Longbank High Speed BLDC Motor

Longbank is a fully qualified high speed BLDC motor manufacturer in China. For over 22 years, we have focused on producing superior quality high speed BLDC motors in different models. If you are starting a motor-related business or have an upcoming project, Longbank is your best go-to source.

We offer a thorough series of high speed BLDC. This is available in different colors, dimensions, and structures. Also perfect for broad industries and applications. As a professional motor supplier and manufacturer in China, we serve personal electronics, industrial, and automotive industries.

Longbank high speed BLDC motor offers key features such as integrated motor control, smart gate drive, functional safety design packages, and integrated FETs. It also ensures high efficiency, high power, and compact designs. The features mentioned will give the entire high speed BLDC motor a power-dense, efficient, and quiet solution.

More specifications of Longbank high speed BLDC motor are:

• Maximum Speed Control Range: 80 ~ 4000 r/min
• Advanced Performance
• Features with Easy to Use Controls
• Torque Limit Function
• Metric or Imperial Shafts Available
• IP67, IP66, and IP65 Types Available
• More compact and efficient
• Long life, Quiet maintenance-free operation
• High power, light, and slim

Longbank high speed BLDC motor is your ultimate solution to boost your business. We can be your one-stop high speed BLDC motor supplier that you can fully rely upon.

As always, we execute the strictest quality inspection for high speed BLDC motors. This is to ensure we can bring to you the best, most flawless small motors in any model. Thus, we are only using ROHS-detected materials for production; therefore, you have no worries about design errors. Longbank, together with our professional engineers, will do our best to achieve the outcome you expected.

As a well-certified manufacturer, we can help you get the right product for you. Whether small or big orders, we will surely accommodate your specific requirements.

Every day, more than 50,000 sets of motors are distributed to customers worldwide. Here at Longbank, you can guarantee you’re in good hands!

Contact us for needed assistance.

High Speed BLDC Motor: The Comprehensive FAQ Guide

High speed BLDC is an electrical device which converts electrical energy into mechanical energy using a direct current electric power.

It is regarded as one of the most efficient motors in the market used in a wide range of applications.

This article discusses numerous aspects surrounding this electrical component, such as its working principle, speed, torque, and other technical elements.

In essence, it allows you to make informed decisions when shopping for one in the market.

How Does High Speed BLDC Motor Work?

Notably, the working principle of this motor is more or less similar to that of a brushed DC motor.

It adheres to the Lorentz force law stating that whenever current carrying conductor is put in a magnetic field, it experiences a force.

As a result of reaction force, the magnet experiences an equal and opposite force.

The current carrying conductor in a high speed BLDC motor is stationary; hence the permanent magnet is always moving.

Thus, when the sector coils get supply from a source, it becomes electromagnet and begins producing an even field in the air gap.

Of course, the supply source here is in DC, but switching enables it to generate AC voltage waveform with a trapezoidal shape.

As a consequence of interaction force between permanent magnet rotor and electromagnet stator, the rotor keeps rotating.

Switching of windings as low and high allows corresponding winding to be energized as South and North poles.

Hence, the permanent magnet rotor with South and North poles align with stator poles to actuate the motor to rotate.

What Are The Main Types Of High Speed BLDC Motor In The Market?

High speed BLDC motors are usually classified into three categories, which include the following;

• Single-phase– This type of BLDC motor operates by using a single-phase power supply but contains hot and neutral types of wiring. Power voltage supply for this motor may vary in accord but may range up to 3Kw.

• Two-phase– It features a system with two voltages that are 90° apart. Essentially, it has an alternator with two windings placed at 90° from each other. It needs two live and one ground wire working in two phases.

• Three-phase– This is a type of motor consisting of three main components, which include; rotor, stator, and enclosure. Mostly, this design often requires speed control and is usually used for loads.

What Does Design Construction Of High Speed BLDC Motor Entail?

A typical high speed BLDC motor features permanent magnets attached to the rotor.

It also has current carrying conductors placed on the stator.

Ideally, a BLDC motor is synchronous in the aspect that magnetic field generated by stator and the rotor rotate at same frequency.

