DC motor | All-round talent for countless applications

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Details: Released: 04.04.2022; Last updated: 08.08.2024; Hits: 15286

The DC motor is a multi-talent. The all-rounder is not only suitable for many applications in the Automotive engineering, where he is in z. B. steering is used. Also in the Medical Technology It is used in pumps or surgical instruments. Countless other applications can be found in smart homes, scanners, toys, video surveillance, drones, to name just a few. We present them to you here New developments:

DC motor Kocomotion

Content

DC motor 2024 – The most important things in brief
DC motor innovations
Archive for DC Motor News
Frequently Asked Questions

DC motor 2024 – The most important things in brief

The DC motor, too DC motor, remains an essential part of modern drive technologies and has proven itself to be versatile in use through continuous developments and improvements. Current trends in DC motors focus on increasing energy efficiency, reducing maintenance costs, and integrating advanced electronic control systems that enable more precise manipulation and real-time feedback.

Especially the development of brushless DC motors (BLDC) marks an advance in drive technology as they require less maintenance and have a longer service life. These motors are known for their efficiency and high power density, making them ideal for mobile applications including electric vehicles and portable electronic devices.

Stepper motor with encoder + controller

In addition, the miniaturization of DC motors continues, which enables integration into even smaller and more complex systems. Because of these advantages and continued innovation, DC motors remain a preferred choice in many industries, from robotics to medical technology.

DC motor innovations

High-performance frameless motor with minimal space requirements

08.08.2024 | koco Motion now offers frameless motors in various performance classes. The low-noise motors are highly efficient, durable and very reliable. Such a frameless motor requires very little installation space due to the direct integration and the hollow shaft concept. Support with design and integration is included.

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BLDC motor spindle for brushing and deburring

06.08.2024 | With the BLDC motor spindle, MD compressed air technology for the first time an electric drive for use in a domain of Compressed air technology The first users are likely to be manufacturers who previously had no compressors or no suitable compressors for brushing and deburring. Getting started with the new electric drives is comparatively inexpensive and therefore makes economic sense even for smaller brushing and deburring applications.

»In the near future, our customers will be able to choose whether they want to implement a desired application with pneumatic or electric drive. Or whether they want to use a mix of both systems, because each technology has its strengths,« says Claus Werner Bay, Managing Director of MD Drucklufttechnik.

The new series is available in two sizes: The smaller model with a diameter of 36 mm covers a speed range of 700 to 6000 rpm and has a maximum torque of 1 Nm. The 1,1 mm design has less spin at 45 to 700 rpm and 4500 Nm, but more power. Other models are to follow soon, including drives with axial/radial deflection and quick-change chucks.

Initially, the developers were concerned with the speed that can be achieved with classic drives for brushing and deburring. high surface quality In applications such as automated deburring of sensitive surfaces using brushes, high-torque, electric robot spindles achieve a previously unattainable level of quality.

The electric robot drive by Mannesmann Demag can build up a high torque even at low speeds thanks to the gear. The torque can be used to finely vary the contact pressure of the BLDC spindles. The electric motor keeps its speed constant as long as the contact pressure and torque do not exceed the maximum of the spindle - a big difference to surface treatment with compressed air, because with pneumatic drives you often need several drives to change the speed.

DC motor as a multi-talent for modern vehicles

DC motor production at Schaeffler in Bühl

31.03.2022/XNUMX/XNUMX | The brushless DC motor is a key component for many applications in the Vehicle. The EC motor, which is only about 5 cm small, can be found in the drive to the steering. Schaeffler develops and manufactures DC motors in Bühl with immediate effect. The automotive supplier is thus entering a growing field of business.

The DC motor is becoming increasingly popular when used in modern vehicles: the electric motor can be found in Dual-clutch transmission, hybrid transmission, rear-axle steering, thermal management or seat adjustment. Schaeffler now builds the DC motors itself in Bühl. They are used as standard in a hydrostatic clutch actuator. With the help of the motors, the required pressure is built up here in order to Clutch to operate.

Rotary encoders for axes in drives, machines and systems

"EC motors are true all-rounders and vehicles can no longer be imagined without them," says dr Jochen Schroeder, Head of the Electromobility division at Schaeffler in Bühl. Compared to motors that have mechanical sliding contacts, brushless DC motors are much more durable, more efficient and work much more reliably. Incidentally, the abbreviation EC stands for “electronically commutated”. The electronic commutator electronically changes the voltage from one motor winding to the next.

