| Light-Duty Conveyor |
Continuous rotation with moderate starting torque and relatively stable load. |
Brushless DC motor or AC induction motor with a gear reducer. |
24 VDC, 48 VDC, or 100–240 VAC, depending on the machine architecture. |
Motor speed commonly 1,500–3,000 rpm; output speed often 10–200 rpm after reduction. |
Approximately 0.5–20 N·m at the geared output for compact conveyors. Confirm using belt force, pulley radius, and acceleration. |
S1 continuous duty
Allow for frequent starts, stops, and speed changes if the conveyor is indexed. |
IP54 is commonly suitable for clean indoor areas; IP65 is preferable where dust or water spray is present. |
Hall sensors for basic speed control; encoder feedback for accurate positioning or synchronization. |
Check gearbox service factor, shaft loading, noise level, mounting position, brake requirement, and conveyor safety compliance. |
| Automated Guided Vehicle or Mobile Robot |
Repeated acceleration, deceleration, direction changes, and operation from a battery. |
Brushless DC servo motor or permanent-magnet synchronous motor with a planetary or spur gearbox. |
24–72 VDC battery systems are common in mobile equipment. |
Output wheel speed typically 50–500 rpm, depending on wheel diameter and travel speed. |
Approximately 2–60 N·m per drive wheel for small and medium mobile platforms. Include rolling resistance, slope, payload, and acceleration torque. |
Intermittent duty with high peak torque. Regenerative braking and thermal cycling must be evaluated. |
IP54–IP65 is typical; use sealed connectors and suitable cable protection for floor-level operation. |
Incremental encoder, Hall sensors, or absolute encoder for closed-loop speed and odometry control. |
Verify battery undervoltage behavior, electromagnetic compatibility, brake release power, connector durability, and CAN or other communication interfaces. |
| Electric Pump |
Continuous rotation with torque determined by pump type, pressure, flow, and fluid viscosity. |
AC induction motor or brushless motor matched to a fixed-speed or variable-speed drive. |
Single-phase or three-phase AC; low-voltage DC is also used in portable systems. |
Approximately 1,000–3,600 rpm for many compact pump systems. |
Common small-system ratings range from 50 W to 2.2 kW. Pump power should be calculated from pressure, flow, efficiency, and fluid density. |
S1 continuous duty
Use variable-speed control when flow or pressure must be regulated. |
IP55 or higher for protected industrial locations; select corrosion-resistant materials for humid or chemically exposed areas. |
Basic on/off control, analog speed reference, or closed-loop pressure and flow feedback. |
Check shaft seal compatibility, maximum fluid temperature, overload protection, priming behavior, vibration, and applicable electrical certifications. |
| Cooling Fan or Blower |
Low-to-moderate torque with a strong relationship between speed, airflow, and noise. |
External-rotor BLDC motor or AC motor with integrated or external speed control. |
12–48 VDC for compact fans; 100–240 VAC for larger equipment. |
Approximately 500–3,000 rpm, depending on impeller design and required airflow. |
Usually 10–500 W for compact air-moving equipment; determine operating point from airflow, static pressure, and fan efficiency. |
S1 continuous duty
Thermal stability and low acoustic noise are often more important than peak torque. |
IP44–IP65 depending on dust, moisture, and installation location; consider elevated ambient temperatures. |
Open-loop voltage or PWM control; tachometer output or closed-loop speed feedback for critical cooling. |
Compare acoustic performance, bearing life, airflow curve, stall protection, restart behavior, and thermal derating. |
| Robotic Joint or Rotary Actuator |
High acceleration, frequent reversals, short positioning cycles, and variable static holding loads. |
AC servo or brushless servo motor combined with a precision gearbox. |
48–400 VDC bus systems or 100–240 VAC servo drives are common. |
Motor speed commonly 2,000–6,000 rpm; geared output speed may be below 100 rpm. |
Continuous torque may range from 1–50 N·m, with peak torque commonly 2–3 times continuous torque for short periods, subject to the motor datasheet. |
