The basic definition for Brushless Motors is an automatic device that uses an error-correction routine to correct the motion of the Brushless Motors. The general term Brushless can be applied to systems other than a Brushless Motors that use a feedback mechanism such as an encoder or other feedback device to control the motion parameters. Typically when the term Brushless is used it applies to a 'Brushless Motors' but this term is also used as a general control term with the meaning of a feedback loop to position whatever the item is including a Brushless Motors.

A Brushless Motors are different from other controlled motors in that they are controlled by a time-based derivative commonly referred to as the PID loop. A Brushless Motors are used to control position must be capable of changing the velocity of the output shaft because the time-based derivative, or the rate of change of position, is velocity.

A Brushless Motors are used in a variety of applications in many different industries. Some of the applications are Appliances, Automotive, Aerospace, CNC, Consumer, Instrumentation, Medical, Packaging Equipment, and Semiconductor.

The Stator
The stator of brushless motors consists of stacked steel laminations the windings are placed in the slots that are cut inside the laminations. The stator of brushless motors is similar to that of an AC motor however the windings are different. Brushless motors have three stator windings connected in either a star or Delta configuration. Each of these windings are constructed from multiple coils connected together to form a winding. Anaheim Automation typically has six coils per brushless motor which are made into a three-phase winding. There is usually an even number of polls

There are mainly two types of stator windings trapezoidal and sinusoidal. The difference is made on the basis of the interconnection of the coils of the stator windings which results in a different type of back EMF the trapezoidal variant gives its back EMF in the shape of a trapezoid. The sinusoidal variation gives its brushless motors a back EMF in the sinusoidal fashion going along with the current the faulted also has the shape of a trapezoid and a sinusoid. The difference between the two brushless motors is that the sinusoidal brushless motor has smoother output torque than that of a trapezoidal brushless motor. The stator will winding can be wound for multiple folk voltages. This can be customized for almost any particular applications are speed and torque requirements.

The Rotor
The rotor is made up of permanent magnets in typically have between two and eight poles the magnets are bonded onto the rotor core in alternating north and south pole fields. Ferrite magnets are normally used to make the permanent magnet rotor. For higher power density applications rare earth magnets are being used more frequently the ferrite magnets are less expensive but have lower flux density when compared to the rare earth magnets. The cost of rare earth magnets is also coming down. Higher power density means that the brushless motors can put out more torque in a smaller volume which is advantageous to manufacturers that are continuously pushed provide smaller and smaller packages.

Rare earth magnet types:
Neodymium (Nd)
Samarium Cobalt (SmCo)
The alloy of Neodymium, Ferrite, and Boron (NdFeB)

Anaheim Automation provides many different accessories for our brushless motors. These accessories include a brake, encoder, connector, cable and a driver.

The brushless motors brake is a 24vdc system. These brushless motor brakes are perfect for any holding applications. They are available on any of Anaheim Automation brushless motors, and are already attached to the rear of the brushless motors. The brushless motor brakes have a low voltage design for applications that are susceptible to weak batter, brown out, or long wiring runs. When electric power is applied to the brushless motor brake the armature is pulled by the electromagnet force in the magnet body assembly, which overcomes the spring action. This allows the friction disc to rotate freely. When electrical power is interrupted, the electromagnetic force is removed and the pressure spring mechanically forces the armature plate to clamp the friction disc between itself and the pressure plate.

Brushless motor cables can be made with the supplied brushless motor connector, or can be purchased from Anaheim Automation.

Many brushless motors types today are being made with the housing less design. In this design the laminations are exposed and are coated with a paint to prevent the laminations from rusting. Some brushless motor types are still housed in an extrusion or aluminum or steel cylindrical housing and the laminations of the stator are placed and secured in that housing.

The feedback for brushless motors is done by the use of Hall sensors when rotating the brushless motors in the stator windings need to be energized sequentially. The controller needs to know the rotor position in order to understand the next winding to be energized following the correct energizing sequence. The rotor position is sensed by the Hall sensors embedded in the back end cap of the brushless motors housing. The brushless motors utilize three Hall sensors. They are separated by either 60° or 120°. The Hall sensors sense either the rotor magnet or an external magnet placed on the back and shaft. They give a digital signal signifying whether or not a north or South Pole has passed the censors using the signals from these sensors the brushless motor controller can easily maintain the brushless motor velocity. The Hall sensors are normally mounted on a PC board and fixed to the back end cap on the non-driving end of the brushless motors

For low-speed applications it is recommended to use an encoder for the feedback rather than the Hall sensors. The Hall sensor counts per revolution can only be as great as a number of polls times the number of Hall Sensors. The brushless motors controller can use this higher count to its advantage when operating the brushless motors. With more counts per revolution at its disposal, the brushless motor controller can use this additional information to more precisely control the velocity of the brushless motors. The higher the resolution on the encoder to more finely the brushless motor controller can control the brushless motors. Even though the expense is much greater for encoders when compared to Hall sensors this price can be justified as it can result in very precise control for a much lower cost than alternative technologies such as Servo motors were AC motors or synchronous motors.