High level of vertical integration facilitates adjustments

A DC motor from Schaeffler is characterized by the single tooth construction with the stator it contains. The stator teeth are individually stamped, stacked, insulated with injection molding and then assembled into a chain after being wrapped with enameled copper wire. This design offers a significantly higher power density compared to the full cut, in which the laminated core of the stator consists of a closed ring.

“When manufacturing the DC motor, we rely on in-house production from punching stator teeth to the finished product,” says Mr. Schröder. This high level of vertical vertical integration offers many advantages. The employees in production can react more flexibly to customer requests for adjustments and continuously optimize production itself, because the entire process chain from the individual part to the finished motor is implemented in Bühl.

Sensor technology protects WKA rotor blade from ice and damage

The complete production line for the series production of DC motors was realized in just over a year. It is the result of one person working together cross-site teams from Bühl, Höchstadt, Herzogenaurach and Haguenau. The production comprises a total of around 25 process steps. These run fully automated and fully interlinked with two integrated injection molding machines, winding machines and end-of-line testing.

A driverless transport system supplies the system with individual parts and transports the finished products. “The tight schedule could only be adhered to because this project was carried out in close cooperation,” says Benjamin Hofrth, Head of Operations in the Actuator Systems division at Schaeffler in Bühl. He is responsible for setting up production, in which more than one million DC motors will be manufactured every year from now on.

"For the development and production of future DC motors, our team in Bühl relies particularly on flexibility," says Mr. Hoffarth. This is how a specially developed production kit of stators with three diameter gradations (53 mm, 75 mm and 86 mm) cover different motor sizes and thus different applications. The aim is also to adapt the future EC electric motor portfolio so that it can be used in the areas of actuators, e-mobility and industry as diverse as possible.

BLDC Motor Innovations from Minebea Mitsumi

November 16.11.2021, XNUMX | BLDC motors are all-rounders and are suitable for countless applications. This is how the BLDC motor converts e.g. B. in power tools, pumps, conveyor belts, Robot and other machines efficiently convert electrical energy into motion. With their high power density properties, a large number of e.g. B. save weight in automobiles. Minebea Mitsumi offers such a Brushless Motor Portfolio.

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DC motor and other drives for medical technology

01.03.2021 | koco Motion offers a comprehensive product range of drive technology for the currently booming medical technology sector. DC motor, bell rotor motor, brushless DC motor, precision gear motor, precision servo motor and miniature stepper motor Constar's portfolio allows almost all developers' wishes to be fulfilled.

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BLDC motor for driverless transport systems in logistics

Ebm papst BLDC motor 24.01.2020 | EBM-Papst presents intelligent drives for driverless transport systems and shuttle applications for innovative logistics. As a novelty, the drive specialist is presenting a driving and steering system that uses BLDC brushless direct current motors for mobile Battery operated applications is operated. The DC motors are also used in shuttle applications.

The market for driverless transport systems (AGV) is growing disproportionately. The drives for Freely navigating AGVs must meet high requirements. The users require intelligent networking via bus systems and rapid commissioning. Fulfilling this requires a high power density with minimal installation space and maximum efficiency.

BLDC motors for driving and steering system and shuttle

The new Driving-wheel steering system from EBM-Papst is an innovative drive solution for mobile battery-powered applications. It enables the surfaces to be moved by the vehicles and consists of Motor, Transmission, Sensor and wheel.

EBM-Papst uses the brushless DC motors ECI-63 and ECI-80 in the new drive-steering system or as a direct drive Wheel Drive. The BLDC require little installation space. The brushless DC motors and achieve a high torque with just 24 V. For a short time, the BLDC can deliver three times the output. The integrated intelligence in the motors allows predictive maintenance and condition monitoring in the sense of green intelligence. Together with the Optimax gearboxes, robust, compact and intelligent drives are created.

Shuttles are currently the trend Intralogistik. Nowadays, warehouses are built taller in order to keep a warehouse's space consumption as low as possible. All storage positions on all levels are then approached by shuttle vehicles. The requirements for positioning accuracy, service life and dynamics are also met by the brushless motors ECI-63 and ECI-80 in combination with the Optimax gear units.

