Brushless Drivers/Speed Controller
Anaheim Automation's Brushless DC drives/speed controller products are designed for high volume OEM applications keeping a low unit cost as the primary objective. Choose from 0-5VDC input control or by a simple turn of a potentiometer, it's doesn't get any easier than that. With our combination low prices and high quality products, your search for Brushless DC drives/speed controller products has ended!
Brushless Motor
Anaheim Automation's Brushless Motor is designed for high volume OEM applications with low cost being the primary objective. Choose from a range of sizes from 0.9" to 4.8" in diameter, from under 1 Watt to 1500 Watts of power. There are hundreds of Brushless Motor products off-the-shelf and many custom options are also available. Options include optimizing the maximum speed, torque, current, voltage, cabling, wiring, connectors, and shaft modifications.
Brushless Motors with Integrated Speed Controller
Anaheim Automation's Brushless Motors with Integrated Drivers/Speed Controller products offer you the covenience of having both motor and driver already connected as one unit. These compact velocity contol drivers are available from 1.1" diameter to 2.3" diameter models and power ratings from 1 watt to 150 watts. These high quality brushless motors with integrated drivers/speed controller products are designed for that clean look with less wiring. Choose from our broad line of products as we're sure to have a product that fits your application.
Brushless Gear Motors
High quality, high speed, and high torque - Anaheim Automation's Brushless Gear Motors are reasonably priced and offered in a wide selection. Our inventory includes Brushless Planetary or Spur Gearboxes with torque ratings up to 145 oz-in with ratios from 3:1 to 326:1. With a variety of power and ratios to choose from, Anaheim Automation will surely have a Brushless Gear Motor that's right for your application. Customization is available to match specific voltage, current and max speed.
  • Brushless Speed Controller Applications
  • Brushless Speed Controller Environmental Considerations
  • Brushless Speed Controller Wiring
  • Brushless Speed Controller Mounting
  • Brushless Speed Controller Customization
  • Brushless Speed Controller Hall Sensor Feedback
  • Brushless Speed Controller Encoder Feedback

A Brushless Electric Motor and a Brushless Speed Controller is used in a variety of applications in many different industries. Some of the applications are Appliances, Automotive, Aerospace, CNC, Consumer, Factory Automation, Instrumentation, Medical, Packaging Equipment, and Semiconductor.

The following environmental and safety considerations must be observed during all phases of operation, service and repair of a brushless speed controller system. Failure to comply with these precautions violates safety standards of design, manufacture and intended use of the brushless speed controller and motor. Please note that even a well-built brushless speed controller operated and installed improperly, can be hazardous. Precaution must be observed by the user with respect to the load and operating environment. The customer is ultimately responsible for the proper selection, installation, and operation of the brushless speed controller system.

The atmosphere in which a brushless speed controller is used must be conducive to good general practices of electrical/electronic equipment. Do not operate the brushless speed controller in the presence of flammable gases, dust, oil, vapor or moisture. For outdoor use, the brushless speed controller and motor must be protected from the elements by an adequate cover, while still providing adequate air flow and cooling. Moisture may cause an electrical shock hazard and/or induce system breakdown. Due consideration should be given to the avoidance of liquids and vapors of any kind. Contact the factory should your application require specific IP ratings. It is wise to install the brushless speed controller and motor in an environment which is free from condensation, electrical noise, vibration and shock.

Additionally, it is preferable to work with the brushless speed controller system in a non-static protective environment. Exposed circuitry should always be properly guarded and/or enclosed to prevent unauthorized human contact with live circuitry. No work should be performed while power is applied. Do NOT plug in or unplug the connectors when power is ON. Wait for at least 5 minutes before doing inspection work on the brushless speed controller and motor system after turning power OFF, because even after the power is turned off, there will still be some electrical energy remaining in the capacitors of the internal circuit of the brushless speed controller.

Plan the installation of the brushless speed controller in a system design that is free from debris, such as metal debris from cutting, drilling, tapping, and welding, or any other foreign material that could come in contact with circuitry. Failure to prevent debris from entering the brushless speed controller system can result in damage and/or shock.