Besides, BLDC motor hardly has any current carrying commutators.

As such, the field inside this motor is switched via an amplifier, which is actuated by a commutating component such as an optical encoder.

Ordinarily, high speed BLDC motor layout may vary based on its style, such as follows;

• Out-runner– In this layout, the field magnet is a drum rotor revolving around the stator. It is an ideal style for applications that need high speed and low rpm.

• In-runner– Here, the stator is a fixed drum where the field magnet rotates. It is popular for producing less torque than the out-runner layout, but it can spin at higher RPMs

What Is The Maximum Speed Of High Speed BLDC Motor?

It entirely depends on several factors surrounding the features of the specific BLDC motor you are using.

The core factors include the following;

• Output power
• Gear options
• Power supply
• Rated torque

For instance, a BLDC motor power with an output power of 30W running on a single phase power supply will have a maximum speed of 800 r/min.

What Is The RPM Of A Typical High Speed BLDC Motor?

Like speed, RPM of this motor is also dependent on several factors, including the following;

• Power supply
• Torque
• Current
• Gear options

However, the minimum rpm for an ideal BLDC is 2,000 rpm, whereas the maximum could range up to 100,000 rpm.

How Do You Increase The Speed Of High Speed BLDC Motor?

The most appropriate way of increasing speed of this motor is by increasing the frequency.

For instance, if you use a BLDC motor with a base speed of 60 Hz, you can only raise it to 120 Hz by increasing the frequency to 120 Hz.

In essence, BLDC speed is directly proportional to frequency.

You must keep volts to hertz ratio constant to prevent the motor windings from heating up.

How Do You Increase The Torque Of High Speed BLDC Speed?

Notably, increasing torque of this motor is dependent on how a speed controller works.

Often, if the speed must remain constant, it means the back-emf shall also remain constant.

Hence, the only way of increasing torque in high speed BLDC motor is by increasing armature current.

Ideally, you can only increase armature current by increasing the power supply in effect of how speed control works.

How Efficient Is High Speed BLDC Motor?

High speed BLDC motor is immensely efficient since it does not use brushes hence requires less system downtime and routine maintenance.

Generally, the efficiency of this motor are in the range of between 80-95%.

Nonetheless, the efficiency of this motor is determined by three main factors, which include the following;

• Speed controllers

They use internal sensing and algorithm necessary for speed regulation and setting control loop parameters for torque.

Speed is proportional to voltage, as torque is proportional to current.

Therefore, effective speed controllers of high speed BLDC motor increases their efficiency significantly.

• Position controllers

Typically, a position controller uses an interface with position sensors on the BLDC motor and at the load.

Position loop is often the outer control loop in this device.

Thus, the torque and speed loops must be tuned depending on motor and system parameters for this device to attain its optimum efficiency.

• Torque controllers

Technically, torque controllers come in handy in applications, which need holding torque and changes in direction.

It is imperative since these controllers retain smooth transition in torque through zero speed.

Ideally, controlling torque/current to high speed BLDC motor enhances precision speed control.

Besides, torque controllers use a position sensor on the motor to establish shaft position to energize proper winding for precision control.

Can You Increase High Speed BLDC Motor Torque Without Increasing Speed?

Yes.

However, you’ll need to increase the applied voltage to increase torque without reducing rpm.

Ordinarily, if you increase load shaft torque on a high speed BLDC motor, it will have to slow down to lower the back emf.

This is what enables the larger armature current and consequently develops torque accordingly.

In essence, you can never prevent this from happening, but you can always find ways to compromise it through ideal feedback control.

One way you can use to compensate for it is by increasing terminal voltage.

Alternatively, you can attain it by decreasing the field current or executing both actions.

You execute any of these measures using a feedback controller or speed loop.

Generally, only one method is commonly used to provide the fastest response time.

How Does Brushed Motor And High Speed BLDC Motor Compare?

Ordinarily, the working principle of these motors is more or less similar.

However, they tend to vary on various grounds, and the main ones include the following;

• Durability

Brushed motor experiences immense mechanical wear on the brushes and commutator.

