Ningbo Yinzhou Leisheng Machinery Co.,Ltd , https://www.nblscasting.com
In the industrial world, parallel shaft AC gear motors have long been the standard choice. However, right-angle brushless gear motors are becoming increasingly popular due to their ability to reduce machine footprint—especially in applications like conveyors.
One key factor to consider is the type of gears used in the gearhead. Worm gear technology is widely used, but its efficiency can vary between 50% and 90%, depending on the gear ratio. In contrast, hypoid gear technology maintains a consistent efficiency range of 80% to 95%, regardless of the ratio. This higher efficiency allows for more torque to be transferred from the motor to the load, and in some cases, even smaller motors can be used.
The image below shows a belt conveyor equipped with a parallel shaft gear motor. Notice how the motor and gearhead extend beyond the conveyor’s frame, increasing the overall space it occupies. This not only affects the layout of the system but can also pose safety risks. Additionally, extra components such as couplings and mounting plates are often required for installation.
**CHALLENGE: Improve efficiency & minimize equipment footprint**
Traditional setup: An AC induction motor is mounted on the conveyor using a parallel shaft gearhead and a coupling mechanism. A variable frequency drive (VFD) is typically used for speed control.
**Problems with conventional setups:**
- The motor and transfer mechanism protrude from the conveyor, taking up unnecessary space and making it difficult to add more conveyors side by side.
- Installation requires excessive parts and labor hours.
- Parallel shaft gear motors often use helical or spur gears, which are less efficient than hypoid gears.
**SOLUTION: BMU Series brushless motor + JH gearhead + AC input driver**
Using a compact and high-power right-angle hypoid motor helps reduce the motor's protrusion on the conveyor. The efficient JH gearhead also simplifies installation, requiring fewer parts (face mount or torque arm). Since both brushless motors and JH gearheads are more efficient than traditional AC motors and parallel shaft gearheads, the motor size and power consumption can be reduced. To make it easier to replace AC motors and VFDs, we offer complete solutions for our brushless motors. The easy-to-install BMU Series also improves operational efficiency by reducing labor time.
The images show a belt conveyor with a right-angle gear motor and a torque arm installation. The BMU Series offers several advantages:
- High rigidity, torque, and efficiency with the JH right-angle hypoid gearhead
- Reduced motor protrusion
- Smaller motor size
- Face mount or torque arm options
- Fewer parts needed for installation
This design not only saves space but also reduces installation time and complexity. By using fewer parts, the overall labor hours are significantly reduced.
To see how a right-angle gearhead can improve machine design and installation, check out the video below.
Read the next post to learn how much mass can be reduced by switching to brushless motors.
Also, explore more about our solutions here.