Stepper Motors, DC Motors & Brushless DC Motors

A: The functioning of an electric motor is based on the interaction between magnetic fields, which can be generated by electrically energized coils or permanent magnets. The process begins in the stator, the fixed part of the motor, where coils receive electrical current. The magnetic fields generated drive the rotor, the moving part of the motor.

The key to movement lies in the changing polarity of the magnetic fields, which ensures that the rotor rotates continuously in one direction. The rotor is connected either directly, via a coupling, or with an intermediate gearbox to a shaft that transmits the rotary motion to various applications such as linear actuators or rack and pinion systems.

A: Brushless DC motors (EC/BLDC motors) have one of the highest efficiencies. This is because they operate without carbon brushes. This results in less energy loss due to friction, and the motors can efficiently convert electrical power into mechanical power. igus offers EC/BLDC motors that are particularly suitable for dynamic applications and higher speeds.

The power of an electric motor, specified in watts (W), varies depending on the size and area of application. Smaller motors, such as those often used in automation systems or linear axes, have power ratings ranging from a few watts to several hundred watts.

Typically, stepper and DC motors do not specify power, but rather torque and speed. For EC/BLDC motors, you can find the power ratings in the product details in the igus online shop.

A: The speed of an electric motor depends on its design and control system. As standard, igus® electric motors achieve speeds between 1,500 and 3,000 revolutions per minute. Stepper motors operate with a controlled step-by-step movement in the medium-to-high speed range, so their advantages lie in their precise positioning.

Brushless DC (BLDC) motors are suitable for high speeds and forces, while DC motors can be easily regulated in terms of speed by adjusting the power supply. Motor controllers from igus enable precise speed adjustment for individual applications.

A: The number of electric motors that can be operated with a single controller depends on the controller’s design, power rating, and communication interface. Most standard motor controllers are built to handle one motor, but advanced multi-axis controllers can operate several motors simultaneously for synchronized motion. Choosing the right controller ensures efficiency, safety, and scalability for applications ranging from automation to robotics.

igus® offers drylin® E controllers and drivers that can just operate one motor. In the portfolio are controllers for stepper motors, BLDC motors, and DC motors.

A: DC motors are cost-effective, easy to control and can be operated with just one battery, for example. Stepper motors enable precise positioning without feedback. These types of motors have a high and full torque at standstill. Brushless DC motors (EC/BLDC) offer high efficiency, long service life and require no maintenance. In general, EC/BLDC motors can be used for dynamic and higher speeds.

A: DC motors have a comparatively shorter service life of roughly 3,000 operating hours due to wear on the brushes and commutator. Stepper motors are much more robust and brushless, allowing them to achieve a service life of up to 20,000 operating hours. Brushless DC motors offer a similar service life, as they are also brushless and show little mechanical wear and tear.

A: DC motors are simple electric motors operated with direct current (DC) voltages, allowing them to be operated with basic batteries and making them a particularly cost-effective option. However, the disadvantage of DC motors without motor control is that they do not switch off automatically when the torque increases, but instead draw more current until they come to a standstill. If a blockage is permanently present the motor could become thermally defective. Typical applications of DC motors include electric toothbrushes, children’s toys, and fans. However, they are also used in cars as drives for windshield wipers or seat adjusters.

A: The lifespan of an electric motor typically ranges from 15,000 to over 30,000 hours, depending on the quality, usage conditions, and maintenance. Factors like load, temperature, and proper lubrication play a major role in extending motor life. With regular maintenance and correct sizing, many industrial electric motors can reliably operate for 10 years or more.

igus® uses high-quality ball bearings for its stepper motors and BLDC motors. This means that these motors can achieve up to 20,000 operating hours. igus® DC motors can achieve up to 3,000 operating hours thanks to their carbon brushes.

A: The voltage required for an electric motor depends on its type, size, and application, with common ranges from 12V and 24V DC for small devices to 120V, 240V, or even 480V AC for industrial motors. Using the correct voltage is critical to ensure efficiency, performance, and safety. Always check the manufacturer’s specifications to determine the proper operating voltage for your electric motor.

At igus®, a voltage of 12-48V DC is required for the controllers that then supply power to the motors.

A: Electric motors can be operated using direct current (DC) or alternating current (AC) power sources, depending on the motor design. They are typically controlled through motor controllers, drives, or inverters that regulate speed, torque, and direction. Modern applications also use advanced controllers with sensors and software for precise and energy-efficient motor operation.

At igus®, the controllers for the motors require DC voltage. This means that power supplies are needed, which igus® also offers.

A: To choose the right motor, you should know the desired torque, speed, and duty cycle of the application. If you have a simple and non-accurate movement, a DC motor could be the right choice. For high-precision, a stepper motor is a good option. And for dynamic movements, a brushless DC motor will perform well. igus® offers an online tool to assist in motor selection as well.

A: igus® offers motor controls for stepper, DC and brushless DC motors. With the D1, all motors from igus® and motors from other manufacturers can be controlled. For DC motors, the D3 and D5 controllers are ideal. Finally, the D7, D8 and D9 can all be used to control stepper motors.

A: igus® offers motor accessories such as connection cables, power supply units, gearboxes, control units, proximity switches, and more.

A: The stepper motors offered by igus® — hybrid stepper motors — combine the advantages of both permanent magnet stepper motors and reluctance stepper motors. Hybrid stepper motors can apply high torque at a standstill and have a precise step angle. The disadvantage of a stepper motor is the high energy requirement, as they always operate at maximum current. However, this can be counteracted by using a rotary encoder and closed loop. Hybrid stepper motors are primarily used for industrial positioning tasks that require precise motion control.

A: The primary advantage of an brushless DC motor is the lack of carbon brushes, making them maintenance-free and allowing them to achieve a significantly longer service life than brushed motors. However, this comes at a higher cost relative to stepper and DC motors. Typical areas of application include actuators, robotic joints, and pick and place applications.