DC 24V/48V Adjustable Speed Brushless Gear Motor Driven Roller

DC 24V/48V Adjustable Speed Brushless Gear Motor Driven Roller

Motor driven roller (MDR) is a self-powered roller by integrating the motor, gear reduction box and sensor  and reasonably installing them into steel tube. Thus the conveying system does not consider motor, chain, intermediate shaft or other auxiliary  driving elements. No need for bulky gear reduction box. Just install the motor driven roller on the  rack and connect the cable to the power supply, and the job is done. The conveying system is  cleaner, denser, beautiful, safe and reliable. Motor driven roller is widely applied in food processing, medical production, electronic assembly,  airport logistics, postal services, distribution and various industries. It meets diversified and  automatic needs of different industries.

Core Structure and Working Principle

• Brushless DC Motor (BLDC): The core power source of the roller. The motor rotor consists of permanent magnets, and the stator contains multi-phase windings. Unlike brushed motors, it has no mechanical brushes or commutator; operation is achieved through electronic commutation.

• Planetary Gear Reducer: Tightly integrated at the rear of the motor, it converts the motor's high speed and low torque into low speed and high torque at the roller output end. This is key to achieving high driving force.

• Roller Shell: Serves as the final output and load-bearing component, making direct contact with conveyed items. The surface can undergo various treatments (rubber coating, chrome plating, etc.) to adapt to different friction requirements.

• High-Precision Bearings and Seals: Ensure smooth roller rotation and provide a high protection rating (e.g., IP65), suitable for harsh environments.

• Built-in Sensors (Typically Hall Sensors): Detect the motor rotor's position, providing crucial signals for the controller's electronic commutation and forming the basis for accurate speed feedback.

• External Controller (Required): This is an independent electronic drive unit responsible for:

• Power Drive: Converts DC power to three-phase AC power, supplying it sequentially to the motor windings.

• Speed Regulation: Precisely controls motor speed by receiving external analog voltage (e.g., 0-5V), PWM signals, or digital communication commands (e.g., RS485, CANopen, Modbus).

• Function Control: Enables complex functions such as start/stop, forward/reverse rotation, braking, and position control (requires an encoder).

Main Features and Advantages

• Low-Voltage Safety and Flexible Power Supply: 24V/48V safety voltage eliminates high-voltage risks. It can be directly powered by switching power supplies, battery packs, or solar systems, making it particularly suitable for mobile equipment (e.g., AGVs), portable devices, and human-robot collaboration scenarios.

• High Efficiency, Energy Saving, and Long Service Life: Brushless motors are highly efficient (typically >85%), with no brush wear or sparks, offering a far longer lifespan than brushed motors and minimal maintenance costs.

• Excellent Speed Regulation and Control Performance:

• Wide-Range, Smooth Speed Control: Broad speed adjustment range (often up to 1:100 or higher), with stable torque at low speeds and no crawling.

• Fast Dynamic Response: Quick start, stop, acceleration, and deceleration, supporting high-frequency jogging operations.

• High-Precision Constant Speed: Maintains constant speed under varying loads via the controller.

• High Starting Torque and Overload Capacity: The gear reduction structure provides torque multiplication from several to hundreds of times, resulting in high starting torque and strong short-term overload capability.

• Intelligence and Networking: Easily integrates into PLC, industrial computer, or IoT systems via communication interfaces, enabling centralized control, status monitoring, and data analysis. It is a core component of smart factories.

• Low Noise and Low Electromagnetic Interference: Quiet operation, with significantly lower electromagnetic interference from electronic commutation compared to brushed motors.

Typical Application Scenarios

• Flexible Conveying and Sorting Systems: Intelligent conveyor lines and parcel sorters requiring frequent speed changes, starts/stops, and reverse operation.

• Mobile Robots (AGV/AMR): Serves as the direct power source for drive wheels, enabling precise movement and speed control.

• Food, Pharmaceutical, and Electronics Cleanrooms: Low-voltage safety, no sparks, easy cleaning, meeting high hygiene and explosion-proof requirements.