Sonic motors for durable devices

10.01.2020 | koco Motion have now Sonic motors included in his program. The drives, which are available in sizes from 14 to 32 mm in diameter, are often used in toothbrushes, massage or facial cleansing devices. The Drives from the manufacturer are compact, run quietly and are very reliable. Visually, the Sonic motors hardly differ from normal rotary drives.

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Archive for DC Motor News

Brushless DC outrunners with high power density
Ironless motors for battery powered applications
Brushless DC flat motors for tight installation conditions
Vibration motor for automobiles and other applications
200 watt coreless motor
Brushless flat motors for robotics, medical technology and drones
Brushless DC motor for Micro Drive servo drive
Brushless DC motor with Profinet interface
Brushless DC motors with individual control
DC motor with new coil segment winding
Sterilizable, BLDC mini motors for surgical hand tools
Power increase with copper-graphite-commutated DC-Micromotor
Customized BLDC motors with integrated electronics
DC motors with and without brushes
BLDC motors with and without iron, electronically commutated

Brushless DC outrunners with high power density

11.12.2019 | Brushless external rotor motors combine a small installation space with a high power density. koco Motion presents a new addition to the product family that offers impressive characteristics thanks to the choice of materials and magnets. The portfolio of these brushless DC motors from Koco Motion includes drives with a diameter of 10 to 90 millimeters.

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Ironless motors for battery powered applications

November 12.11.2019, XNUMX | The ironless DC motors from koco Motion have already proven themselves very well in many applications. They are very efficient, offer high speeds and a long service life. The drive specialist is now expanding its series Coreless motors to new versions that are specially designed for the requirements of medical technology and safety technology.

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Brushless DC flat motors for tight installation conditions

Faulhaber flat motors Sep 27.09.2019, XNUMX | More and more applications in the areas of robotics, prosthetics, laboratory automation, medical technology, pumps and aircraft cabin equipment require high torque with a very short overall length. Faulhaber with the market launch of the flat brushless DC motor family BXT with grooved winding meet these requirements.

Thanks innovative winding technology and optimized design are External rotor high-performance drives only 14, 16 and 21 mm long, but deliver torques up to 134 mNm with a diameter of 22, 32 or 42 mm. They are designed for a continuous output power of up to 100 W and thus exceed the standards of this drive class, especially with regard to the ratio of torque to length, volume and weight. This benefits applications in confined spaces.

The series comes standard with digital Hall sensors fitted. It is designed for speeds of up to 10.000 rpm and can be combined with various gearboxes, encoders, brakes and controls from the manufacturer's portfolio. This specializes in modifications to the mechanical and electrical interfaces of the motors and can therefore offer solutions that are individually configured for each application. The motors have individual strands as standard and thus offer a flexible electrical interface with several industrial connectors.

Brushless flat motors for robotics, medical technology and drones

Servotecnica DC motor 10.09.2019 | Servotecnica is expanding its product line for application areas such as medical technology, robotics and drone technology with new brushless flat motors from the SVTM F series. They offer high torque in the smallest space with a simple design and high-quality material selection.

Equipped with external runner and Iron core winding The SVTM flat motor series is suitable for applications that require high torque with compact dimensions: all motors with an output of 200 W are available in sizes from 20 to 90 mm in diameter.

The flat motors with a long service life are used, for example, in gripping robots, in prostheses and Exoskeletons as well as for conveyor belts. Integrated encoders, special solutions for cables and customized shaft and flange geometries are possible.

Brushless DC motor for Micro Drive servo drive

Dunkermotoren Brushless DC motor 15.04.2019/24/48 | With the brushless DC motors (45 to 65 volts) of the BG 75, BG 95(S), BG XNUMX and BG XNUMX series dark engines has been the market leader in the power range from 20 to 1100 W for years. As part of a product partnership with Siemens, the drives are now also available in a specific version that is compatible with the new Simatic Micro-Drive servo drive system.

By simply integrating the servo drive into the Simatic world the engineering time is significantly reduced. The integration into Siemens Automation services is made possible via the TIA Portal and simplifies commissioning and service. Communication takes place via Profinet IRT with Profisafe and Profidrive profiles. The new Safety Integrated function SLT (Safely Limited Torque) ensures a limited torque by monitoring the motor current during operation.

