Small Size, Long Life Span Push BLDC Motors to Manufacturing Priority

DC motors are widely used in consumer electronics, household appliances, electric tools, medical equipment, and the automotive, robotics and industrial fields. Of the two types available, brushless (BLDC) units have become increasingly popular in recent years. Owing to their construction, which does away with brushes and commutators, these motors are smaller, lighter, quieter and more efficient than traditional brushed kinds. This also means a longer life span as they have no parts that are prone to mechanical wear. While BLDC motors have comparatively more expensive electronics, they require no periodic replacement of worn brushes and are more cost-effective in the long run.

Globally, the BLDC motor market reached $13.25 billion in 2022 and will increase further to $22.28 billion by 2028, at 9.05 percent CAGR, according to a report posted by MarketWatch. The Asia-Pacific region will realize significant growth, bigger than in other areas, and China is at the center of this market.

An earlier estimate of China’s BLDC motor industry made by market research firm Leading Industry Research placed its CAGR at 15 percent from 2018 to 2023.

To benefit from this momentum, Chinese manufacturers of brushless DC motors have set higher sales and export targets beginning 2023. Some are investing in production expansion in anticipation of greater demand. One company, Anhui DeAoLaiYin, allotted $29.4 million to a new project in Xuzhou. The facility, with a total area of 30,015sqm, is scheduled to start mass production in August 2023. When fully operational, it will output 10 million DC and asynchronous AC motors and achieve a total production value of up to $44 million every year. BLDC motors will constitute a larger proportion than brushed kinds.

Other suppliers will focus on developing smaller and more durable BLDC motors. One of Dongguan Dihui’s units, also available in a water-resistant version, measures 37x25mm and has a speed of 5,000rpm and a life span of up to 50,000 hours at 25 C.

Sensored vs sensorless BLDC motors

According to a report released by Fact.MR, sensorless control or employing the motor’s intrinsic back electromagnetic force (EMF) for motor commutation results in more compact and lightweight BLDC motors. This development is expected to further boost their adoption and market reach.

“The introduction of sensor-less controls for BLDC type is anticipated to increase the product’s longevity and dependability, decreasing the number of mechanical misalignments, electrical connections, as well as the product’s weight and size,” Fact.MR stated.

In many BLDC motors, Hall-effect sensors are widely used at present. However, they “increase the complexity of the design and require additional wiring to limit their use in harsh conditions like high temperatures or humidity,” according to Technavio. Back EMF, meanwhile, “reduces the need for expensive Hall sensors and complicated controllers in various applications.”

China’s BLDC motor industry

Hundreds of companies comprise China’s DC motor manufacturing sector, with more than 60 percent consisting of small and midsize domestically owned enterprises. Major suppliers include Johnson Electric from Hong Kong SAR and Linix Motor. The latter is a subsidiary of the Hengdian Group, one of the largest private conglomerates in the country.

Most Chinese manufacturers ship their products overseas, with export ratios varying from 30 to 80 percent. Some allocate output entirely to markets abroad.

Many factories are found in Shenzhen, Dongguan, Zhongshan, Changzhou, Suzhou and Ningbo, with a few operating in provinces in northern China such as Shandong.

Brushed & BLDC motors

To cater to diverse requirements, Chinese manufacturers of DC motors continue to offer both brushed and brushless types.

Brushed units available in mainstream supply have 0.64 to 115mNm torque, 1.5 to 300V rated voltage and about 80 percent efficiency. Diameters range from 8 to 35mm.

In the BLDC segment, typical units have 6 to 380V rated voltage and over 80 percent efficiency. They come in diameters of 20 to 130mm, although smaller versions can also be made.

Both types have built-in protection from overload, -current and -voltage, and meet industry safety standards such as CE, CCC, RoHS and UL. They are available in water-resistant designs, usually with at least an IP65 rating.

These motors can be customized to match intended applications.

Buyers’ preferences on the sources of components, including stators, rotors, magnets and shafts, are accommodated as well. Usually, Chinese suppliers obtain them from domestic companies.

The cost of these manufacturing inputs is expected to remain generally stable in the next 12 months. Some companies will continue to lower their quotes to attract more orders.

The products in this gallery have been handpicked by our Chinese mainland-based market analyst for representing current trends in DC motors from Chinese mainland and Hong Kong SAR manufacturers.