High Power Brushless DC Motors- Suzhou Retek Electric Technology Co., Ltd.

Structural Engineering for Kilowatt Continuous Output

High power BLDC motors are designed to operate continuously at outputs greater than 1kW, challenging the thermal and mechanical limits of standard motors. They often feature an elongated, square, or large-diameter cylindrical frame (e.g., BL130 series, 86mm square CNC motor).

The key is efficient heat removal. This is achieved through large surface area heat sinks, internal flow channels for forced air (e.g., CNC Spindle motor with air cooling), or liquid cooling jackets. Electrically, these motors are optimized for higher voltage (310VDC or 230VAC) to reduce the current (I=P/V) and therefore minimize I2R losses, improving overall efficiency to 90% or greater. The rotors are typically inertia-optimized to handle the high speeds often associated with high power applications (e.g., blowers and spindles) while maintaining mechanical integrity at high centrifugal forces.

Introduction

Detailed Parameters and Performance Data

RETEK: Building Reliability for Heavy Industry and Automation

Suzhou Retek Electric Technology Co., Ltd. serves the high-end industrial power market, where motor sizing and thermal management are paramount. Our high-power motors (e.g., 2kW, 3.5kW) are engineered to deliver high dynamic performance comparable to traditional AC servo motors but with the superior efficiency of BLDC technology. We provide comprehensive thermal analysis and mechanical FEA reports for our industrial clients, guaranteeing performance under continuous rated load. The BL86mm Square Motor 310VDC is a solution for compact yet powerful drives in industrial automation.

Applications

Advanced Technology Highlights

High Power, High Duty Cycle Application Environments

Industrial Ventilation and Air Movement: Large-scale heavy-duty blower motors (e.g., BL130 2kW) for drying, filtering, and climate control in factories and data centers. Challenge: High acoustic output and continuous operation at varying speeds.
High-Speed Machining Spindles: Motors for milling and engraving (e.g., 3.5kW CNC spindle motor) requiring extremely smooth high-speed rotation and high power density. Challenge: Precise speed control across a wide RPM range and effective removal of internal heat.
Electric Vehicle Traction: Motors for industrial vehicles (e.g., airport tugs, large AGVs) or high-performance golf carts requiring sustained high torque and power for acceleration.
Industrial Pump and Compressor Drives: Motors for large compressors, high-pressure washers, and hydraulic pumps.

Technical Specifications

Industrial & Commercial Usage

Technical Parameters

Parameter	Range / Typical Value	Unit
Rated Continuous Power	1 to 5+	kW
Operating Voltage (DC Bus)	170 VDC to 310 VDC	V
Peak Current Density	Optimized Low	A/mm$^2$
Efficiency (Maximum)	> 90	%
Rotor Balancing Grade	G2.5 or better	Standard
Cooling Method Options	Passive/Forced Air/Liquid Cooled	Type

Additional Information

Supplementary Details & Notes

Integrated Production and Customization Workflow

Production for high-power motors emphasizes robust mechanical assembly, including hydraulic pressing of components and precision interference fits to manage large thermal expansion/contraction cycles. Final QC involves high-voltage insulation tests (Hi-Pot) and full load dynamometer testing.

Cooling Interface Design: Customization of the cooling manifold (inlet/outlet port locations) for integration with client-specific thermal management systems (e.g., specific fluid couplings).
Integrated Sensors: Custom fitting of temperature sensors (PT1000 or NTC thermistors) directly into the winding end-turns for superior thermal monitoring and protection via the external drive.
Custom Shaft Extensions: Providing double-ended shafts, specialized splines, or threaded features for direct connection to pump impellers or gearboxes.
High-Speed Balancing: Individual balancing of rotors to meet the specific G-grade requirement for the maximum operating speed of the application.

Service & Support

Technical Advantages and Core Design Features

High System Efficiency (>90%): Achieved through high-voltage operation and low-loss magnetic steel, translating directly into significant long-term energy cost savings.
Integrated Cooling Solutions: Custom-designed internal air flow passages or integrated water jacket interfaces ensure heat is rapidly dissipated, sustaining continuous power delivery.
Robust High-Speed Bearings: Utilizes ceramic hybrid or high-precision steel bearings (e.g., ABEC-7) to handle the centrifugal forces and thermal expansion associated with high-speed, high-power rotation (e.g., in spindles).
VPI Encapsulation: All high-voltage windings undergo Vacuum Pressure Impregnation for superior dielectric strength, vibration damping, and heat transfer.
High Torque-to-Inertia Ratio: Optimized rotor design allows for quick changes in speed and load, essential for dynamic CNC and process control applications.

Frequently Asked Questions

Common Inquiries Regarding High Power BLDC Motors

Q: Why are high-power motors often designed for high voltage (e.g., 310VDC)?
A: High voltage minimizes current for a given power output (I=P/V). Lower current reduces I2R heat losses in the windings and allows for smaller, less costly motor cables and driver electronics, leading to better overall system efficiency.

Q: What is the typical lifetime difference between air-cooled and liquid-cooled high-power motors?
A: Liquid cooling is generally preferred for the highest power density and continuous 24/7 operation, as it maintains a lower, more consistent motor temperature, significantly extending the life of the winding insulation and bearings. Air-cooled systems are simpler but less effective at removing high continuous heat loads.

Q: What maintenance is required for high-power BLDC motors?
A: BLDC motors are inherently low maintenance. The primary maintenance item is the bearing system; depending on the application and load, bearings may require re-greasing or replacement after a specified operating interval, which we detail in the maintenance manual.

Resources

Advanced Material Selection Guide

Magnets: High-temperature stability NdFeB magnets (H or EH grades) are crucial to prevent irreversible demagnetization at the high operating temperatures of high-power systems.

Laminations: Thin gauge (e.g., 0.2mm) silicon steel is used to minimize eddy current losses at the high switching frequencies of high-voltage PWM drivers.

Shaft: High-tensile steel alloys (e.g., 4140, 42CrMo) are selected and heat-treated for high yield strength to withstand the high torsional stress of kilowatt power transmission.

About Suzhou Retek Electric Technology Co., Ltd.

Unlike other motor suppliers, Retek engineering system prevents the selling of our motors and components by catalogue as every model is customized for our customers. The customers are assured that every component they receive from Retek is designed with their exact specifications in mind. Our total solutions are a combination of our innovation and a close working partnership with our customers and suppliers.

As China High Power Brushless DC Motors Manufacturers and Wholesale High Power Brushless DC Motors OEM/ODM Suppliers, Retek business consists of three platforms: Motors, Die-Casting and CNC manufacturing and wire harness. Retek products are widely supplied for residential fans, vents, boats, airplanes, medical facilities, laboratory facilities, trucks and other automotive machines.

Welcome to send us an RFQ, it is believed you will get the best cost-effective products and services here!

Customized Solutions

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Suzhou Retek Electric Technology Co., Ltd.

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