Smart components in the engine, together with a patented data transmission, put the controller in a default state after connecting to the motor. Complicated drive tuning and parameterization of the controller control loops are therefore a thing of the past.

Brushless DC motor with Profinet interface

08.05.2018 | The BLDC drive BG 65 from dark engines is equipped with an integrated Profinet interface and is compatible with Siemens controllers from the S7 series. The DC machine can be easily integrated into PLC controls using function blocks.

With a continuous power output of 60 to 190 W and a peak of 341 W, the BG 65 PN electric motor with its compact design is suitable for industrial automation and the Engineering. Because of its built-in absoluteencoders no referencing is necessary.

The manufacturer sees areas of application for the BG 65 PN, for example, in linear axes or lifting cylinders for positioning tasks. With its integrated modular system, the drive specialist can offer planetary and worm gears to match the motor with a continuous torque of up to 160 Nm.

Vibration motor for automobiles and other applications

17.12.2018 | Koco Automotive presents its new integrated vibration motor VC2039, which can be used in a wide variety of applications with little design effort. In its water- and foam-resistant housing, the DC motor can withstand increased pressure in liquid media, such as that which occurs when foaming into a steering wheel.

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200 watt coreless DC motor

15.02.2018/XNUMX/XNUMX | On the SPS IPC Drives effect koco Motion two new powerful ones ironless drives presented, which supplement the previous sizes in the diameter range from 4 to 25 mm. The new Glocken Anker DC motors in the 30 and 32 mm diameter range feature robust copper-carbon commutation and offer peak power of up to 200 W.

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Brushless DC motors with individual control

22.01.2018/XNUMX/XNUMX | If a mechanically commutated DC motor reaches its limits in terms of service life or performance, it is time to switch to brushless DC motors. The demand for brushless DC motors is unbroken - and the trend is rising. on this koco Motion set and offers a comprehensive BLDC motor Program.

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DC motor with new coil segment winding

Faulhaber DC motor winding Oct 04.10.2017, 2264 | The four-pole motor 4…BPXNUMX from Faulhaber achieves a torque of 59 mNm with a weight of only 140 g and a diameter of 22 mm. The engine can also run up to 34.500 rpm^-1, The reason for this performance is the coil's new coil segment winding, developed for the BP4 family of brushless DC motors.

Thanks to the overlapping, individually wound segments, you can create a special coil in the coil large amount of copper accommodate. A desirable side effect is the high winding symmetry with minimal losses and correspondingly high efficiency. With its low moment of inertia, the motor is well suited for dynamic start/stop operation.

Integrated analogue Hall sensors As an option, they can replace an encoder in most applications and determine the position of the output shaft very precisely. Compatible optical and magnetic encoders are also available for high-precision applications. The motor is used, among other things, in industrial automation and in handpieces of electric tools, for example for electric pruning shears and screwdrivers, motorized instruments for surgery, grab and Robot, but also for aviation or active prostheses.

Sterilizable, BLDC mini motors for surgical hand tools

Portescap DC motor 25.01.2016 | Portescap announces the introduction of application-specific motors for surgical hand tools such as arthroscopy shavers, ENT microdebriders and large bone drills. The basis for the product design is the standard motor, which can withstand up to 1000 autoclave cycles.

The brushless DC mini motors for Arthroscopy shaver are designed to power surgical hand tools for minimally invasive joint surgery. The idle speed of these engines is 4000 to 7000 rpm, the maximum continuous torque is 1 mNm and 117 mNm.

The brushless DC mini motors for large Bone drill feature drilled gear and motor combinations that allow the insertion of intramedullary nails and Kirschner wires and provide high torque at operating speed. These battery-powered solutions offer high torque without tipping. This is necessary for joint replacement operations on the knee, hip and shoulder, for example. The engine offers an idle speed of 950 rpm with a maximum continuous torque of 1 mNm.

The DC motors are also suitable as motor-driven surgical hand tool for minimally invasive ENT operations and arthroscopic procedures on small joints. With an idle speed of 11.800 rpm and a maximum continuous torque of 1 mNm, these motors are designed to precisely cut tissue and cleanly mill bones. Spinal, cranial, facial and otological surgery requires drilling at extremely high speeds. The engines offer an idle speed of 39 rpm and a maximum continuous torque of 90.500 mNm.

