Posted by: Sarah Prais | September 22, 2015

New 34B/SR-WX Brushless DC Gearmotors – 12/24VDC, CI/D2

New Brushless DC Gearmotors with Control – 12/24VDC, CI/D2, type 34B4/SR-WX

These new 34B/SR-WX, brushless DC, 12 or 24VDC, INTEGRAmotor gearmotors are ideal for low-voltage applications in remote locations that operate off-grid, from battery or solar power. These new gearmotors are also suitable for a wide range of industrial or medical applications that only allow low-voltage electronics due to user-safety considerations.

Bodine Brushless DC Gearmotor with control 12/24VDC, meets C1D2

The gearmotors feature a built-in speed control with speed pot, and are IP-44 with proper conduit installed. These new standard products are also UL listed for operation in hazardous locations per NEC, Class I, Div 2 environments (Groups A, B, C or D). Minimum order quantities and lead-times apply. Please contact your regional Bodine sales manager for assistance with samples and with further questions.

Connection Instructions for 34B/SR-WX Gearmotors in Non-Hazardous Locations Bodine App-Note_34B-SR-WX_non-haz-remote-wiring

This application note explains the steps to properly wire these new, standard 34B/SR-WX, 12/24VDC gearmotors for remote operation in a non-hazardous location. Click here to download the PDF. For remote operation of these products in Class I/Div 2 environments, please refer to all local safety rules and regulations. Contact our tech support team at 773-478-3515 or via, if you require further assistance.

User Manual, Sell Sheet, Product Specifications and 2D/3D CAD Drawings are Available Online

User Manual 34B-SR-WX Gearmotors 12-24VDC_IntegraTo download the gearmotor and control user manual, detailed product information and specifications, and our product sell sheet, please visit our product series page by clicking here. To download our press release and product photo for these new 34B4/SR-WX INTEGRAmotor low-voltage gearmotors, click here.To learn more about the definitions for Class I/Div 2, here is a link to a related Wikipedia page. As most of you know, CI/D2 is not the same as ex-proof (CI/D1).

Copyright Bodine Electric Company © 09/2015. All rights reserved.

Posted by: Sarah Prais | August 4, 2015

Brushless DC Gearmotor Overview – Features and Benefits

Brushless DC (EC) Gearmotors and Motors – What Is a Brushless DC Motor?

Brushless DC motors could be called “inside-out permanent magnet motors” because brushless DC motors have their magnets on the rotating part of the motor instead of on the stationary part. Accordingly, they have their windings on the stationary part of the motor instead of on the rotating part, as in a permanent magnet DC motor. Despite the differences in construction, their speed-torque curves are very similar to those of permanent magnet DC motors.

BLDC Gearmotors Bodine Products 08/2015

Operation of a brushless DC motor is similar to a permanent magnet motor except that the winding phases are switched on and off electronically by means of a control device. That is why we also refer to these motors as Electronically Commutated (EC). The control “knows” when to switch the windings because of feedback it receives from rotor position Hall effect sensors.


Brushless DC Advantages Bodine-Gearmotor-BLDC-Blog-4

Brushless DC motors require less maintenance, provide long life, low EMI, and quiet operation. They produce more output power per frame size than AC or permanent magnet DC motors and gearmotors. Low rotor inertia improves acceleration and deceleration times while shortening operating cycles, and their linear speed/torque characteristics produce predictable speed regulation. With brushless DC motors, brush inspection is eliminated, making them ideal for limited access areas and applications where servicing is difficult or not desired. Low voltage models are ideal for battery operation portable equipment, or medical applications where shock hazards cannot be tolerated.


Applications and Industries:

• Laboratory equipment where quiet, clean, long-life operation is critical such
as blood analyzers, centrifuges, mixers, shakers, MRI or cat scan equipment
• Packaging equipment for labeling, bottling, glue applicators, shrink tunnels
• Factory automation and conveyor systems
• Photocopiers, printers, and printing presses
• Pallet feeders for plastic processing
• Metering pumps for chemical treatment, lab equipment, and industrial processes
• Solar power, alternative energy sources, remote locations
• Food processing, food handling, commercial ovens
• Automated barriers, parking lot gates, door openers


Frequently Asked Brushless DC Motor and Gearmotor Questions:

Q: Can I make my own extension cable? What do I have to consider?
A: Yes, you can make your own cable, however they must have EMI and RFI shielding. Most wiring errors are due to improper or missing shielding.

Q: How long can the cable be?
A: 50 Feet maximum

Q: What is the minimum speed of Bodine brushless DC stock motors?
A: 150-200 RPM, depending on what kind of control is being used. Lower when used with a servo amplifier.