The following environmental and safety considerations must be observed during all phases of operation, service and repair of a brushless motor system. Failure to comply with these precautions violates safety standards of design, manufacture and intended use of the brushless motors and controllers. Please note that even a well-built brushless motor products operated and installed improperly, can be hazardous. Precaution must be observed by the user with respect to the load and operating environment. The customer is ultimately responsible for the proper selection, installation, and operation of the brushless motor system.

The atmosphere in which brushless motors are used must be conducive to good general practices of electrical/electronic equipment. Do not operate brushless motors in the presence of flammable gases, dust, oil, vapor or moisture. For outdoor use, the brushless motors and controllers must be protected from the elements by an adequate cover, while still providing adequate air flow and cooling. Moisture may cause an electrical shock hazard and/or induce system breakdown. Due consideration should be given to the avoidance of liquids and vapors of any kind. Contact the factory should your application require specific IP ratings. It is wise to install brushless motors and controllers in an environment which is free from condensation, electrical noise, vibration and shock. Additionally, it is preferable to work with the brushless motor and controller system in a non-static protective environment. Exposed circuitry should always be properly guarded and/or enclosed to prevent unauthorized human contact with live circuitry. No work should be performed while power is applied. Don't plug in or unplug the connectors when power is ON. Wait for at least 5 minutes before doing inspection work on the brushless motor system after turning power OFF, because even after the power is turned off, there will still be some electrical energy remaining in the capacitors of the internal circuit of the brushless motor controller.

Plan the installation of brushless motors and controllers in a system design that is free from debris, such as metal debris from cutting, drilling, tapping, and welding, or any other foreign material that could come in contact with circuitry. Failure to prevent debris from entering the brushless motor system can result in damage and/or shock.

The following information is intended as a general guideline for wiring of the Anaheim Automation brushless motors product line. Be aware that when you route power and signal wiring on a machine or system, radiated noise from the nearby relays, transformers, and other electronic devices can be inducted into the brushless motor and encoder signals, input/output communications, and other sensitive low voltage signals. This can cause systems faults and communication errors.

WARNING - Dangerous voltages capable of causing injury or death, may be present in the brushless motor system. Use extreme caution when handling, wiring, testing, and adjusting during installation, set-up, tuning, and operation. Don't make extreme adjustments or changes to the brushless motor system parameters, which can cause mechanical vibration and result in failure and/or loss. Once the brushless motors are wired, do not run the brushless motor controller by switching On/Off the power supply directly. Frequent power On/Off switching will cause fast aging of the internal components, which will reduce the lifetime of brushless motor system.

Strictly comply with the following rules:
- Follow the Wiring Diagram with each brushless motor
- Route high-voltage power cables separately from low-voltage power cables.
- Segregate input power wiring and brushless motor power cables from control wiring and brushless motor feedback cables as they leave the brushless motor controller. Maintain this separation throughout the wire run.
- Use shielded cable for power wiring and provide a grounded 360 degree clamp termination to the enclosure wall. Allow room on the sub-panel for wire bends.
- Make all cable routes as short as possible.

NOTE: Factory made cables are recommended for use in our brushless motors and driver systems. These cables are purchased separately, and are designed to minimize EMI. These cables are recommended over customer-built cables to optimize system performance and to provide additional safety for the brushless motor system and the user.

WARNING - To avoid the possibility of electrical shock, perform all mounting and wiring of the brushless motors and controller system prior to applying power. Once power is applied, connection terminals may have voltage present.

The following information is intended as a general guideline for the installation and mounting of the brushless motor system. WARNING - Dangerous voltages capable of causing injury or death may be present in the brushless motor system. Use extreme caution when handling, testing, and adjusting during installation, set-up, and operation. It is very important that the wiring of the brushless motor and controller be taken into consideration upon installation and mounting.

Subpanels installed inside the enclosure for mounting brushless motor system components, must be a flat, rigid surface that will be free from shock, vibration, moisture, oil, vapors, or dust. Remember that the brushless motors and controllers will produce heat during work, therefore, heat dissipation should be considered in designing the system layout. Size the enclosure so as not to exceed the maximum ambient temperature rating. It is recommended that the brushless motor controller be mounted in position as to provide adequate airflow. The brushless motors should be mounted in a stable fashion, secured tightly. NOTE: There should be a minimum of 10mm between the brushless motor controller and any other devices mounted in the system/electric panel or cabinet.

