Brushed DC Motor Custom Guide: Streamlining Design with Integrated Units

Is integrating standalone motors and sourcing separate components slowing down your process?

When working with motors, engineers often face challenges such as the time-consuming task of designing and sourcing gears or sensors separately, or struggling to find the optimal combination with gears and encoders. At MinebeaMitsumi, we go beyond offering standalone motors. By custom-designing and integrating gears, sensors, and connectors, we propose the optimal unit tailored to your requirements and support you through to mass production.

This article details the specific components available for customization.

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1. MinebeaMitsumi DC motor custom options

• Motors

  

  Customize characteristics by selecting a round, flat, or square shape to match your specifications.

• Brush Materials

  

  Ideal materials tailored to your application, such as metal for low voltage and quick start-up or carbon for high current and long life.

• Gearboxes

  

  Integrate planetary, spur, or worm gears tailored to your application, torque, and space requirements.

• Torque Limiters

  

  Incorporate torque limiters to protect components from unexpected overloads.

• Potentiometers & Encoders

  

  Provided as an integrated unit with the motor to achieve high-precision control and exact positioning.

• Connectors

  

  Accommodate detailed specifications including connector assembly, cable tubing, and ID printing. Individual connectors are also available for purchase.

2. Form factors tailored to installation space and application

Motor overall view and cross-sectional view

Select the optimal base motor shape to accommodate your housing design, including device miniaturization and unique installation spaces.

Round

Standard shape offering high versatility.

Flat

Low-profile design for mounting in tight spaces.

Square (S series)

Compact series featuring high torque^*1 and low noise^*2

< Select by shape >

• Round
• Flat
• Square

^*1,*2 Compared to our conventional models

3. Brush materials to optimize motor life and performance

Due to the structural design of brushed DC motors, the contacts (brushes) wear down during rotation. Therefore, brush lifespan is a critical factor directly affecting the service life and maintenance frequency of both the motor itself and the entire device it is integrated into. MinebeaMitsumi proposes the ideal material tailored to your application, such as metal for low voltage and quick start-up, or carbon for high voltage, high current, and long life.

Metal brushes

Low contact resistance ensures excellent start-up performance even at low voltages. Minimal performance loss; ideal for small, low-voltage, low-current motors.

Carbon brushes

Delivers a long lifespan even under high-voltage and high-current conditions. Ideal for large motors requiring high durability.

4. Gears and torque limiters for torque adjustment and overload protection

Gears and torque limiters for torque adjustment and overload protection

Spur gears

Simple and low-cost.

Planetary gears

Coaxial design offering high torque and excellent wear resistance.

Worm gears

Right-angle transmission that prevents back driving, making it highly effective for position holding.

By combining these gears with a protective torque limiter, we deliver a safe, reliable drive unit tailored to your exact requirements.

5. Potentiometers and encoders for high-precision control and position

We can incorporate potentiometers specialized for position detection, or encoders that offer even higher precision^*3 in detecting rotational speed and position. Choose between optical or magnetic encoders to suit your application. Pre-assembling these sensors into an integrated motor unit eliminates the effort of retrofitting and enables advanced feedback control for your equipment.

^*3 Compared to our potentiometers

6. Other available DC motors

We present application examples and our product lineup featuring DC motors combined with integrated components.

7. FAQ

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