Carbon brushes are often used in such motors, and since they tend to be sacrificial, they are often replaced periodically in line with routine maintenance.

Besides, soft commutator copper also gradually wears out and gets to a point where the motor no longer operates.

On the other hand, high speed BLDC motor does not have moving contacts thus hardly suffers from such tear and wear.

• Electrical noise

In a brushed motor, the commutator and brush usually form some type of electrical switch.

The switches open and close as motor runs, while significant current flows inductive rotor windings leading to arcing at the contacts.

Hence, it generates a significant amount of electrical noise that usually gets coupled in sensitive circuits.

High speed BLDC motor, on the other hand, operates quietly since it never experiences arcing at the contacts.

• Speed and acceleration

The brushes, commutator, and rotor mass can inhibit rotational speed in brushed motors.

Usually, brush to commutator contact can become erratic at extremely high speed and these increase brush arcing.

Besides, many brushed motors use laminated iron core in rotor to give them larger rotational inertia.

In essence, this limits acceleration and deceleration rates of the motor.

On the other hand, you can always operate a brushless DC motor at high speeds continuously and attain the desired results always without any inhibitions.

• Cost-effectiveness

Ordinarily, high speed BLDC needs more complex electronics making its general drive cost higher than that of a brush motor.

Besides, manufacturing and assembling costs of BLDC motor is relatively higher than that of a brushed motor.

• Acoustic noise

Brushed motor is relatively inferior to a high speed BLDC motor as far as acoustic noise and torque ripple is concerned.

Torque generation in brushed motor is dependent on rotor rotation since windings get switched on and off.

However, BLDC motor can control the winding currents to gradually transition current from winding each other, lowering torque ripples.

What Makes High Speed BLDC Motor To Lose Torque?

Usually, when you overload a high speed BLDC motor, it is likely to lose torque since rotor rotation is resisted.

As such, this action allows the counter EMF to easily overcome applied voltage and decrease torque.

Technically, additional EMF is created in high speed BLDC motor when current to the shunt field increases, reducing torque and speed.

In essence, when the motor runs at optimum speed and back EMF closely matches the input voltage, there will be no output torque.

Moreover, if the motor is decoupled from the mechanical load suddenly, the torque decreases but still delivers torque to rotate the shaft.

In the event that the high speed BLDC motor stalls to zero speed, it will instead be delivering breakdown torque.

And if this persists, the motor will overheat and burn, but the torque will not necessarily be lost.

What Makes High Speed BLDC Motor Better Than Induction Motor?

Several factors attribute to superiority of high speed BLDC motor to induction motor, which includes the following;

• High speed operation

High speed BLDC motor systems can provide flat torque over numerous speed ranges.

On the other hand, induction motors usually lose torque the more the speed increases.

Thus, the former guarantees efficiency even in applications where load and speed are of significant concern, unlike the latter.

• Service and maintenance

Ordinarily, high speed BLDCs exhibit a longer service lifespan are cleaner and quieter since they do not necessarily require frequent in-depth maintenance.

Induction more, on the other hand, has a relatively shorter service lifespan and usually requires thorough service and maintenance.

Also, most of its components require frequent replacement since they tend to wear out faster due to contact.

• Efficiency

Essentially, system’s efficiency is determined by the amount of output received in terms of input’s percentage.

Hence, high speed BLDC motor exhibits better energy efficiency.

It enables you to obtain a reasonably high mechanical power in exchange for electrical power you use.

On the other hand, induction motors use energy to create an electromagnet, which decreases its efficiency.

What Factors Cause Failure In High Speed BLDC Motor?

Typically, high speed BLDC motor at some point may fail due to various reasons.

However, the cause of failure is dependent on a wide range of factors, which include the following;

• Low resistance

Low resistance in this motor arises from insulation degradation of the windings due to several conditions like corrosion, overheating, physical damage, etc.

It causes inadequate isolation between the windings and conductors, which is likely to cause short circuits and leakages.

• Contamination

Dust, chemicals, and dirt are among the leading causes of BLDC motor failure.

