The BLV Series is one of our two offerings for DC-input brushless motor speed control systems. Featuring a brushless motor with hall-effect sensor feedback, it delivers constant torque, a wide speed range, and precise speed regulation. The BLV driver, on the other hand, brings unique functionalities tailored for mobile robots, such as low battery operation and ramp operation.
If we take a look at the image below, you’ll see a BLV Series brushless gear motor paired with its driver on the left. On the right, we’ve got a BLV gear motor combined with a pre-assembled FR gearhead, which is a flat-style hollow shaft gearhead designed for high-torque applications. The dedicated motor driver on the left controls the motor speed and operation, with the terminal side showing where all the wires are connected. Optional parallel shaft gearheads or electromagnetic brakes can be added.
Here’s a glimpse at the original BLV Series lineup with 200 W and 400 W options along with some key specifications.
While listening to customer feedback, we recognized a strong demand for compact 100 W gear motors in the AGV/AMR/mobile robot and material handling industries. To meet this demand, we extended the BLV Series and its AGV-specific features into the 100 W range. A new 100 W type has been added to the lineup, though it maintains the same appearance with slight variations in specifications.
Differences:
- The 100 W models only accept 24 VDC, so 48 VDC is not supported.
- The speed range is narrower, ranging from 10~3000 r/min (analog) or 80~3000 r/min (digital).
- The maximum extension distance between the motor and driver has reduced to 1.5 meters.
- The IP rating for the motor has increased from IP40 to IP65.
Similarities:
- Speed regulation remains unchanged at +/-0.5% (analog) or +/-0.2% (digital).
- The driver's IP rating stays at IP20.
- Safety standards remain consistent.
Below is a comparison chart for the 100 W, 200 W, and 400 W BLV Series models.
Two cable lengths are available: 0.2 m (0.7 ft) or 1.0 m (3.3 ft). However, a round-shaft, ungeared version isn’t available for the 100 W type.
Here’s an overview of the overall system configuration. Accessories like mounting brackets, couplings, and external speed potentiometers are also available.
Notice that besides the OPX-2A "Control Module" in the image, MEXE02 support software also appears as a new way to program the stored data on the driver. Next, we’ll delve into the second major design change in the BLV Series.
Now, the MEXE02 software supports the BLV series, making data setup even easier.
The MEXE02 software provides an intuitive UI, simple point-to-point motion profile programming, and monitor functions. Originally, the stored data on the BLV driver could be programmed using either the OPX-2A handheld teaching pendant or via Modbus RTU through RS-485. With this update, all drivers across wattages can use the universal MEXE02 support software for simpler data setup.
When an updated BLV driver is connected to a PC, the MEXE02 software interface shows fields for rotation speed [r/min], torque limiting value [%], acceleration time [s], and deceleration time [s]. You can input the desired values or stick with the default ones. The BLV Series supports eight speed profiles, corresponding to the product. For instance, the AZ Series stepper motor drivers offer 256 motion profiles.
Don’t forget to save your data by performing a data write operation.
In addition to the straightforward programming, the MEXE02 software’s teaching, monitoring, and testing functions are invaluable during setup or troubleshooting. Let’s explore these functions.
Teaching and Remote Operation:
The teaching operation window lets the operator manually move the motor to a specific position, storing it to 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 testing the motion profiles stored in the driver without needing to wire the I/O.
When no product is connected, the monitored values show 0. During operation, real-time values will appear. Under OUTPUT, green indicates the output is ON, while white indicates OFF.
Remember to check the box to start any teaching, remote, or monitor operation.
Real-time information, such as feedback speed (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.
Monitor Operations:
There are several monitor operations you can perform to assist with troubleshooting and understanding the system.
Monitor operations include unit information monitor, status monitor, D-I/O, R-I/O monitor (direct I/O and remote I/O), internal I/O monitor, alarm monitor, warning monitor, RS-485 communication monitor, and waveform monitor.
The alarm monitor is especially helpful during troubleshooting as it shows the exact alarm code causing the issue. It retains up to 10 alarm records. Refer to the "Cause" and "Measure" sections to determine the necessary actions.
The waveform monitor records the timing of I/O as the system operates, aiding in troubleshooting by comparing actual versus expected behavior.
Another useful feature is the RS-485 status monitor, which checks the status of communication. This is particularly beneficial when setting up an RS-485 industrial network.
The I/O test checks the 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 functioning correctly.
Increased Usability:
Along with the major design changes mentioned above, there are additional functions that enhance the usability of the BLV Series to improve machine operation.
DIR Output:
A rotation direction output has been added to the BLV Series drivers, allowing users to monitor the motor direction remotely. ON means forward, and OFF means reverse. Previously, the speed could be calculated by monitoring the pulses from SPEED-OUTPUT, but the rotation direction couldn’t be confirmed. We added this feature based on market feedback.
Load Factor Monitor Commands:
New monitor commands have been introduced for master-slave operations with upper-level PLCs or HMIs. The original BLV Series drivers couldn’t monitor load fluctuations when operated via network communication, so we've enhanced 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.
Flange Drive Adapter:
The addition of a flange drive adapter simplifies setup and increases both radial and axial load capacity.
Takeaways:
- The BLV 100 W parallel shaft gear motors and FR flat hollow shaft gear motors have been added to the BLV Series based on 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 perfect for customers requiring DC or battery-powered brushless motors, conveyor manufacturers, and those needing 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.
To learn more about the AGV-specific functions of the BLV Series, please subscribe!
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