Brushed DC Motor in Linear Actuators: Overview and Working

A brushed DC motor is a simple, small motor used in linear actuators. It utilizes mechanical brushes to commutate the motor, enabling rotational motion, which is then converted to linear motion by the actuator. A brushed DC motor comprises four key components – stator, rotor, commutator, and brushes.

Once DC voltage is applied across the brushes, current begins to flow through the rotor windings, creating a magnetic field around the rotor. The stator also has its magnetic field which interacts with that of the rotor, prompting it to spin. The commutator also rotates, changing the current flow direction. This process is called commutation, which ensures continuous changes in the magnetic field and maintains rotational motion by alternating the rotor and stator magnets. In a linear actuator, the motor’s rotational movement is then converted into linear motion via a lead screw or similar mechanism, driving the actuator’s mechanical parts to produce the desired movement.

Brushless DC Motor (BLDC) in Linear Actuators: Overview and Working

A brushless DC motor (BLDC) is an advanced motor used in linear actuators for precise, efficient motion. The motor consists of a rotor, stator, and electronic speed controller (ESC). In a linear actuator, the ESC sequentially energizes the stator windings, creating a rotating magnetic field. Its interaction with the rotor’s permanent magnets causes it to spin, converting rotational motion into linear movement via a lead screw or ball screw. The ESC ensures smooth, controlled operation, minimizing power loss and heat generation for efficient actuator performance.

Difference Between Brushed and Brushless Motors in Linear Actuators

Here are some key differences between brushed and brushless DC motors when used in linear actuators

• Working: While the basic principle of both motor types is the same, brushed motors use mechanical brushes for electrical contact, whereas brushless motors rely on electronic controllers for the same purpose. Brushless motors have a more advanced design, making them better suited for precision and efficiency in linear actuators.
• Efficiency: Efficiency of brushed motors may reduce over the time due to the friction between the brushes and the commutator. The brushes need to be replaced regularly to avoid such issues. In contrast, brushless motors are more efficient since they eliminate friction from brushes, resulting in lower wear and heat generation, and providing better overall performance. This makes them ideal for applications that require long-lasting performance in linear actuators.
• Noise: Brushless motors are much quieter than brushed motors, making them a better choice for applications with strict noise requirements, such as medical devices, robotics, or assistive technology that uses linear actuators.
• Complexity: Brushed motors are simple and easy to operate, which makes them ideal for cost-sensitive linear actuator applications. However, brushless motors require more complex control systems and algorithms to manage the electronic commutation, offering more precise and reliable performance in linear actuators that need fine control and smooth motion.
• Cost: While brushless motors are generally more expensive than brushed motors, their lower maintenance requirements, longer lifespan, and improved efficiency can make them more cost-effective in the long run, especially in linear actuators where continuous, high-performance operation is critical.

Learn more on this topic in our related blog: Understanding DC Gear Motors: Working Principles, Selection, and Applications

Are you looking for standard or custom DC motors for your linear actuators? If yes, ensure you partner with a reliable manufacturer that can meet your specific needs. The motor must align with the required speed, range, precision, and repeatability of your application, offering the right level of control. Many DC Motor manufacturers across the US offer custom options to cater to your exact requirements. Making the right motor choice is crucial, as it drives your actuator’s efficiency and enables smooth, precise movements, enhancing the overall performance and reliability of your system.

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Step-by-Step Procedure of DC Motor Replacement on Fifth Wheel Landing Gear

The landing gear repair or replacement is performed in two phases. The first step is preparatory and the second stage is where the DC motor is actually repaired. The stage-wise steps followed in landing gear repair are as follows.

• Preparatory Stage: The preparatory stage of the fifth wheel landing gear repair focuses on the diagnosis and parts collection. In the preparatory stage, following steps are performed.
  • Problem Diagnosis: There are two basic tests one should perform for problem diagnosis. At first, the driver must check if the leg is hitching and unhitching with the 5th gear. If not then it is a problem, which can be easily resolved by repairing the landing gear. If the vibration has increased and the car makes a choking noise while the DC motor assembly bounces, then it is a problem too. This problem needs DC motor assembly replacement. Sometimes, the failure may have been caused due to poor quality accessories.
  • Parts Collection: Before starting repair or replacement, the operator must have all required parts, accessories, and mounting tools. In the case of replacement, the operator may require a new DC motor assembly, mounting brackets, power kit, parts kit, crank handle assemblies, and so on.
• DC Motor Replacement Stage: Once the preparatory stage is done, the operator begins with the DC motor replacement. The steps followed to replace DC motor assembly are detailed below.
  • At first, the operator exposes the drive shaft that transmits power to the leg. This shaft is exposed by detaching the retaining bolts mounted on the sliding sheath. Once the bolts are off, the sheath can be slid back and forth. It exposes the drive shaft.
    
  • The motor assembly is secured by a plastic retainer. It is supported by a screw and by taking the screw off, the DC motor assembly can be taken off the leg.
    
  • The motor assembly is supposed to be slid off the drive shaft along with the gearbox.
    
  • Once the DC motor and gearboxes are off, the operator detaches the DC motor from the gearbox. The motor is bolted on the gearbox with the help of four bolts, in which only two are required to be removed by the operator and the motor comes off.
    
  • Once the motor is taken off, the operator replaces it with the new one that matches requirements.
  • However, re-attachment of the motor assembly is performed by moving opposite leg shaft aside. Then a manual attachment or override shaft is inserted into the housing. The operator aligns the center of assembly and the significant location on the drive shaft. Then the assembly is center nutted.
    
  • This completes the assembly process but then to finalize it, the component attachment is required to be done.
  • The operator activates the landing gear switch to ensure the position of the motor assembly. Once the position is assured, the operator re-attaches the plastic retainer.
    
  • The final step is to re-attach the opposite leg shaft and activating the landing gear switch by using a manual wrench. When this is done, the assembly is finalized with retainer bolts.

Learn more on this topic in our related blog – Which are the Types of DC Gear Motor Controls?

Although the above-discussed process of changing DC motor n 5th wheel landing gear is easy to follow, it is always recommended to get it done by professionals. Also, it is important that you use a branded or quality replacement parts. Venture Mfg. Co offers RV and 5th wheel landing gear and 12 VDC power kit.

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