Selecting the right BLDC motor assemblies can make the difference between a system that simply works and one that performs reliably for years. Whether you are designing for industrial automation, robotics or medical equipment, understanding how BLDC motors fit into your application makes a difference.
At Novara Technologies, we work closely with engineers and OEMs to supply brushless DC motors and fully integrated assemblies that meet the most exacting performance requirements. Here is what to consider when making your choice.
What Is a BLDC Motor Assembly?
A BLDC motor assembly goes beyond a standalone motor. It combines the core motor with additional components to create a ready-to-integrate motion solution.
This can include:
- Integrated encoders for position and velocity feedback
- Planetary or spur gearboxes
- Custom shafts and housings
- Brake systems
- Custom cabling and connectors
By integrating these elements into one solution, BLDC motor assemblies reduce how long an installation takes, simplify procurement and improve reliability.
At Novara, we supply brushless DC motors in a range of different sized frames from NEMA 17 (42mm) to NEMA 42 (110mm). Our motors are 3-phase designs available in 4 and 8-pole configurations, with commutation and velocity loop feedback provided by hall sensor signals. We then tailor assemblies to suit your exact system requirements.
Define Your Speed and Torque Requirements
One of the first decisions is understanding the speed range and torque your application needs.
BLDC motors are ideal for applications requiring stable velocity control over a wide speed range. If your system operates continuously or under variable load conditions, brushless DC motors offer smooth torque delivery and consistent performance.
When specifying your assembly, consider:
- Required continuous torque
- Peak torque conditions
- Maximum and minimum operating speeds
- Duty cycle
At Novara Technologies, we offer three designs to improve efficiency and optimise performance against cost. This allows us to help you select the most cost-effective solution without over-specifying the motor.
Consider Feedback and Control
Many modern systems rely on accurate speed and position data. Integrated feedback devices play a critical role here.
Our BLDC motor assemblies can include encoder solutions with customised resolution to suit your control architecture. Hall sensors provide reliable commutation and velocity feedback, ensuring smooth operation and precise control.
For applications that demand enhanced accuracy, such as automation equipment or medical BLDC motor solutions, encoder selection becomes especially important.
Think About Space and Integration
Space constraints often affect the type of motor. Compact, lightweight brushless DC motors are well suited to installations where available space is limited.
Beyond the size of the motor, integration matters. Gearboxes can be combined with BLDC motors to increase torque output without increasing footprint. We offer both planetary and spur gearboxes that have been rigorously tested for long life and maximum efficiency.
Custom shaft modifications, mounting adjustments and tailored cabling also help ensure the motor assembly fits seamlessly into your equipment.
By working with us early in the design phase, you can avoid costly redesigns later.
Factors Affecting the Environment and Reliability
Operating conditions should never be overlooked. Temperature, vibration and continuous run time all affect motor performance and lifespan.
All our motors are manufactured using high quality materials and anti-high temperature permanent magnets. This supports high reliability, low motor heating, low vibration and smooth running.
For sectors such as healthcare, reliability is critical. Our medical BLDC motor solutions are designed to operate quietly, require minimal maintenance and have a long service life. These qualities are essential in diagnostic devices, laboratory systems and other sensitive medical equipment.
Support for Customisation
Off-the-shelf products do not always meet complex project requirements. That is why we provide custom motor solutions across our entire range.
Our expert team can modify:
- Windings
- Housings
- Shaft designs
- Encoder specifications
- Gearbox configurations
- Brake add-ons
- Cabling arrangements
As a trusted global company with experience in advanced interconnect solutions, cable assemblies and medical device assemblies, we understand that the motor is only one part of a wider system. Our design-for-manufacture approach ensures your BLDC motor assemblies are optimised not only for performance but also for cost and long-term supply.