Intermittent duty with defined acceleration, deceleration, dwell time, and peak torque duration. |
IP54–IP65; select higher protection where washdown, dust, or exposed cabling is expected. |
High-resolution incremental or absolute encoder; servo drive required for precise position, velocity, and torque control. |
Check backlash, torsional stiffness, encoder resolution, peak current, emergency-stop response, brake holding torque, and gearbox life. |
| Linear Actuator for Adjustable Equipment |
Short extension and retraction cycles with high axial force and limited travel. |
DC geared motor or BLDC motor driving a lead screw or ball screw. |
12, 24, or 48 VDC are common choices. |
Motor speed typically 1,000–4,000 rpm; actuator rod speed often 5–100 mm/s. |
Typical actuator force ranges from 500 N to 8,000 N. Calculate required force from load, angle, friction, and desired acceleration. |
Intermittent duty; many actuators require a rest period to prevent overheating. |
IP44–IP66 depending on indoor, medical, agricultural, or outdoor use. |
Limit switches for end-of-travel protection; Hall sensors or encoder feedback for position control. |
Verify screw efficiency, self-locking behavior, static load rating, duty-cycle limits, noise, anti-pinch protection, and mechanical end stops. |
| Outdoor Gate, Door, or Barrier |
Low-speed movement with high breakaway torque, holding load, and exposure to weather. |
Geared DC motor, BLDC motor, or AC motor with an electromagnetic brake. |
24 VDC, 48 VDC, or 100–240 VAC depending on gate size and control cabinet design. |
Output speed commonly 5–100 rpm or a linear movement of approximately 50–300 mm/s. |
Approximately 5–150 N·m at the output shaft for compact and medium mechanisms; calculate from gate mass, friction, slope, and wind load. |
Intermittent duty with repeated opening and closing cycles; include a safe manual-release method. |
IP65 or higher is often appropriate; consider UV exposure, condensation, corrosion, and temperatures from approximately −20 °C to 50 °C. |
Limit switches, magnetic sensors, encoders, obstruction detection, and controlled braking are commonly used. |
Confirm regional electrical safety requirements, emergency release, anti-crush protection, corrosion resistance, and cold-start performance. |
| Precision Positioning Stage |
Low backlash, repeatable movement, controlled acceleration, and stable positioning under changing loads. |
Servo motor or two-phase stepper motor with a precision transmission. |
24–80 VDC for compact stages; higher-voltage servo buses are used in larger systems. |
Approximately 100–4,000 rpm, depending on lead pitch, travel speed, and required resolution. |
Typical motor torque ranges from 0.1–10 N·m. Select based on reflected inertia, acceleration, friction, and vertical-axis holding force. |
Intermittent or continuous motion; resonance, settling time, and thermal drift must be assessed. |
IP40–IP54 for clean indoor equipment; use higher protection for dust or coolant exposure. |
Encoder feedback for servo systems; open-loop or closed-loop stepper control for selected applications. |
Check repeatability, resolution, backlash, runout, bearing preload, vibration, homing accuracy, and drive tuning compatibility. |
| Industrial Mixer or Agitator |
High starting torque, variable viscosity, and possible shock loads during material changes. |
Three-phase induction motor or high-torque BLDC motor with a helical, planetary, or worm gearbox. |
200–480 VAC three-phase is common in industrial installations. |
Output speed commonly 10–300 rpm. |
Approximately 20–1,000 N·m at the geared output, depending on batch size, viscosity, impeller geometry, and required mixing time. |
S1 continuous duty
Allow for high transient torque and possible overload during start-up. |
IP55–IP66; select suitable shaft seals and materials for washdown, dust, or corrosive process environments. |
Variable-frequency drive with overload monitoring; speed feedback may be required for process consistency. |
Verify service factor, gearbox thermal rating, shaft and bearing loads, sanitary or hazardous-area requirements, and process temperature. |
