Brushless DC motors are widely used for their high reliability and efficiency and long operating life. Unlike brushed types, they do not have brushes and commutators, eliminating friction and electrical arcing that result in high noise, vibration and heat levels. The absence of these parts also leads to reduced wear, maintenance needs and overall costs. In medical applications, the use of brushless motors means enhanced patient safety and comfort.
BLDC motors are usually employed in respirators, including those used in sleep apnea treatment, compression devices for blood clot prevention, and diagnostic and fluid handling machines. Patient lifts and beds, surgical instruments, other medical equipment and those used in dental procedures also use such motors.
As most applications continue to favor miniaturization, manufacturers of BLDC motors will comply, with upcoming releases expected not only to be smaller but still pack high power density.
Slotless motors
In China, suppliers are also looking to develop slotless types, which in addition to being brushless do away with slots in the stator core. These slots are where the stator windings are found in a conventional slotted motor. In a slotless design, these windings are placed directly onto the stator surface. This configuration eliminates cogging torque, ensures smoother operation and better performance at high speeds, reduces electrical noise, improves efficiency and makes the motor easier to cool.
Chinese companies hope to produce more slotless motors for medical, robotics and aviation applications in the coming years. Moons, a leading BLDC motor manufacturer in China, has already introduced its versions available in rated voltages of 6, 9, 12, 18 and 24V. These units, with a frame diameter of 13mm, have a maximum speed of 40,000rpm and rated torque ranging from 1.24 to 264.4mNm.
Growing market
The manufacturing sector for BLDC motors will continue to benefit from the expansion of the global market for medical devices. The latter is forecast to reach $511.2 billion by the end of 2024, with the biggest chunk of $74.75 billion coming from cardiology devices, according to Statista. By 2028, this category will reach $638 billion, registering a CAGR of 5.7 percent from 2024.
The same source said that the US is the largest market for medical devices, followed by China, Germany, Japan and the UK. China will post $36.38 billion in revenue by end-2024 and $50.04 billion by 2028 for an 8.3 percent CAGR.
In the BLDC motor sector, China reached $7.5 billion in 2023, accounting for 27.6 percent of the global market, according to S&P Consulting, a market research firm in the country. In addition to medical devices, the key applications included household appliances, automotive, industrial control, electric tools and toys. Electric vehicles, robotics and medical equipment are expected to lead in the coming years and keep the market upbeat.
Globally, the BLDC motor category is forecast to reach $13.91 billion by the end of 2024 and $23.59 billion by 2032 for a 6.8 percent CAGR, according to the latest findings of Polaris Market Research.
Manufacturing expansion
Anticipating this rising adoption of BLDC motors, many Chinese suppliers have plans to boost production through 2025. Shenzhen Hofon Electronic Technology Co. Ltd, one of the manufacturers interviewed by Global Sources, spent $1 million on new equipment, enabling it to increase output by 5 percent in the past 12 months. It will continue to do so, aiming for as much as a 10 percent rise in the months ahead.
Moons, meanwhile, has invested $8.3 million on growing its slotless BLDC motor category and will realize an annual capacity of 2.27 million units after mass production.
China has hundreds of manufacturers of BLDC motors and the majority can produce units for medical applications. Most are small and midsize operations. In addition to Moons, the top homegrown makers include Zhaowei and Weizhen.
The foreign companies with production facilities there and catering to the medical industry include tier-one companies such as Mabuchi Motor, Nidec, Lin Engineering and MinebeaMitsumi. In the second tier are Panasonic, Maxon Motor and ebm-papst, joined by China-based Wolong Electric Group.
Holtek and HengDrive are also major players in this field and have factories in China.
All also manufacture various types of motors used in the automotive, industrial, office automation sectors and electric tools. Their facilities are found in Shenzhen, Dongguan, Zhongshan, Ningbo, Wenzhou, Suzhou, Shanghai, Changzhou and Qingdao.
Motors for medical devices
Typical BLDC motors for medical devices in China are available in versions with a rated voltage of 12, 24 or 48V and a maximum output power of 50W. Most have a diameter of less than 38mm and a no-load speed of 50 to 20,000rpm. Water-resistant types can also be sourced, usually with an IP65 to IP68 rating.
These motors are produced to CE, RoHS and UL standards. They can be customized to meet the voltage, current, speed, torque and size requirements of intended applications.
Chinese manufacturers usually use stators, rotors, magnets, windings and cases sourced from domestic providers. The cost of materials and components is expected to remain steady throughout 2024 and keep BLDC motor prices stable.
BLDC motor, up to 20,000rpm no-load speed
Company: DSD Motor & Electronics
Rated at 12 or 24V, DSD’s DS-BL2838 BLDC motor has 40 to 320mA current and 4,600 to 20,000rpm speed at no load. At maximum efficiency, it has 1.08 to 16.93W power, 150 to 2,400mA current, 1,050 to 16,500rpm speed and 55 to 500gf.cm torque.
MOQ: 1,000 units
Lead time: 30 days
BLDC motor, 17 to 3,500rpm no-load speed
Company: Shenzhen Hofon Electronic Technology Co. Ltd
The PG16-1636BLN BLDC motor from Shenzhen Hofon has 12 or 24V nominal voltage, 0.08A no-load current, 17 to 3,500rpm no-load speed and 180 to 5000gf.cm torque at rated load. The output power at rated load is 4.8 or 5.89W.
MOQ: 1,000 units
Lead time: 25 days
BLDC motor, 2,849rpm on-load speed
Company: Shenzhen Weizhen Motor Development Co. Ltd
Shenzhen Weizhen markets the W3650BL BLDC motor with 2,849rpm full-load and 3,560rpm no-load speed ratings and 177.39mN.m starting torque. It has 12VDC nominal voltage, 10 to 15VDC operating voltage, 0.168A no-load current, 8.388W maximum efficient power and 16.3W output power.
MOQ: 5,000 units
Lead time: 30 days
BLDC motor, 38rpm on-load speed
Company: Shenzhen Zhaowei Machinery & Electronics Co. Ltd
Model ZWPD016016-216 6-5755 from Shenzhen Zhaowei is a BLDC motor with 1.5 to 6V voltage range, 6V rated voltage, 120mA no-load and 200mA full-load current, and 0.2W output power. With load, the speed is 38rpm and the torque 365gf.cm.
MOQ: 3,000 units
Lead time: 10 days