Q: What should I check first if a brushless DC motor stops working?
A: Check set-up, wire harness and connections.

Q: My red fault light is on!
A: Noise might be coming into the input of the control or there might be overvoltage to control input.

Q: Can I have preset fixed speed settings?
A: Yes, replace the pot with a resistor divider with rotary switch. Or control the analog voltage signal to the speed pot input via a PLC or other controller.

Q: Can we run faster than 2500 RPM?
A: Yes, by adjusting the MIN/MAX pot – However, the available speed range will change.

Bodine Gearmotor Comparison of Variable Speed Systems

We Offer a Large Selection of Standard Products:

• Matched gearmotor-control system solutions
• 12, 24, and 130 VDC motors, gearmotors, and controls
• High speed (up to 20,000 RPM) motors and controls
• Two-year limited warranty for matched Bodine motor-control systems
• 22B/SR and 34B/FV 24VDC INTEGRAmotors™ provide integrated motor, control and feedback systems

And when a Standard Product won’t fit – Custom Solutions from Bodine:

• 48B motor achieves up to 1.5 HP with matched speed control (type EBL)
• Analog (SR) and Digital (FV) interface INTEGRAmotor options
• Environmentally protected versions for OEM applications
• Third-party markings, including Class I/Div 2
• Custom control designs available for OEM applications

To download a PDF version of this blog post, please click here.

Copyright Bodine Electric Company © 08/2015. All rights reserved.

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Posted by: Edmund Glueck | June 24, 2015

Electromagnetic Holding Brakes for Small Gearmotors and Motors

Holding, or “Power-Off,” brakes provide extra safety in applications where the load must remain in position in the event of power loss or equipment failure. Our design engineers have helped OEMs develop brake systems for hundreds of AC and DC applications, from home stairlifts to industrial applications. In this article, we focus on the principles of operation for the most common type of electromagnetic brake, the power-off design. For more information on clutches and braking techniques, see Chapter 10 in the Bodine Handbook.

Principles of Operation and Terms Bodine-Gearmotor-Brake-Post-1

The friction disc of a power-off brake is constrained and does not allow rotational motion when no voltage is applied to it. Another common term for this design is a “fail safe” brake.

The brake is designed with a wound coil that resides within a steel cup body. When voltage is applied, the armature plate is pulled toward the cup body by the magnetic force. The force is high enough to overcome the compression springs. When no voltage is applied, the compression springs exert a force on the armature plate to hold the friction disc firmly against the pressure plate, prohibiting rotation. The friction disc is coupled to the hub by a close fit geometric shape, usually hexagon or spline.

Brakes can be designed for any DC voltage. For AC voltage brakes, a bridge rectifier is used to convert AC voltage into DC. The bridge rectifier is either internal or external to the brake depending on the size of the brake.

Bodine-Gearmotor-Brake-Post-2   bodine-gearmotor-brake-post-3a



Dynamic vs. Static Braking

Depending on the type of application, either a static or dynamic brake may be required. The power-off brake design uses a friction disc material specific to static or dynamic braking applications. The more common version is the static brake design, where ideally the brake is engaged after the motor shaft has come to a stop. Static brakes are intended to hold static loads and the friction material experiences negligible wear over its life. Dynamic brakes are designed with a more durable friction material that wears over the life of the brake. When compared in a similar mechanical size package, dynamic brakes frequently will have a lower published torque rating than static brakes.

Brake Performance

Typical Holding Brake

Typical power-off holding brake

The brake has two states: power off and power on. During the transition to the power-off state, the magnetic field decays because of the removal of voltage to the brake. Here, the armature loses its magnetic couple with the wound coil, which clamps the friction disc to the pressure plate, applying the holding torque. The manufacturer can adjust the transition time, but is typically in the millisecond range. The performance of a 15in-lb. brake is shown in Figure 2. The sharp “spike” during the voltage decay is where the armature engages with the friction disc. Actual transition time is 60 milliseconds.

While charging the coil, there is a sharp “spike” when the armature   makes complete contact with the wound coil and releases the friction disc. Actual time for this event is 32 milliseconds.

Bodine-Gearmotor-Brake-Post-5Brakes are designed to operate continuously without overheating in the static holding position. Designs that include both dynamic and static braking require brakes with intermittent ratings. The duty cycle (braking and stop cycle) determines this rating.





To download a PDF version of this blog post, please click here.

Copyright Bodine Electric Company © 06/2015. All rights reserved.

Bodine Gearmotor - Motor Constants - 12Motor constants are needed to calculate permanent magnet DC (PMDC) or brushless DC (BLDC or EC) motor specifications and ratings, or to match the motor properly to an amplifier. The motor constants are required in order to predict the PMDC or BLDC motor’s performance with changing variables, such as different input voltages or different loads. (See below PDF link for Bodine stock PMDC and BLDC motor constants.) This application note explains what the constants are, how they are derived and how to use them.

