteresis losses as the magnetic field in the rotor alternately magnetizes and demagnetizes. These losses are proportional to the rotor speed and current, so they decrease with increasing speed and torque.

To understand how a specific BLDC motor performs, you can look at its efficiency map. A graph like this shows the power loss per kilowatt (kW) versus RPM and torque for a given load. You can then use the trend lines to determine the optimal size, Kv and brand of motor for your application, whether it’s maximizing flight time for a drone or increasing the payload capacity of an electric vehicle.

Power

High torque BLDC motors operate on electromagnetism, converting electric currents into mechanical motion using the power of magnetism. They have a stationary part called the stator, which contains one or more sets of windings made from coiled copper wire. When an electric current passes through these windings, it creates a magnetic field that attracts or repels magnets on the rotor, creating rotation.

Unlike brushed DC motors, brushless motors have no brushes and commutator to wear down and generate sparks. This makes them more durable and less prone to failure over time. Additionally, since a BLDC motor has fewer moving parts, it requires less maintenance and can run more quietly.

A key advantage of BLDC motors is that they can operate at low speeds and deliver the necessary torque for control. This allows them to operate with lower noise and vibration than their brushed counterparts, making them ideal for use in embedded applications where space is at a premium.

ePowerHobby offers an extensive selection of 120mm BLDC motors that deliver high performance and durability. Browse a wide range of options to find the perfect motor for your next project!

Torque

A high torque BLDC motor can deliver a great deal of mechanical force and has good speed regulation capabilities. This is important for applications where it’s essential to maintain a consistent and stable speed, such as in robotic applications or manufacturing systems. In contrast to other types of motors, high-torque BLDC motors can be easily controlled by simple voltage adjustments.

The fixed part of a high-torque BLDC motor is called the stator and it uses permanent magnets to provide a magnetic field. This field attracts and repels the rotor to create continuous rotation. In order to control the current flow to the armature coils, there is a sliding electrical switch called a commutator that reversibly switches the direction of the current. The continuous rotation of the rotor generates mechanical motion and the reversal of the commutator’s switching creates a torque.

Torque motors from Baumuller are available in a wide range of force ratings and operate at high speeds with low noise. They can be driven directly without the use of gearboxes or worm gear drives, saving space and reducing maintenance costs. This is particularly important for industrial applications where large forces must be transferred over a short distance, such as in a hydraulic system. The direct drive of the motor eliminates transmission losses and pressure loss, thereby increasing efficiency.

Noise

A BLDC motor has many benefits over traditional electric motors, such as better efficiency, speed regulation, and a longer service life. It also emits significantly less noise and vibration, thanks to the fact that it doesn’t use brushes and commutator contacts. Instead, a DC current is injected into the windings of a permanent magnet rotor via a commutatorless drive circuit, which eliminates contact arcing and other electrical noise.

However, this design feature isn’t without its drawbacks. Noise can be a nuisance in some applications, especially when it’s loud enough to interfere with audio systems or other equipment. In addition, high-torque BLDC motors can generate mechanical noise due to torque ripple. This can cause a vibration that’s hard to hear, and it can affect the performance of other mechanical devices.

To reduce noise, a BLDC motor uses an electromagnetic analysis model to predict small hub motor structural and acoustic vibration modes. A response optimization was then performed to find a design parameter that maximizes torque while minimizing noise. The optimum model identified the stator slot depth and stator tooth width as the most effective parameters for reducing noise.

It’s important to note that a BLDC motor’s noise can be amplified by other sources of vibration, including loose bolts or metal plates. This is why it’s critical to isolate the motor from other sources of vibration when troubleshooting.

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