Brushless motors: what advantages do they offer in the manufacturing sector 

Brushless motors what advantages do they offer in the manufacturing sector - IPC

Efficiency and innovation are essential aspects of maintaining a competitive advantage in the industrial field, as demonstrated by the increasingly widespread adoption of brushless motors. Over time, these components have proven to offer numerous benefits, especially in the manufacturing world, a sector that – by its very nature – is continually seeking solutions to improve productivity, reduce operating costs, and promote sustainability. 

Brushless motors, as is well known, offer more precise control of speed and position compared to brushed motors. This is due to several factors: the absence of friction, first and foremost, which affects the smoothness and accuracy of movement, but also the reduced inertia. These characteristics, combined with easy integration with advanced electronic control technologies – such as digital servo drives, integrated electronics, or PLC/motion controllers – ensure an optimal level of precision in all applications requiring accurate and repeatable movements, from the production of electronic components to the processing of complex goods and materials. 

Brushless motors: compact, lightweight, cost-effective 

Brushless motors are also appreciated for their compactness and thus their ability to reduce the footprint of a machine or line, an aspect that guarantees greater design and installation flexibility in many sectors (automotive, textile, pharmaceutical, woodworking, food & beverage, etc.). 

The management of commutation with position sensors, such as encoders or Hall effect sensors, provides real-time feedback on the rotor position, allowing the control system to adjust the electric current to achieve more precise and consistent movement. 

Another recognized advantage is their intrinsic efficiency: a more efficient transmission of electrical energy into kinetic energy is indeed a crucial factor for all those applications (almost all) where reducing consumption is necessary, also for obvious economic reasons. 

In terms of costs, one cannot overlook the better wear resistance, both in absolute terms and regarding maintenance needs. Reducing friction means reducing the likelihood of mechanical failures, as well as the need for frequent replacements or cleaning interventions. This aspect is invaluable in all manufacturing sectors where machinery and equipment must operate without interruption to ensure continuous production with minimal downtime. 

 

Brushless motors: a low environmental impact positioning choice 

In industrial automation processes, brushless motors are often used in industrial robots, handling systems, robotic arms, and assembly lines, as well as electric actuators in various devices such as valves, pumps, and regulation mechanisms. Their ability to provide precise control is crucial in applications where it is necessary to regulate flows, pressures, or other parameters. 

Brushless motors are also widely used in the food industry and in all applications requiring fast automation, especially in packaging and wrapping stages. Their easy cleaning, the absence of brushes that could contaminate food, and the ability to provide precise speed and position control make them ideal for this sector. CNC machine tools also use this type of motor to drive movement axes. Their ability to provide constant torque, variable speed, and precise control makes them the ideal choice for material processing in applications such as milling, turning, and cutting. 

More generally, one could say that brushless motors are preferred in all applications requiring quick and accurate positioning, good management of rapid accelerations, braking, or motion reversals, fine-tuning applications, interpolated motion control, tension and force controls that require precision and linearity, or power generation systems with high average efficiency. 

On the environmental front, it is worth mentioning the quieter operation compared to traditional motors. This characteristic is considered a plus in almost all production sectors: quieter production not only improves operator comfort but also helps reduce the overall noise level in the working environment. By reducing energy consumption, maintenance costs, and waste, companies can work towards a medium-to-long-term perspective, meeting the growing demands of a market increasingly oriented towards sustainability.

 

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