The following information is intended as a general guideline for wiring of the Anaheim Automation brushless speed controller product line. Be aware that when you route power and signal wiring on a machine or system, radiated noise from the nearby relays, transformers, and other electronic devices can be inducted into the brushless speed controller and encoder signals, input/output communications, and other sensitive low voltage signals. This can cause systems faults.

WARNING - Dangerous voltages capable of causing injury or death, may be present in the brushless speed controller system. Use extreme caution when handling, wiring, testing, and adjusting during installation, set-up, tuning, and operation. Donít make extreme adjustments or changes to the brushless speed controller system parameters, which can cause mechanical vibration and result in failure and/or loss. Once the brushless speed controller and motor are wired, do not run the brushless speed controller by switching On/Off the power supply directly. Frequent power On/Off switching will cause fast aging of the internal components, which will reduce the lifetime of brushless speed controller and motor system.

Strictly comply with the following rules:
• Follow the Wiring Diagram with each brushless speed controller
• Route high-voltage power cables separately from low-voltage power cables
• Segregate input power wiring and brushless speed controller power cables from control wiring and brushless electric motor feedback cables as they leave the brushless speed controller. Maintain this separation throughout the wire run.
• Use shielded cable for power wiring and provide a grounded 360 degree clamp termination to the enclosure wall. Allow room on the sub-panel for wire bends.
• Make all cable routes as short as possible.

NOTE: Factory made cables are recommended for use in our brushless speed controller and motor systems. These cables are purchased separately, and are designed to minimize EMI. These cables are recommended over customer-built cables to optimize system performance and to provide additional safety for the brushless speed controller system and the user.

WARNING - To avoid the possibility of electrical shock, perform all mounting and wiring of the brushless speed controller and motor prior to applying power. Once power is applied, connection terminals may have voltage present.

Brushless Speed Controller Applications

Brushless Speed Controller Blog

Brushless Speed Controller Information

Brushless Speed Controller products

The following information is intended as a general guideline for the installation and mounting of the brushless speed controller and motor system. WARNING - Dangerous voltages capable of causing injury or death may be present in the brushless speed controller system. Use extreme caution when handling, testing, and adjusting during installation, set-up, and operation. It is very important that the wiring of the brushless speed controller and motor be taken into consideration upon installation and mounting. Subpanels installed inside the enclosure for mounting brushless motor system components, must be a flat, rigid surface that will be free from shock, vibration, moisture, oil, vapors, or dust. Remember that the brushless speed controller and motor will produce heat during work, therefore, heat dissipation should be considered in designing the system layout. Size the enclosure so as not to exceed the maximum ambient temperature rating. It is recommended that the brushless speed controller be mounted in position as to provide adequate airflow. The brushless speed controller and motor should be mounted in a stable fashion, secured tightly. NOTE: There should be a minimum of 10mm between the brushless speed controller and any other devices mounted in the system/electric panel or cabinet.

NOTE: In order to comply with UL and CE requirements, the brushless speed controller and motor system must be grounded in a grounded conducive enclosure offering protection as defined in standard EN 60529 (IEC 529) to IP55 such that they are not accessible to the operator or unskilled person. As with any moving part in a system, the brushless motor should be kept out of the reach of the operator. A NEMA 4X enclosure exceeds those requirements providing protection to IP66. To improve the bond between the power rail and the subpanel, construct your subpanel out of zinc-plated (paint-free) steel. Additionally, it is strongly recommended that the brushless speed controller be protected against electrical noise interferences. Noise from signal wires can cause mechanical vibration and malfunctions.

Anaheim Automation was established in 1966 as a manufacturer of "turnkey" motion control systems. Its' emphasis on R&D has insured the continued introduction of advanced motion control products, such as the brushless speed controller and motor product lines. Today, Anaheim Automation ranks high among the leading manufacturers and distributors of motion control products, a position enhanced by its excellent reputation for quality products at competitive prices. The brushless speed controller product line is no exception to the Company's goal.

Anaheim Automation offers a wide variety of standard brushless speed controller products. Occasionally, OEM customers with mid to large quantity requirements prefer to have a brushless speed controller that is custom or modified to meet their exact design requirements. Sometimes the customization is as simple as shaft modification, brake, oil seal for an IP65 rating, mounting dimensions, wire colors, or label. Other times, a customer might require that a brushless speed controller meet an ideal specification such as, speed, torque, and/or voltage.