• Precision Assembly and Inspection Lines: Precision workstations requiring slow, smooth, and programmable speed control.

• Special Equipment: Stage machinery, exhibition display automation, laboratory instruments, and other applications requiring quiet, controllable drive.

• Battery-Powered Equipment: Devices like cleaning robots and special vehicles that rely on battery life benefit from its high efficiency, extending operational time.

Technical Parameters and Selection Points

• Rated Voltage: DC 24V or DC 48V (must match the controller).

• Rated Power: Common range from 10W to 500W.

• Rated Torque: Determined jointly by motor power and reduction ratio; a core selection parameter (unit: N.m).

• Rated Speed: Output shaft speed after reduction; common range from 10 RPM to 300 RPM.

• Reduction Ratio: Fixed value, e.g., 3:1, 5:1, 10:1, 50:1, etc., determining output speed and torque.

• Control Method:

• Signal Type: PWM speed control, analog voltage speed control, communication control.

• Feedback Element: Standard Hall sensors (for commutation and basic speed measurement); optional high-precision encoder (for closed-loop position/speed control).

• Protection Rating: Typically IP54 or IP65, offering dust and water resistance.

• Mechanical Interface: Output shaft type (plain shaft, keyway, threaded hole) or flange mounting method.

System Components and Precautions

• Essential Three Components:

1. Brushless Geared Motor Roller unit.

2. Compatible Brushless Motor Controller.

3. Suitable DC Power Supply (with sufficient power margin).

• Heat Dissipation: Monitor the temperature rise of both the motor and controller during continuous high-load operation. Some models feature motor housings with cooling fins.

• Selection Calculation: Precisely calculate the required continuous torque and peak torque based on load weight, friction coefficient, speed requirements, and acceleration requirements. Use these calculations to select the motor power and reduction ratio.

• Technical Support: Compared to AC direct-drive rollers, this system is more complex. Supplier support for controller parameter setting, wiring, and debugging is often necessary.

DC24V/48V DGBL50 Gear Motor Driven Roller

Brief Introduction 

• DGBL50 direct current motor driven roller is driven by a direct current motor and can handle light, medium, and high loads with adjustable speed.

• Built-in direct current brushless gear reduction motor matched with controller, with great efficiency.

• Optional motors include the AS standard power motor and HAS high power motor.

• Uses a 24V or 48V direct current safety voltage.

• Roller speed range 8 - 200 m/s

• 10%–150% of speed adjustment range.

• To implement IO control, ZPA functionalities, RS485, EtherCAT, and internet interface, several clever controllers have been adapted.

• Galvanized steel or stainless steel roller pipe, length is customzied.

• SoThe driven head of the roller can be fixed with a groove or a pulley, sprocket, timing pulley, V-pulley, or polyvee pulley.

• Intelligent control and simple installation.

DC24V /48V Gear Motor Driven Roller-DGBL50 Corresponding Name of Parts

Some Pictures of Customized Motor Driven Roller

poly-v pulley belt driven galvanized steel motor driven roller with controller and fixing bracket

steel poly-v pulley galvanized steel motor driven roller

plastic poly-v pulley PU coating steel motor driven roller

poly-v pulley tapered motor driven roller with new controller

The 24V/48V DC adjustable-speed brushless geared motor-driven roller is a paradigm of mechatronic integration and intelligence. It is no longer merely a simple power component but a complete, programmable "motion axis." Its characteristics of low-voltage safety, high efficiency, and controllability give it an irreplaceable advantage in modern automation fields that pursue flexibility, intelligence, and human-robot collaboration, especially in mobile automation and precision control scenarios. Selection requires systematic consideration from three dimensions: mechanical load, electrical compatibility, and control requirements.

Technical Specifications of DC24V/48V DGBL50 Gear Motor Driven Roller

Intelligent Control Drive

Fixing Bracket

Fixing shaft to cable end by standard terminal box base plate and fixing plate.

Mounting example