Parallel shaft AC gear motors have long been the standard in the industry. However, right-angle brushless gear motors are becoming increasingly popular due to their ability to reduce the footprint of machines, such as conveyors.
Another important factor to consider is the type of gears used in the gearhead. While worm gear technology is widely used, its efficiency can vary between 50% and 90%, depending on the gear ratio. In contrast, hypoid gear technology maintains an efficiency range of 80% to 95%, regardless of the gear ratio. This higher efficiency allows for more torque to be transferred from the motor to the load shaft, and in some cases, even smaller motors can be used.
An ideal example of this application is shown below, where a parallel shaft gear motor is installed on the side of a belt conveyor. Notice how the motor and gearhead protrude from the conveyor, increasing the machine's footprint and potentially posing a safety risk. Additionally, extra components like couplings and mounting plates are often required for installation.
CHALLENGE : Improve efficiency & minimize equipment footprint
Conventional Equipment: An AC induction motor is mounted on the conveyor with a parallel shaft gearhead and a coupling mechanism. A variable frequency drive (VFD) is typically used for speed control (not shown).
Problems with Conventional Equipment:
- The motor and transfer mechanism protruding on the side of the conveyor take up more space than necessary, making it difficult to add more conveyors side by side.
- The number of parts and labor hours needed for installation is excessive.
- Parallel shaft gear motors typically use helical or spur gears, which are less efficient in torque transfer compared to hypoid gears.
SOLUTION : BMU Series brushless motor + JH gearhead + AC input driver
Using a compact and high-power right-angle hypoid gear motor reduces the motor’s protrusion on the side of the conveyor. The efficient JH gearhead also requires fewer parts for installation (face mount or using a torque arm). Since both brushless motors and the JH gearheads are more efficient than traditional AC motors and parallel shaft gearheads, the motor size and power consumption can also be reduced. To make it easier to replace AC motors and VFDs, we offer solutions for our brushless motors. The easy-to-install BMU Series also improves operational efficiency by reducing labor hours.
Advantages offered by BMU Series:
- JH right-angle hypoid gearhead features high rigidity, torque, and efficiency
- Reduces motor protrusion
- Smaller motor size
- Face mount (left) / torque arm (above)
- Fewer parts required for installation
RESULT : Reduced labor hours by using fewer parts
How a right-angle gearhead can improve machine design and installation.
Read the next post to see how much mass can be reduced by switching to brushless motors.
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