What motors do you use for pumps? For variable speed pump applications that typically use 3-phase AC induction motors with variable frequency drives (VFDs), there is another type of motor that can transfer fluids more consistently and help reduce the footprint.
Let's take a look at two typical motor challenges in pump applications.
For many pump applications, such as fluid control, speed consistency is pretty important. You want to be able to control the rate of fluid transfer to a certain degree so the same result can be expected.
VFDs are able to control the speed of the pump motors by regulating the frequency of the supplied voltage. While there are several types of control methods available, the open loop scalar volts-per-Hertz (V/f) control method is arguably the most common implemented VFD control method in basic applications (i.e., pumps and fans) and has a speed regulation of +/-2~3%. If the application requires more precise speed control, encoders can be added to close the loop, or vector control can be utilized. However, encoders are expensive, and vector control requires a more advanced CPU on the VFD.
It's also important to note that in either open loop scalar (V/f) or vector control, motor response is not guaranteed due to lack of physical feedback. Load fluctuations, which can be caused by a difference in type of fluid or viscosity, can slow the motor down and result in inconsistency in transferred volume.
Brushless motors offer a cost-effective alternative to VFDs with built-in hall-effect sensor feedback and dedicated drivers that provide precise speed regulation. Oriental Motor's BMU Series brushless motor systems have a speed regulation of +/-0.2% max. As a comparison, the BX II Series brushless motors with encoder feedback have a speed regulation spec of +/-0.05% max (at rated speed); regardless of fluctuations in load, voltage, or temperature.
In some cases, the effective speed range can be extended with brushless motors compared to VFD-driven AC motors. Standard brushless motors offer an 80~4,000 RPM (50:1 speed ratio) while VFD-driven AC motors offer 90~3,600 RPM (40:1 speed ratio). The constant torque output of brushless motors provides consistent performance throughout the entire speed range, and the limited duty torque boosts motor torque for dynamic acceleration or deceleration.
Brushless motors are more efficient than AC motors, which makes them much more compact and helps reduce energy consumption. They significantly reduce power consumption because the use of permanent magnets in the rotor prevents secondary loss from the rotor, resulting in a large decrease in power consumption (approx. 27%) when compared to AC motors.
Brushless motors are smaller and lighter compared to three-phase induction motors of the same output specifications. For example, when 200 W (1/4 HP) motors are compared, the overall length of the brushless motor is 83 mm shorter and the mass is 3.2 kg lighter.
With higher efficiency, brushless motors are more compact, consume less power, and do not need built-in cooling fans to lower its temperature for continuous duty operation. The lack of a fan also helps prevent dust dispersion or foreign particles from contaminating products such as food, cosmetics, or resin.
If you're looking for alternatives to traditional AC motors in your pump applications, consider exploring brushless motor solutions. These motors offer superior performance, efficiency, and reliability. Whether you need precise speed control, reduced energy consumption, or a smaller footprint, brushless motors are an excellent choice.
Explore our range of brushless motor systems today and discover how they can enhance your pump applications. From high-speed precision to energy savings, we've got the right solution for your needs.
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