The BLV Series is one of our two offerings for DC-input brushless motor speed control systems. It’s well-known for providing constant torque, a broad speed range, and precise speed regulation, thanks to the brushless motor with hall-effect sensor feedback. But the BLV driver takes things further by introducing unique features tailored specifically for mobile robots, such as the ability to operate efficiently under low battery conditions and manage smooth ramp operations.
Take a look at the BLV Series brushless gear motor and its driver in the image below. On the right, you’ll notice a BLV gear motor equipped with a pre-assembled FR gearhead. This is a space-saving, flat-style hollow shaft gearhead designed to handle high-torque applications. On the left, the dedicated motor driver controls the motor speed and operation. All the wires are connected on the terminal side. Optional parallel shaft gearheads or electromagnetic brakes can be installed as needed.
Here’s a glimpse of the original BLV Series 200W/400W lineup and some of its specifications:
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While listening to feedback from our customers, we recognized a strong demand for compact 100W gear motors within the AGV/AMR/mobile robotics and material handling industries. As a result, we extended the BLV Series and its AGV-specific functions into the 100W range. A new 100W type has been added to the lineup. Despite maintaining the same appearance, there are slight differences in the specifications.
**Differences:**
- The 100W models accept only 24VDC; 48VDC is no longer supported.
- The speed range is narrower, ranging from 10 to 3000 rpm (analog) or 80 to 3000 rpm (digital).
- The maximum extension distance between the motor and driver has been reduced to 1.5 meters.
- The motor's IP rating has been upgraded from IP40 to IP65.
**Similarities:**
- The speed regulation remains consistent at ±0.5% (analog) or ±0.2% (digital).
- The driver's IP rating remains at IP20.
- The safety standards remain unchanged.
Here’s a comparison chart for the 100W, 200W, and 400W BLV Series models:
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Two cable lengths are available—0.2m (0.7ft) or 1.0m (3.3ft). However, a round-shaft, ungeared version is not available for the 100W type.
This is what the overall system configuration looks like. Accessories like mounting brackets, couplings, and external speed potentiometers are also available.
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Notice that besides the OPX-2A "Control Module" in the image, MEXE02 support software is now another method to program the stored data on the driver. Next, we’ll explore the second major design change on the BLV Series.
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**Easy Data Setting with MEXE02 Support Software**
The MEXE02 software offers an intuitive user interface, simple point-to-point motion profile programming, and monitor functions. The stored data on the original BLV driver could be programmed either with the OPX-2A hand-held teaching pendant or via Modbus RTU through RS-485. Now, all drivers from all wattages can use the universal MEXE02 support software for even easier data setup.
The screenshot below shows the MEXE02 software when an updated BLV driver is connected to a PC. You need to input the rotation speed [rpm], torque limiting value [%], acceleration time [s], and deceleration time [s]. You can either enter the values you prefer or use the default settings. Eight speed profiles are available with the BLV Series, corresponding to the product. For instance, 256 motion profiles are available with the AZ Series stepper motor drivers.
Don’t forget to save your data by performing a data write operation.
Besides the easy, intuitive programming, the MEXE02 software's operation teaching, monitoring, and testing functions are invaluable during setup or troubleshooting. Let’s dive into these functions.
**Teaching, Remote Operation**
The teaching operation window allows the operator to manually move the motor to a specific position so that it can be taught and stored in the driver. You can use the arrow keys to move the motor and select the data number to save the data to. Remote operation allows you to test the motion profiles stored in the driver without having to wire the I/O.
The two screenshots below have no product connected, so the monitored values show 0. When the system is operating, there will be values changing in real-time. Under OUTPUT, green indicates that the output is ON, while white indicates OFF.
Real-time information, such as feedback speed (at the motor and gearhead output shaft), command speed, load factor, inverter voltage, and alarm code, are shown on the top right corner. Only certain output statues are shown here. For advanced I/O status check, refer to I/O test operation.
Remember to check the checkbox to start any teaching, remote, or monitor operation.
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**Monitor Operations - Many Available**
There are many monitor operations you can perform to assist with troubleshooting and understanding how the system works. Let’s go over a few monitor operations here.
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The **alarm monitor** is useful during troubleshooting because it shows the exact alarm code that is causing the alarm. It also retains up to 10 alarm records. Refer to the "Cause" and "Measure" to determine what to do.
The following screenshot shows an "RS-485 communication timeout." The cause is that the time set in the "communication timeout" parameter has elapsed without establishing communication. The fix is to check the connection between the master controller and driver. For more information, please refer to the manuals.
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The **waveform monitor** records the timing of I/O as the system is operating. This is particularly useful during troubleshooting as you want to know what it’s doing versus what it’s supposed to do.
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One more. The **RS-485 status monitor** checks the status of communication. This is especially useful when trying to set up an RS-485 industrial network.
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**I/O Test**
The I/O test checks real-time statuses of driver I/O; including direct I/O and remote I/O via RS-485. It’s useful during troubleshooting to determine why something isn’t working.
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**Increased Usability**
Along with the major design changes mentioned above, there are some new functions that increase the usability of the BLV Series to improve machine operation.
**DIR Output**
A rotation direction output was added to the BLV Series drivers. This allows the user to monitor the motor direction remotely. ON means forward, and OFF means reverse. In the past, the speed could be calculated by monitoring the pulses coming out of the SPEED-OUTPUT. However, the rotation direction couldn’t be confirmed. We added this after receiving some feedback from the market.
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**Load Factor Monitor Commands**
New monitor commands have been added for master-slave operations with upper-level PLCs or HMIs. The original BLV Series drivers couldn’t monitor the load fluctuation when operated via network communication, so we’ve improved the product by adding more monitor commands. Newly added load factor monitor commands include speed (gear shaft), speed decimal point position, conveyor traveling speed, conveyor traveling speed decimal point position, external analog speed setting, external analog torque limiting, and external analog voltage setting.
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**Flange Drive Adapter Simplifies Setup and Increases Both Radial and Axial Load**
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**Takeaways:**
- BLV 100W parallel shaft gear motors and FR flat hollow shaft gear motors have been added to the BLV Series as a result of AGV and material handling feedback.
- The easy-to-use MEXE02 support software is now compatible with all BLV Series drivers.
- New DIR output and network monitor commands increase the usability of the BLV Series.
The BLV Series is ideal for customers who require DC or battery-powered brushless motors, conveyor manufacturers, and customers who require industrial network communication. The FR gearhead is recommended for high torque applications where motor length is also a constraint. The addition of MEXE02 software support for the BLV Series enables many benefits, such as easy data programming and status monitoring.
Learn more about the AGV-specific functions of the BLV Series.
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