Power increase with copper-graphite-commutated DC-Micromotor

Faulhaber DC motor November 09.11.2015, 2668| The DC motor XNUMX … CR from Faulhaber offers significantly more power than comparable drives and is the most powerful copper-graphite commutated DC micromotor on the market in its size class. Thanks to an enlarged NdFeB magnet and a higher copper content in the winding, it delivers a nominal torque of 70 mNm. With a diameter of 26 mm, it weighs only 189 g.

In addition, with its high impulse torque, it reaches full power very quickly. This makes the 2668…CR particularly suitable for professionals High performance tools such as pruning shears or motorized screwdrivers. The motor’s copper-graphite brushes are characterized by great stability and low wear. The housing is made of coated steel. The motor can be combined with high-resolution optical or magnetic encoders.

In addition to handheld devices, it is also suitable for many other applications such as in aviation, robotics, medical technology, special purpose machinery, dosing systems or automation solutions.

Customized BLDC motors with integrated electronics

Aug 19.08.2015, XNUMX | Again and again, it is the service life that pushes a mechanically commutated DC motor to its limits due to spark erosion and mechanical friction. However, as soon as applications require a correspondingly long runtime, they are available brushless DC motors from koco Motion as an alternative because they are electrically commutated.

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BLDC motors with and without iron, electronically commutated

13.02.2014/XNUMX/XNUMX | The demand for engines with longer service life is growing in all industrial sectors. Just a year ago, the manufacturer and distributor of compact, highly integrated electric drives and controls koco Motion brushless DC motors have been added to its portfolio. Today it already offers a product range that... almost nothing to be desired leaves.

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Frequently Asked Questions

How does a DC motor work?

A DC motor converts converts electrical energy into mechanical motion by allowing direct current to flow through the windings of an electromagnet. This current creates a magnetic field that interacts with a permanent magnet in the motor, causing the motor's rotor to rotate. The direction of rotation of the motor can be changed by reversing the polarity of the current. The speed of the motor is regulated by the voltage level, while the torque is influenced by the current flow. Efficient commutation, i.e. switching the direction of current in the windings, is essential for the performance and longevity of the motor.

What are the disadvantages of a DC motor?

Although DC motors offer precise control and easy speed regulation, they also have some disadvantages:

wear: The brushes and commutator required to supply power to the rotor are subject to mechanical wear that requires maintenance and replacement.
Sparks: The friction between the brushes and the commutator can cause sparks, which damage the components and pose potential safety risks.
Maintenance intensity: The need for regular inspections and replacement of brushes increases maintenance costs and effort.
Limited capacity at high speeds: At high speeds, DC motors can lose power due to centrifugal forces and the limitation of the brush commutator mechanism.

Which is better DC motor or AC motor?

The choice between DC motor and AC motor depends largely on the specific application:

DC motors are ideal for applications requiring precise speed control as they allow easy speed regulation over a wide range. They are compact and offer high starting torque, making them ideal for portable devices and vehicles.
AC motors are characterized by their robustness and lower maintenance requirements. They are typically more durable and less expensive to produce. Due to the simpler design without brushes and commutator, they are more suitable for industrial applications where durability and low maintenance are required.

What types of DC motors are there?

DC motors can be classified into different types depending on their structure and functionality:

Brushye DC motors use brushes and a commutator to switch the current in the motor windings. They are easy to control and offer high starting torque.
brushlesse Direct Current Motors (BLDC) eliminate brushes and commutator by using an electronic control that switches the motor windings in the correct order. They are more efficient, require less maintenance and have a longer lifespan.
direct currentservomotors specialize in precise control of movement and positioning in automated applications. They can be both brushed and brushless.
Universal motorAlthough they are powered by alternating current, they are technically DC motors because they work equally well with direct current and alternating current. These motors are often used in household appliances.

What is a permanent magnet motor?

A permanent magnet motor is an electric motor in which the magnetic field in the rotor is generated by permanent magnets instead of by current-carrying windings. These motors are particularly efficient because no energy is required to generate the magnetic field, which is the case with conventional electric motors with field windings. Permanent magnet motors offer a high power density, are more efficient and require less maintenance compared to other types of motors. They are often used in applications that require high speed and precise control.

Source: This article is based on information from the following companies: Dunkermotoren, EBM-Papst, Faulhaber, Koco Motion, MD Drucklufttechnik, Portescap, Schaeffler, Servotecnica.