Why Top Textile Factories Are Procuring Textile Machinery Equipped with BLDC Motors?

I. Background and Introduction

Amid the wave of industrial automation and smart manufacturing, as the textile industry continues to demand higher for production efficiency and product quality, textile machinery is undergoing an unprecedented technological revolution — and BLDC motors stand as the core driving force behind this transformation.

In textile machinery, equipment such as spinning and knitting machines, braiding machines, looms, and jacquard machines all require precise control over the movement of yarn guide mechanisms. Leveraging their characteristics of fast response, precise control, and high torque-to-inertia ratio, BLDC motors can fulfill these precision control requirements. They are gradually replacing traditional AC induction motors and brushed DC motors, becoming the core choice for power systems in modern textile machinery.

II. Application Scenarios of BLDC Motors in Key Processes of Textile Machinery

The textile production process involves multiple stages such as spinning, weaving, dyeing and finishing. Each stage have unique requirements for the dynamic performance of motors.

(I) Spinning Process: Precise Control Ensures Yarn Quality

Spinning is a fundamental process in textile production, encompassing sub-processes such as cotton opening, carding, drawing, roving, and spinning. It has stringent requirements for the speed regulation accuracy and stability of motors.

In spinning frames, traditional induction motors have a narrow speed regulation range, making it difficult to meet the production needs of yarns with different counts. However, BLDC motors, leveraging vector control technology, can achieve precise speed regulation of drafting rollers. When the yarn count is adjusted from 10S to 100S, the motor speed can switch smoothly within the range of 500-2500 rpm, ensuring the yarn evenness CV value is controlled within 12%—an improvement of 30% compared to traditional equipment.

In roving frames, BLDC motors drive the winding mechanism. By real-time feedback of yarn tension signals and dynamic adjustment of speed, they effectively reduce the yarn breakage rate and increase production efficiency by more than 20%.

At the same time, their low-noise advantage (operating noise below 75 dB) improves the workshop working environment.

(II) Weaving Process: Stable Drive Improves Weaving Efficiency

The core equipment of the weaving process includes air-jet looms, water-jet looms, and rapier looms, all of which require motors to provide stable and adjustable power for the main shaft, weft insertion mechanism, and beating-up mechanism.

Taking air-jet looms as an example, their weft insertion speed directly determines weaving efficiency. Traditional motors have slow response speeds, so their weft insertion speed usually does not exceed 1800 m/min. In contrast, BLDC motors have a response time of less than 10 ms, enabling high-speed start-stop of the weft insertion mechanism. This increases the weft insertion speed to over 2200 m/min and improves weaving efficiency by 20%.

At the same time, BLDC motors have small torque fluctuations. When driving the main shaft to operate, the speed fluctuation rate is less than 0.3%, which effectively reduces warp breakage and weft misweaving. As a result, the first-grade rate of grey fabric increases from 85% to 95%.

In rapier looms, BLDC motors drive the rapier head for reciprocating motion. Through precise position control, the positioning error of the rapier head is controlled within ±0.1 mm, which adapts to the weaving needs of various yarn materials. This performance is particularly prominent in the production of heavy-weight fabrics and jacquard fabrics.

(III) Dyeing and Printing Process: Constant Temperature & Speed Ensure Dyeing Uniformity

The dyeing and printing process involves desizing, scouring, dyeing, printing, and finishing, which have strict requirements for the motor’s corrosion resistance, speed regulation stability, and temperature control capability.

In dyeing machines, the circulation speed of the dye liquor directly affects dyeing uniformity. BLDC motors drive the circulation pumps and can precisely adjust the speed within the range of 500-1500 rpm according to fabric materials and dyeing processes. This controls the dye liquor circulation flow error within ±5%, avoiding problems such as uneven dyeing and color differences.

In printing machines, the speed stability of the screen roller determines printing precision. BLDC motors, through servo control systems, achieve synchronous matching between the screen roller speed and the fabric feeding speed, with a synchronization error of less than 0.1 m/min, meeting high-precision printing needs.

In addition, BLDC motors adopt a fully sealed structural design, with a protection level of up to IP65. This design can effectively resist the erosion of acid and alkali mist in the dyeing and printing workshop, extending their service life by more than 50% compared to traditional motors.

III. Motor Selection for Textile Machinery

Volcano Electric has extensive experience and well-developed products in the field of textile machinery motors, standing at a leading position in the industry.Our "Permanent Magnet Direct-Drive Drum" (referred to as PMDD Drum for short) for textile machinery is a new type of permanent magnet direct-drive system. Equipped with a vector driver featuring sensorless vector control technology, the entire drive system achieves intelligence, with characteristics including variable-frequency soft start, multi-motor drive power balance, and data recording. Meanwhile, the system adopts digital communication technology, enabling unattended operation, remote control, online monitoring, and fault diagnosis.

1. Large starting torque and strong overload capacity

Equipped with either sensorless vector control technology or sensor-based control technology, the PMDD Drum achieves a starting torque and overload torque of 2 times the rated torque or more.

2. Maintenance-free system operation

The external permanent magnet direct-drive motor drum requires no maintenance at all.

3. Small footprint and simple installation

The PMDD Drum directly integrates the permanent magnet direct-drive motor with the main shaft of the drive drum, eliminating the installation space required by traditional drive systems..

4. Standardized product design and wide application range

The product adopts a standardized design. The stator of the direct-drive motor is potted and sealed, producing no electric sparks and thus meeting the requirements of any working condition.

In terms of product specifications and models: the drum diameter covers a wide range; the power range is from 2.2kW to 30kW; the belt speed range is 1.6～5m/s.