Such substances find their way into the motor, thus easily dent balls and bearing raceways resulting in high vibration and wear levels.

Besides, they can block the cooling fan and inhibit motor from regulating temperature hence possibility of overheating.

• Electrical overload

It often arises from low supply voltage; hence the motor draws in more current, attempting to maintain its torque.

Besides, electrical overload could be due to excessive voltage or short-circuited conductors.

• Overheating

Overheating in BLDC motors usually occurs due to excessive temperature operating environment or poor power quality.

Often, this reduces motor’s ability to function at optimum levels hence fails.

• Vibration

If the high speed BLDC motor keeps on vibrating during operation, it can ultimately fail prematurely.

Vibration usually causes positioning of motor on an unstable or uneven surface.

Even so, vibration can arise from underlying issues regarding the motor, like corrosion, misalignment, or loose bearing.

What Are The Benefits Of High Speed BLDC Motor?

Typical high speed BLDC motor offers a broad range of advantages, making it an ideal consideration over brushed motor.

Some of these benefits include the following;

• Exceptional efficiency

This motor can control continuously at maximum torque.

Of course, this is advantageous since it enables the motor, even a small one, to deliver significant power.

• Controllability

You can easily control BLDC motor using a feedback mechanism to deliver exactly desired rotation speed and torque.

Essentially, precision control minimizes heat generation and energy consumption.

And in applications where the motor is battery powered the battery service lifespan increases.

• High durability

High speed BLDC motors offer immense durability and quietness due to lack of brushes.

Of course, this, in the long run, makes it cost-efficient since you will save a significant amount of money you’d otherwise spend on replacing it.

Besides, it creates a serene environment in specific applications it is used since it hardly generates noise.

• Less maintenance

Maintaining this motor is easy and quite rare since it does not have brushes, which would require frequent routine maintenance.

• Highly reliable

This motor guarantees high operation speed, whether in loaded or unloaded conditions, since it does not have brushes, which may inhibit its speed.

Besides, it doesn’t have commutator and related problems, thus assuring desired reliability in its respective applications.

• Compact size

It features a smaller motor geometry, and it is relatively lightweight than induction motors making it highly portable.

What Is The Service Lifespan Of High Speed BLDC Motor?

The actual lifespan of this motor is dependent on various aspects.

For instance, maintenance, operating temperature, and load are the core elements that determine the actual durability of this motor.

Besides, the actual applications also define the specific duration a motor can last.

Some applications tend to be relatively aggressive, thus shortening the lifespan of this device.

On the other hand, some applications are gentle hence enabling this motor to have an extended lifespan.

However, if all factors are held constant, a typical high speed BLDC motor can serve up to 10 000 hours.

Can You Rebuild High Speed BLDC Motor?

It depends on prevailing circumstances.

You can rebuild high speed BLDC motors essentially to keep them running for several years while guaranteeing high performance.

However, these motors usually must have field coils and armatures rewound and insulated.

Thus, they are repairable in some instances, but in other instances, rewinding is normally necessary to achieve acceptable performance.

Nevertheless, rebuilding this motor requires precision by a skilled professional.

Can You Use High Speed BLDC Motor As A Generator?

Yes.

Ideally, you can use any high speed BLDC motor with a permanent magnet electric motor as a generator.

All you need is to apply an external power source to enable it to spin the shaft or the permanent magnet motor.

In essence, the external power source acts as a rectifier, which gives you a DC output, and your motor becomes a generator.

What Are The Limitations Of High Speed BLDC Motor?

They are quite a few, but the major ones include the following;

• Needs complex drive circuitry
• May require extra sensors
• Relatively costly compared to other alternatives
• The electronic controller for this motor is comparatively expensive

How Much Does High Speed BLDC Motor Cost?

Generally, the cost of the component is dependent on various factors, including the following;

• Capacity

Often, a highly rated high speed BLDC motor is more expensive than one with lower capacity.

• Manufacturer

Different companies sell their respective products depending on various elements surrounding the brand.

Hence, some brands are usually expensive, whereas others tend to be somewhat affordable.

