What Are BLDC Pumps? Benefits, Technology & Applications

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Thomas BLDC Technological Revolution

The future will provide automation to many aspects of our lives. Usage of devices such as drones, robots and self-driving vehicles will increase exponentially over the next decade.

All such devices rely on motors that set them in motion – the motor is “the heart” of every device. The durability and performance of the device depends on the motor’s design, which can enhance the quality of the equipment.

The BLDC technological revolution has influenced the industry by offering improvements to DC motors such as peak-power at optimal efficiency in the smallest possible size and weight. Today, we can find brushless motors in numerous applications. To keep up with the soaring market for these products, manufacturers are turning to a new generation of BLDC motors powered by a lithium-ion (Li-ion) batteries.

Thomas, a brand of Ingersoll Rand is a leading provider of highly engineered products for OEM applications and Thomas is no stranger to BLDC technology. Thomas experienced in-house Engineering team has been designing and developing BLDC motor technology into pump and compressor solutions for over twenty-five years for OEMs around the world.

What Is BLDC Technology?

Brushless DC motors, also known as electronically commutated brushless motors (EC) are powered by a DC electric source and, compared to traditional solutions, spare parts i.e. commutator and brushes have been removed.

In this type of motor design, the mechanical commutator has been replaced by an electronic speed control system, while the traditional rotor winding has been replaced
by properly connected permanent magnets. These motors are growing in popularity and more OEMs are specifying them in their designs because of the overall value.

FEATURES AND BENEFITS:

Higher efficiency than traditional motors
Integrated or externals controllers designed for plug and play
Longer lifespan reducing replacement costs
Compact size for space-saving installation
Lighter weight enhancing system design
Lower lifetime cost compared to AC motors
Suited for sound-sensitive environments
Compatible with IoT applications
Facilitates remote location installations

Want to gain an even deeper understanding of the technical advantages our pumps offer? Click below to access our infographic, and take the first step towards optimizing your system's capabilities today.

BLDC Infographic

What Are Some Differences between BLDC and DC or AC Motor Technologies?

The brushless DC motor is significantly different from a conventional brush type DC motor. It consists of magnets, coils and a commutator, but the coils are stationary inside the casing, and the magnets are placed on the rotor. The commutator is electrically controlled. Its system turns on and off the power to the coils, where the magnetic field causes the rotor to rotate. EC motors operate on the same principle as “DC” motors, which is why they are called “BLDC” motors.

In a standard DC motor, the rotor is set in motion with brushes. There are several considerations to take into account with a brush type design due to friction between brushes and rotor:

Energy losses
Brush replacement is necessary
Brush dust can contaminate environment

Whereas a lack of brushes in a brushless DC motor will result in:

Greater efficiency
Longer life
No service requirements

The following table compares and rates brushless DC motors vs. Brush DC motors vs. AC motors

It is important to note that although the initial cost of BLDC is slightly higher than DC or AC motors, the total cost of ownership is compensated by the motor’s variable output, longer and efficient life, reliability, and less service requirements.

Systems that operate on battery or battery back-up	Applications that require precise flow on a continuous basis
Applications that have stringent regulatory power consumption limits	Sound sensitive applications
Mission-critical systems	Systems that are installed and operated in remote locations
Applications that use multiple compressors or a large reservoir tank	Advanced diagnostic capabilities
Singular system design and installation for anywhere in the world regardless of V/Hz	Applications that cannot tolerate inherent design hazards of DC or AC motors
Applications where AC or DC EMI is an issue	The ability to make your system IOT (Internet of Things) compatible

What Is The Value That BLDC Characteristics Provide OEMs?

VALUE	CHARACTERISTIC
Excellent restart under load with no additional mechanical means or investment Predictable flow insensitive to voltage or load 100% output achievable above synchronous speed	Constant torque over broad range of speed
Less current, power consumption Longer battery life More output capability on main circuit Cooler running	Higher efficiency throughout a broad range of performance
Smaller system design Less weight Less packaging/shipping costs Improved overall logistics Improved manufacturing handling	More power dense
Allows for maximum system up-time Predictive diagnostics for remote operating locations Reduces unexpected service calls	Lends itself well to advanced diagnostics
Improves system design single‑point failure mode in mission‑critical systems On‑demand system usage maximizes life Less down‑time Can compensate for variations in broad system designs	Enhanced system reliability
Control of speed equates to minimizing sound & vibration On/off capability made possible by simple electrical signals instead of complex relays, etc. Eliminates need to oversize other motor technology pumps necessary to compensate for required system reliability Potential to eliminate complicated valving and relays for performance management	On‑demand performance
Reduction in number of SKUs to maintain Reduction in inventory Reduction in agency costs Less burden on customer service	One system design for world‑wide operation

When Should BLDC Motor Technology Be Considered?

BLDC drive systems should be considered for:

Systems that operate on battery or battery back-up	Applications that require precise flow on a continuous basis
Applications that have stringent regulatory power consumption limits	Sound sensitive applications
Mission-critical systems	Systems that are installed and operated in remote locations
Applications that use multiple compressors or a large reservoir tank	Advanced diagnostic capabilities
Singular system design and installation for anywhere in the world regardless of V/Hz	Applications that cannot tolerate inherent design hazards of DC or AC motors
Applications where AC or DC EMI is an issue	The ability to make your system IOT (Internet of Things) compatible

What Markets and Applications Currently Use Thomas BLDC Pumps?

Medical, Laboratory, Food and Beverage, Environmental and Mobile Markets all benefit from the advantages and overall value that only BLDC technology can provide.
These are some of applications that OEMs have benefited from the overall value of our pumps with brushless DC motors:

Air sampling
Altitude training flight simulator
Blood analyzers
Cryotherapy
Diagnostic instruments
Dialysis
Diesel engine exhaust gas after-treatment
Exoskeletons
Fuel atomization
Nitrogen generator
Pipeline robotics
Portable oxygen concentrators
Scent dispensing
Solar irrigation
Solar pond aeration
Surgical wound debridement

Thomas Offers BLDC Motor Controllers

Any BLDC motor requires a motor controller in order to operate. That’s why we provide motor controllers that can be custom designed by our dedicated in-house resources to meet your exact system requirement. Thomas offers advanced BLDC motor controllers: the V Series Controller and the X Series Controller.

Why Choose Thomas?

With a wide range of pressure, vacuum and liquid technologies including WOB-L® piston, articulated piston, diaphragm, miniature diaphragm, rotary vane, miniature rotary vane, linear and peristaltic, Thomas offers the broadest oil-less product range in the industry. With this vast product offering, Thomas can design an ideal, custom pressure or vacuum pump solution which meet our customers’ precise needs.
Our Product Manager, Jamie Campbell is available to answer your questions and help you find the right solution for your specific application requirements. Ask about qualifying for a free sample.