Bodine-3D-printed-gearmotor-adapterIn keeping with our Quality Policy and our dedication to Continuous Improvement, Bodine Electric’s manufacturing and engineering teams joined forces in 2013 to identify and source a 3D printing solution that fits our needs.

The creation of physical prototypes of new castings or moldings or any new part has traditionally been a challenge in the machine shop or tool room because some cast features simply cannot be duplicated. Although stereo-lithography (3D printing) has been around for some time it was fairly expensive to create a part, materials were severely limited and the equipment to produce them was in the $100,000 range. Advances in technology have decreased the size and reduced the cost substantially to allow our joint team to specify and purchase a 3D printer by mid-2013.

Bodine 3D printed Gearmotor face-mount plate

This machine takes modeling input from SolidWorks and creates 3D models as large as 410 cubic inches (about the displacement of a ‘69 Corvette V-8) with a layer resolution of .0039”. Three materials are available for modeling, PLA which is a thermoplastic aliphatic polyesteris, PVA which is Polyvinyl alcohol, and ABS which is acrylonitrile butadiene styrene, all these are available in a wide assortment of colors.

We began using this new teBodine-3D-printed-gearmotor-basechnology in our manufacturing operations to create fixtures for assembly that closely fit our products to facilitate elimination of torque reaction during fastener driving, while incorporating mistake proofing features where applicable and feasible. Then we moved on to the creation of ball bearing installation fixtures and seal expanders for prototypes and new custom gearmotor designs. Other areas of manufacturing productivity improvements were to design and “print” fixtures to directly aid in easing product assembly and in process storage of wound armatures.

From using this new machine initially for simple manufacturing fixtures and tools, our engineering and R&D team now manufacture many new parts for custom-built OEM designs and prototypes. Examples are new motor front- and rear end shields, gear housing covers and motor adaptors. Other parts we “printed” are custom encoder covers, new terminal-box designs, Hall Effect device holders for our brushless DC motors and a new 24A motor shield with IP-44 lead exit capability.Bodine-3D-printed-gearmotor-endshieldThe photos in this article show some parts that we manufactured in house, as well as one part that was printed by an outside supplier. This new technology provides our engineering and manufacturing teams with a tool that enhanced speed to market, allows for rapid prototyping and brings new manufacturing processes faster up to speed. Our customers benefit from it with shorter lead-times and greater productivity during the product development process.

 Copyright Bodine Electric Company © 08/2014. All rights reserved.

Posted by: Sarah Prais | July 29, 2014

Introduction to AC Gearmotors and Motors

This blog post is from an updated section of Bodine Electric’s Small Motors Handbook. To download this article as a PDF, please click here.

Although commutator and brush assemblies may be used in some types of alternating current (AC) gearmotors and motors (series-/universal wound), brushless induction-type designs are by far the most common and most reliable for industrial AC motors and gearmotors that operate from an AC power source or from an AC speed control (adjustable speed drive).


In an AC induction motor or gearmotor, the stator winding sets up a magnetic field which reacts with the current-carrying conductors of the rotor to produce rotational torques. The rotor currents are induced in the rotor conductors by the stator’s changing magnetic field, rather than by means of a commutator and brushes. This induction action is the central operating principle of AC induction motors.

AC power is commercially supplied in both single-phase and three-phase forms. The essential operating characteristics of AC induction motors and gearmotors will vary according to:

1) winding types (split-phase, shaded-pole, three-phase, etc.), and

2) the number of phases, the frequency, and the voltage of the power source.

AC Rotor Core


2.2 POLYPHASE MOTORS (Two or Three Phases)

The production of a rotating magnetic field can be simply illustrated by considering a two-phase motor with two embedded stator windings for establishing the magnetic fields. Read More…

Below information is from our latest Application Note on how to connect and reverse our fixed-speed, 3-wire and 4-wire reversible, AC single-phase gearmotors and motors. We conclude our series of AC application notes with four examples of what types of  reversing switches an engineer or technician can use to reverse our stock gearmotors.