Engineers appreciate that Anaheim Automation's brushless speed controller product line can answer their desire for creativity, flexibility and system efficiency. Buyers appreciate the simplicity of the "one-stop shop," and the cost savings of a custom brushless speed controller design, while engineers are pleased with Anaheim Automation's dedicated involvement in their specific brushless speed controller system requirements.

Anaheim Automation's standard brushless speed controller product line is a cost-effective solution, in that they are known for their rugged construction and excellent performance. A considerable size of its sales growth has resulted from dedicated engineering, friendly customer service and professional application assistance, often surpassing the customer's expectations for fulfilling their custom requirements. While a good portion of Anaheim Automation's brushless speed controller and motor sales involves special, custom, or private-labeling requirements, the company takes pride in its standard stock base located in Anaheim, California, USA. To make customization of a brushless speed controller affordable, a minimum quantity and/or a Non-Recurring Engineering (NRE) fee is required. Contact the factory for details, should you require a custom brushless speed controller in your motion control system design.

All Sales for a customized or modified brushless speed controller are Non-Cancelable-Non-Returnable, and a NCNR Agreement must be signed by the customer, per each request. All Sales, including a customized brushless speed controller, are made pursuant to Anaheim Automationís standard Terms and Conditions, and are in lieu of any other expressed or implied terms, including but not limited to any implied warranties.

Anaheim Automation's customers for the brushless speed controller product line is diverse: companies operating or designing automated machinery or processes that involve food, cosmetics or medical packaging, labeling or tamper-evident requirements, assembly, conveyor, material handling, robotics, special filming and projection effects, medical diagnostics, inspection and security devices, pump flow control, metal fabrication (CNC machinery), and equipment upgrades. Many OEM customers request that we "private-label" the brushless speed controller, so that their customers stay loyal to them for servicing, replacements and repairs.

PLEASE NOTE: Technical assistance regarding its brushless speed controller product line, as well as all the products manufactured or distributed by Anaheim Automation, is available at no charge. This assistance is offered to help the customer in choosing Anaheim Automation products for a specific application. However, any selection, quotation, or application suggestion for a brushless speed controller, or any other product, offered from Anaheim Automationís staff, its' representatives or distributors, are only to assist the customer. In all cases, determination of fitness of the custom brushless speed controller in a specific system design is solely the customers' responsibility. While every effort is made to offer solid advice regarding the brushless speed controller product line, as well as other motion control products, and to produce technical data and illustrations accurately, such advice and documents are for reference only, and subject to change without notice.

The feedback for a Brushless Speed Controller is done by the use of Hall sensors when rotating the Brushless Electric Motor in the stator windings. These need to be energized sequentially. The Brushless Speed Controller needs to know the rotor position in order to understand the next winding to be energized following the correct energizing sequence. The rotor position is sensed by the Hall sensors embedded in the back end cap of the Brushless Electric Motor housing. The Brushless Speed Controller utilizes three Hall sensors which are separated by either 60° or 120°. The Hall sensors sense either the rotor magnet or an external magnet placed on the back and shaft. They give a digital signal signifying whether or not a North or South Pole has passed the censors using the signals from these sensors the Brushless Speed Controller can easily maintain the Brushless Electric Motor velocity. The Hall sensors are normally mounted on a PC board and fixed to the back end cap on the non-driving end of the Brushless Electric Motor.

For low-speed applications it is recommended to use an encoder for the feedback rather than the Hall sensors. The Hall sensor counts per revolution can only be as great as a number of polls times the number of Hall Sensors. The Brushless Speed Controller can use this higher count to its advantage when operating the Brushless Electric Motor. With more counts per revolution at its disposal, the Brushless Speed Controller can use this additional information to more precisely control the velocity of the Brushless Electric Motor. The higher the resolution on the encoder to more finely the Brushless Speed Controller can control the Brushless Electric Motor. Even though the expense is much greater for encoders when compared to Hall sensors this price can be justified as it can result in very precise control for a much lower cost than alternative technologies such as Servo motors, AC motors or synchronous motors.