Common Motor Constants:

The most commonly used motor constants are Torque Constant (Kt), Voltage Constant (Ke), Electrical Time Constant (Te), Mechanical Time Constant (Tm), and Thermal Resistance (Rth). Typical values for these constants are derived by using measured values of No Load Speed, No Load Current, Stall Torque, Circuit Resistance, Circuit Inductance, and Armature Inertia with the following equations:

Torque Constant (Kt) — describes the proportional relationship between torque and current. Kt is usually expressed in the units Oz-in./Amp. See page 2 for additional information about torque constants.

Bodine Electric - Motor Constants - 03.26.2015

Voltage Constant, or Back EMF Constant (Ke) — is the Torque Constant expressed in different units, usually Volts/Krpm, in order to describe the proportional relationship between motor speed and generated output voltage when the motor is back driven as a generator in units of Volts/1000 rpm. See page 2 for additional information about voltage constants.

Bodine Electric - Motor Constants - 2

Electrical Time Constant (Te) — is the time required for a motor to reach 63.2% of its stall current after applying a test voltage with the motor shaft locked. It is usually expressed in milliseconds. Applied Voltage equals Rated Current multiplied by Circuit Resistance:

Bodine Electric - Motor Constants - 11

Mechanical Time Constant (Tm) — is the time required for an unloaded motor to reach 63.2% of its no load speed after applying its rated voltage. It is usually expressed in milliseconds.


Thermal Resistance (Rth) — is useful for predicting the ultimate temperature rise under different loading conditions in order to determine a maximum continuous torque rating. It is usually expressed in the units °C/Watt.

Bodine Electric - Motor Constants - 6

Using Performance Data to Calculate Kt and Ke

This speed/torque graph demonstrates how the linear equation of the current is used to calculate the Torque Constant (Kt) by using the slope “m.” The Voltage Constant (Ke) can then be calculated.

Using Performance Data to Calculate Kt and Ke

This speed/torque graph demonstrates how the linear equation of the current is used to calculate the Torque Constant (Kt) by using the slope “m.” The Voltage Constant (Ke) can then be calculated.

Bodine Electric - Motor Constants - 8

Bodine Electric - Motor Constants - 9

To download this information as a PDF, click here. To download the Motor Constants for Standard Bodine Gearmotors, click here.

To download Chapter 8, or any other section of the Bodine Small Motors Handbook, click here.

Copyright Bodine Electric Company © 04/2015. All rights reserved.

Posted by: Sarah Prais | April 10, 2015

Quiet Gearmotors for Medical Equipment

Bodine Electric_Mammography Machine - Medical EquipmentGearmotors in mammography equipment are used to raise and lower the scanner to accommodate the patient’s height. The primary design objective is smooth and quiet operation. Our team of design engineers addressed four aspects of the gearmotor design that contribute to quiet operation.

Worm Gearing
Bodine recommended a right-angle gearmotor with worm gearing. The sliding tooth action of worm gearing is generally quieter than the rolling action of spur and helical gearing. A second advantage for the application was that worm gears lock in place when there is no power to the gearmotor.

Machined Parts
By machining all mating surfaces of the motor and gearhousing, Bodine insured that the worm and helix gears, the motor armature and the motor end shield are precisely aligned. Better gear alignment translates into less noise. Unlike many gearmotors on the market today, all Bodine gearmotors feature machined surfaces throughout.

Ball Bearings Bodine Electric - Mammography Equipment - 2
Our engineers recommended ball bearings to minimize thrust loads on the driveshaft. Thrust loads can make the driveshaft shift back and forth within the gearbox. Ball bearings are pressed onto the driveshaft, locking it in place.

Quieter Brush and Commutator Components
Bodine engineers took several steps to reduce brush noise as much as possible. Special commutators were designed to prevent vibration and to ensure smooth brush contact. The brush holders were locked into the gearmotor endshield to prevent any “chatter”. Brush material and brush shape were optimized to minimize noise.

Bodine Electric engineers bring 110 years of application engineering and problem solving experience to a wide range of applications in industries as diverse as medical, packaging, industrial automation, and solar powered outdoors equipment. We look forward to working with you on your next FHP gearmotor design challenge.

Bodine Electric - Mammography Equipment - 3

Bodine Gearmotor Worm Gear Set PMDC Gearmotor


To learn more about Bodine Gearmotor Solutions in Medical Applications, click here.

Copyright Bodine Electric Company © 04/2015. All rights reserved.

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