The use of brushless motor technology within CDA France packaging systems is now well established! The company has implemented this technology to dynamically control certain mechanical motions, enabling significant improvements in machine performance. This is particularly advantageous in Pick & Place applications, where both positioning accuracy and capping torque control are essential. Brushless motors are currently integrated into models such as the VS 2000 capping unit and the E-Fill SW monobloc solution.
But what motivated this integration, and why only on selected machines? Let’s uncover the answer in this latest update!
What is a Brushless motor?
A brushless motor (also known as BLDC for Brushless Direct Current) is a DC electric motor that operates without carbon brushes or a mechanical commutator. Unlike conventional motor types (asynchronous, brushed DC, or stepper), it uses electronic commutation controlled via a drive (variable speed controller). This design allows it to:
- Remove wear caused by brush friction.
- Reduce heating, electrical noise, and maintenance requirements.
- Improve energy efficiency.
- Provide precise regulation of speed, position, and torque.
In most configurations, the rotor contains permanent magnets, while the stator is powered and controlled electronically. One key structural benefit is a perfectly constant torque across all operational speeds, which is crucial when stable force and highly repeatable movements are required. Thanks to these strengths, brushless motors are often described as “intelligent motors”.
The 3 operating modes of Brushless motors
Brushless motors stand out for their versatility and can be used in three separate control modes:
- Speed mode: The motor rotates at an extremely stable and calibrated speed. It can also detect fluctuations or drift, making it ideal for conveyor control and container transport stability.
- Position mode: The motor executes a highly accurate number of rotations, validating whether the required position has been reached. This mode is typically used for electric actuators and linear movement systems.
- Torque mode: By monitoring the applied current, the motor can reach and maintain the exact rotational force required. This is invaluable for industrial capping and tightening operations.
Why are Brushless motors called “SMART”?
A brushless motor is generally equipped with a high-resolution encoder, capable of reading the shaft’s angular position with extreme precision (sometimes reaching several million measurement points per revolution). This built-in system intelligence allows the machine to:
- Detect speed drift instantly (speed mode)
- Validate rotation count precisely
- Self-adjust tightening force according to current feedback
- Send an alert signal if torque or position targets cannot be met
This enables brushless-equipped packaging machines to:
- Predict mechanical blockages before failure
- Adjust tightening profiles depending on cap type
- Maintain absolute motion precision at high speeds
- Guarantee motion repeatability for process reliability
Simplified configuration & industrial communication
Brushless motors operate alongside smart motor drives compatible with multiple industrial communication standards. This allows easy, touchscreen-based configuration on CDA HMI panels, including adjustments for:
- Acceleration and deceleration ramps
- Ultra-accurate conveyor speeds
- Precise capping torque settings
Key Brushless motor advantages
- Totally constant torque at all speeds
- Compact size, enabling simpler integration into packaging machinery
- Minimal maintenance thanks to the absence of mechanical brushes
- Extended lifespan and optimised uptime
- Excellent motion precision and repeatability
- Multi-axis synchronisation via servo-style control (master/slave regulation)
CDA and Brushless integration in packaging machines
For several years, brushless motor systems have been used on selected components within:
- The E-Fill SW monobloc, specifically its Pick & Place module, which handles cap transport and automatic tightening
- The VS 2000 automatic capping machine, directly within its tightening head system
It is worth noting that CDA continues to use asynchronous motors as its core motor technology, which remains entirely capable of handling most standard machine functions.
Current technology limitations
As with any advanced innovation, the main downside today is still the high cost of brushless motor systems. CDA has chosen not to deploy these motors across all filling, capping, or labelling platforms. Instead, they are used only where clear performance gains justify the added cost, ensuring machine value and price-to-performance ratio remain CDA’s key priorities.
FAQ
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What is the core difference between an asynchronous motor and a brushless motor?
A brushless motor delivers constant torque without slip, and replaces mechanical commutation with fully electronic control, reducing wear and increasing precision.
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Is a brushless motor suitable for industrial capping torque control?
Yes. In Torque mode, current monitoring enables exact torque output, making it ideal for systems like VS2000 heads.
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Which CDA assemblies currently use brushless motors?
Key integrations include Pick & Place modules, the VS2000 tightening head, and piston motion sub-assemblies.
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Are brushless motors becoming more affordable?
Prices have reduced over recent years, making the technology more accessible.
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Can multiple brushless motors be synchronised?
Yes. Servo-style master/slave regulation is possible via industrial motor drives.