• Quantity

When you purchase this motor in bulk, most sellers usually offer better discounts than when buying a few pieces.

Therefore, you are likely to save a considerable amount of money when purchasing more units.

In a nutshell, there is no definite price for buying a high speed BLDC motor.

How Long Can High Speed BLDC Motor Run Continuously?

It can run for several thousands of hours on average.

Ordinarily, this type of motor does not have brushes, which may limit its running capability due to possible wear.

Thus, you may expect to get thousands of hours when using this motor continuously.

Why Is A Controller Essential In High Speed BLDC Motor?

Essentially, a high speed BLDC motor does not have a brush and commutator between the stator and rotor.

Therefore, controller offers direct current from varying current directions to actuate alternation of current direction of coil within the motor.

What Is The General Power Consumption Of High Speed BLDC Motor?

Generally, this ranges from 6mA to about 20mA.

Why Does High Speed BLDC Motor Have Three Hall Sensors?

The high speed BLDC motor needs a stator coil magnetic field of rotor’s permanent magnet to constitute a specific angle to rotate.

Hence, the stator coil’s magnetic field direction should change to ensure a specific angle is attained when the curve reaches a particular value.

As such, the three hall sensors are in charge of relaying to the controller when it is appropriate to change the current direction.

What Are The Main Applications Of High Speed BLDC Motor?

This motor is used in a wide range of applications across different industries.

Ordinarily, these motors are commonly used in instruments that run continuously due to their efficiency, controllability, and longevity.

Some of the notable devices this motor is commonly used include the following;

• Washing machine
• Air conditioners
• Automotive air conditioner compressor
• Electric stirrer
• drones
• Fans
• Industrial robots
• Hybrid vehicles
• Electric vehicles and bicycles
• Pumps
• Blowers
• Vacuum machines
• Computer Hard disc drives
• Electric screw driver

Essentially, this motor has become popular in the recent past; thus, you are likely to find it in several consumer electronic goods.

Contact us now for any questions of inquiry about high speed BLDC motors.

Longbank Brushless Motor

Are you seeking the most reliable Brushless Motor producer and distributor? Longbank is an excellent place for you. We are delighted to provide various Brushless Motor models to different nations around the world. Longbank is capable of meeting all of your Brushless Motor needs at a reasonable price.

It is a direct current (DC) electric motor that does not use mechanical brushes or a commutator like a typical brush motor. It offers great features over a brush motor and is more cost-effective in the long term, despite more significant starting expenses. No brushes are rubbing against; therefore, there is no energy loss from friction. Therefore much more energy-efficient than brushed motors and may last up to 50% longer on batteries.

Please tell us about your idea so we can discover the Brushless Motors that are appropriate for you! Longbank provides unique solutions as a prominent Brushless Motor provider. Please email us your product specifications so that we can get started.

Brushless Motor Advantages

• It doesn’t have any carbon brushes, which means fewer brush replacements and lower maintenance expenses.
• It offers more outstanding quality and reliability than brushed motors due to electronic control, which allows for finer control of the motor’s speed and position. 
• It has a lifetime of roughly 6 times that of brushed motors.
• It has a lower risk of burnout due to sparking difficulties because there is no spark.
• Because it has a low no-load current, You can use it at low or no load.
• It is capable of constantly providing maximum torque throughout the rotation.
• It may include a feedback control system for monitoring and controlling the speed and torque.

You may rely on Longbank as a skilled Brushless Motor manufacturer. BL4835, BL6324, BL7125, BL10045(Low Voltage, OBL5020, OBL6425, and OBL7527 are some of the Brushless Motor models we may supply based on your requirement.

Our firm employs a competent and skilled workforce. We oversee every step of the procedure, from a selection of materials to manufacturing to shipping. Longbank also uses automated manufacturing lines, testing equipment, and cutting-edge technologies to ensure high-quality and consistent Brushless Motor performance.

Our primary goal is to provide you with high-quality Brushless Motors. As a well-certified manufacturer, we will assist you in finding the perfect motors for your business. Whether you have a small or large purchase, we will do our best to meet your needs.

For additional information, don’t hesitate to get in touch with us!