How to Wire an Optional Reversing Switch to a 3- or 4-wire AC (PSC) Motor or Gearmotor (115VAC/60Hz Models)

These connection diagrams show how to wire an optional switch to reverse the direction of a 3- or 4-wire Bodine permanent split capacitor (PSC) motor/gearmotor. All the wiring diagrams use variations of a double throw switch, with a center-off position. The purpose of the center-off position is to bring the gearmotor to a complete stop before reversing its direction of rotation. This is necessary to prevent gearing damage. Table 1 (below) shows examples of switch manufacturers, part numbers and specifications recommended for use with Bodine products.

3- Wire-Reversible Bodine AC Motor or Gearmotor

Examples 1 & 2 show how to connect a single- or double-pole switch to our 3-wire, PSC, fixed-speed AC gearmotors or motors.  

Example 1- How to connect the single pole, double throw switch

Example 1- How to connect a single pole, double throw switch


Example 2- Connect the double pole, double throw switch

Example 2- How to connect a double pole, double throw switch

 4-Wire-Reversible Bodine AC Motor or Gearmotor

Examples 3 & 4 show how to connect a three- or four-pole switch to our 4-wire, PSC, fixed-speed AC gearmotors or motors. 

Example 3- Connect the three pole, double throw switch

Example 3- How to connect a three pole, double throw switch


Step 4- How to connect the four pole, double throw switch

Step 4- How to connect the four pole, double throw switch


Switch specification examples and part numbers

Switch specification examples and part numbers

If you have any questions about how to connect our stock products, please give our support team a call at 773-478-3515 (Chicago area), or e-mail us at: All our stock gearmotor and motor connection diagrams are available from our web site.

Copyright Bodine Electric Company © 06/2014. All rights reserved.

Posted by: Edmund Glueck | May 7, 2014

Bodine 2014 Distributor Training Conference a Great Success!

We would like to thank all attendees for joining us at this year’s Distributor Conference in Northeast Iowa. Attendees came from all regions of the U.S. and from as far away as England. Besides the classroom sessions and the hands-on training, this 2-day event concluded with a number of factory tours at our Peosta, IA plant. Bodine’s commitment to producing the highest quality products is proudly demonstrated at every step of the manufacturing process. Hope to see you at our next event.

Bodine Electric Company: Peosta, Iowa - Manufacturing Plant 04/2014Bodine Distributor Conference: Plant Tour 04/2014Bodine Distributor Conference: Plant Tour, DC Armatures 04/2014Bodine Main Mfg Plant, Peosta, IA - Plant Tour 04/2014 Read More…

Bodine type 34B4-WX Brushless DC (EC) Class I Div 2 Gearmotors

Bodine type 34B4-WX Brushless DC (EC) Class I Div 2 Gearmotors

We now offer versions of our 34B4-WX brushless DC (EC) gearmotors that are ETL listed and comply with National Electrical Code Class I, Division 2 safety standards. Designed to reduce the risk of accidental fires or explosions in hazardous locations, these gearmotors can be used safely in environments such as petroleum refineries, dry cleaning plants and spray finishing areas.

The gearmotors feature low-voltage 12/24V DC brushless motors, eliminating the danger of high-voltage arcing and shorts. They are ideal for solar- or battery-powered applications. Upgraded terminal boxes provide additional insulation for electrical connections, and specially coated commutator assemblies further reduce the risk of accidentally igniting flammable materials.

The new 34B4-WX Class I, Division 2 designs provide all the maintenance-free, long lasting performance of a standard Bodine brushless DC gearmotor. Their high starting torque and linear speed-torque characteristics make them ideal for a wide range of variable speed applications. The WX gearhead features all-steel helical gears and synthetic lubricant for quiet operation and long life. These gearmotors offer continuous duty torque ratings of up to 205 lb-in (23 Nm) and standard gear ratios from 4:1 to 312:1. Minimum order quantities and lead times apply for these products.

More information:

Copyright Bodine Electric Company © 04/2014. All rights reserved.

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