NOTE: in order to comply with UL and CE requirements, the brushless motor system must be grounded in a grounded conducive enclosure offering protection as defined in standard EN 60529 (IEC 529) to IP55 such that they are not accessible to the operator or unskilled person. As with any moving part in a system, the brushless motors should be kept out of the reach of the operator. A NEMA 4X enclosure exceeds those requirements providing protection to IP66. To improve the bond between the power rail and the subpanel, construct your subpanel out of a zinc-plated (paint-free) steel. Additionally, it is strongly recommended that the brushless motor controller be protected against electrical noise interferences. Noise from signal wires can cause mechanical vibration and malfunctions.

Anaheim Automation was established in 1966 as a manufacturer of "turnkey" motion control systems. Its' emphasis on R&D has insured the continued introduction of advanced brushless motor driver/controller, such as the brushless motors product line. Today, Anaheim Automation ranks high among the leading manufacturers and distributor of motion control products, a position enhanced by its excellent reputation for quality products at competitive prices. The brushless motors product line is no exception to the Company's goal.

Anaheim Automation offers a wide variety of standard brushless motors. Occasionally, OEM customers with mid to large quantity requirements prefer to have brushless motors that are custom or modified to meet their exact design requirements. Sometimes the customization is as simple as shaft modification, brake, oil seal for an IP65 rating, mounting dimensions, wire colors, or label. Other times, a customer might require that a brushless motor meet an ideal specification such as, speed, torque, and/or voltage.

Engineers appreciate that Anaheim Automation's brushless motor product line can answer their desire for creativity, flexibility and system efficiency. Buyers appreciate the simplicity of the "one-stop shop," and the cost savings of custom brushless motors design, while engineers are pleased with Anaheim Automation's dedicated involvement in their specific brushless motor system.

Anaheim Automation's standard brushless motors are a cost-effective solution, in that they are known for their rugged construction and excellent performance. A considerable size of its sales growth has resulted from dedicated engineering, friendly customer service and professional application assistance, often surpassing the customer's expectations for fulfilling their custom requirements. While a good portion of Anaheim Automation's brushless motors sales involves special, custom, or private-labeling requirements, the company takes pride in its standard stock base located in Anaheim, California, USA. To make customization of a brushless motors affordable, a minimum quantity and/or a Non-Recurring Engineering (NRE) fee is required. Contact the factory for details, should you require a custom brushless motor in your design.

All Sales for a customized or modified brushless motors are Non-Cancelable-Non-Returnable, and a NCNR Agreement must be signed by the customer, per each request. All Sales, including a customized brushless motors, are made pursuant to Anaheim Automation's standard Terms and Conditions, and are in lieu of any other expressed or implied terms, including but not limited to any implied warranties.

Anaheim Automation's customers for the brushless motors is diverse: companies operating or designing automated machinery or processes that involve food, cosmetics or medical packaging, labeling or tamper-evident requirements, assembly, conveyor, material handling, robotics, special filming and projection effects, medical diagnostics, inspection and security devices, pump flow control, metal fabrication (CNC machinery), and equipment upgrades. Many OEM customers request that we "private-label" the brushless motors, so that their customers stay loyal to them for servicing, replacements and repairs.

PLEASE NOTE: Technical assistance regarding its brushless motors, as well as all the products manufactured or distributed by Anaheim Automation, is available at no charge. This assistance is offered to help the customer in choosing Anaheim Automation products for a specific application. However, any selection, quotation, or application suggestion for brushless motors, or any other product, offered from Anaheim Automation's staff, its' representatives or distributors, are only to assist the customer. In all cases, determination of fitness of custom brushless motors in a specific system design, is solely the customers' responsibility. While every effort is made to offer solid advice regarding the brushless motor product line, as well as other motion control products, and to produce technical data and illustrations accurately, such advice and documents are for reference only, and subject to change without notice.

The key dissimilarity between brushless motors and their predecessors is the process of commutation. Newer brushless motors are electrically commutated; this is accomplished with Hall elements, by counter EMF, or encoder feedback.

Factors That Affect Motor Life

Bearing failure is a major factor when it comes to brushless motors failing. As a result of using industrial grade components, some brushless motors have the ability to last lifetimes in excess of 20,000 hours or more. Integrated into these systems are permanently lubricated ball bearings that use special grease, thus eliminating the need for re-lubrication. Non-approved lubricants are not recommended for the motor components because they could potentially shorten the life of the motor.

Temperature also plays a key role in the lifespan of a motor. The motor casing in particular must ensure that the heat generated in the motor windings must be dispelled. The motor may face severe damage if it exceeds the specification regarding heat. The motor's performance has a direct correlation with the maximum possible rotor temperature, ambient temperature, and duty cycle. As temperature increases, the winding resistance increases, and magnetic forces decrease, ultimately causing performance to dwindle. When running at high continuous loads, all of these factors must be taken into consideration. Heat sinking and forced air-cooling can considerably lower operating temperatures.