FAULHABER brushed DC motors

Brushed DC motors from FAULHABER

As the UK and Ireland’s sole supplier of FAULHABER motors, EMS offers a selection of brushed DC motors that offer precision to a variety of applications. Unlike brushless motors, which replace the mechanical commutation function with electronic control, brushed DC motors operate based on the mechanical linkage between their commutator and brushes. The key difference between FAULHABER brushed DC motors and conventional brushed DC motors is in the rotor.

In FAULHABER’s brushed DC motor design, the permanent magnet stator is cylindrical and is located on the inside, while the rotor rotates around it on the outside. The rotor consists of an ironless, self-supporting skew-wound copper coil. This technology was developed by Dr. Fritz Faulhaber Sr. and patented in 1958. It is at the heart of what DC micromotors from FAULHABER are all about.

This design not only minimises the moment of inertia of the rotor, but also gives the drives maximum dynamics and precise, cogging-free running. This results in outstanding dynamics across the entire range.

Sizes start from the incredibly small 3mm diameter motor, up to 44mm, making them ideal choices for applications such as medical devices, aerospace, control and instrumentation.

Selecting a brushed DC motor

There are several advantages to using a brushed DC motor in your application:

• High starting torque
• Simple control over a wide speed range
• Torque and motor speed can be controlled by voltage
• Excellent power to weight ratio
• More cost effective compared to brushless

Brushed DC motors from FAULHABER use skew wound coreless motor technology to give unrivalled power-to-weight ratios. The omittance of iron in the winding of these motors improves efficiency and enhances acceleration times to give outstanding dynamic performance together with long life under extreme load conditions.

The motors are available with graphite or precious metal commutation. Graphite commutation is particularly robust and is ideally suited to dynamic high-performance applications, whereas precious metal commutation makes extremely small DC motors possible. 

For low power motors, it’s best to select commutation systems using precious metal brushes because of their extremely low contact resistance. However, copper graphite brushes are recommended for higher power motors to ensure long life even under extreme load conditions.

The total weight of the brushed motors is extremely low. In addition, this structure ensures a minimum moment of inertia and cogging-free, high-precision running. Thanks to these features, DC motors from FAULHABER have particularly high dynamics and high-power density.

Brushed DC motor range

FAULHABER SR

With integrated high-resolution encoders, the SR range of brushed DC motors are the most compact on the market.

They are particularly ideal for use in highly precise applications such as speed control and positioning. The commutation system has a clean, low-noise commutation signal, a small size and low contact resistance. It works best in battery-powered applications where current is limited.

It’s possible to create the best system solution for even the most difficult applications by combining an SR brushed DC motor with a wide range of precision gearheads and DC motor controllers.

The SR brushed motors feature low current and starting voltage, wide operating temperature from -30 °C up to +85°C and steel housing with a corrosion resistant coating. This range starts at 8mm in diameter for the 0816 SR, all the way through to 22mm for the 2232 SR brushed motor.

FAULHABER CXR

Thanks to durable graphite commutation, high quality neodymium magnets and the tried-and-tested winding of the FAULHABER rotor, the CXR series combines power, robustness and control in a compact form. In particular, the strong neodymium magnet featured within the CXR range of brushed DC motors gives the motors a broad torque band with a consistent forces from 3.6 to 40 mNm.

With low rotor inertia, the CXR series has high dynamic performance, plus a wide operating temperature of -30 °C up to +100°C. Additionally, the standard drive can be joined with high-resolution optical or magnetic encoders for applications with exact speed control or positional requirements. This series can meet a wider range of requirements through FAULHABER’s extensive and optimally matched selection of gearheads.

Starting at 13mm in diameter for model 1336 CXR, the range increase to 26mm for the 2657 CXR brushed motor.

EMS offers small to medium-sized brushed DC motors from FAULHABER, which encompass a range of cutting-edge motor technologies. Whether your application demands a high torque motor, or is driven by the need for high power in a lightweight design, we supply high power, reliable, dynamic brushed motors from one the industry’s leading specialists. To learn more, contact a member of the team here.