Small DC motors can be broadly split into two categories: brushed and brushless motors. The difference is in the commutation. Brushed motors operate with a mechanical commutation. Brushless DC motors don’t use any brushes, and instead operate using electronic commutation. To find out more about the differences between brushed and brushless motors, check out our blog here.

A variety of DC motor types are available in either brushed or brushless configuration. The exact type and model of motor will depend on the application, but as general guidance:

High efficiency DC drives: For applications where system efficiency is key, for example battery powered instruments, a high efficiency precious metal commutated DC Motor can often be the best solution.

Peak Performance: For the most demanding applications, whether high power or extended life are required, brushless DC motors are regularly used.

Limited space: For applications with limited space in one dimension, a flat DC motor might be the best solution.

High precision: Where precision is crucial, stepper motors are ideal. These don’t require closed loop control and instead move in precise, repeatable ‘steps’.

In one axis: Linear DC servomotors produce only linear motion, making them ideal for applications requiring high-speed movements in only one axis. 

For more tailored advice on the best small DC motor for your specific application, get in touch with a member of the EMS team on 0118 9817391.

A linear actuator converts the rotary movement of a DC motor into a linear movement.

Linear actuators are typically comprised of three components, including the motor, threaded lead screw and nut. When the motor rotates, the threaded lead screw is turned. The nut, which is mechanically connected to the actual application, transfers linear movement to it.

A linear motor produces motion in one axis, whereas a linear actuator converts rotary movement into translational motion. 

How can you decide between them? Linear motors are often characterised by the high repeatability of their movements. They’re ideal for tasks requiring high precision and speed along a single axis. But for applications with extremely confined spaces, linear actuators may provide an advantage as they offer a much higher force-to-size ratio. 

It can be difficult to find the data you’re looking for on a motor specification. FAULHABER has put together a series of videos explaining motor datasheets and performance diagrams, which are available to view here. 

Precision gearheads are used where there’s a need for higher torques on a small DC motor. Precision gearheads are small gearboxes that sit between the motor and point of power transfer, slowing motor speeds while significantly increasing available torque. EMS offers a variety of precision gearheads, including planetary gearheads and zero backlash spur gearheads. Find out more about our high precision gearboxes and the benefits each type offers here.  

From first contact we can typically have a concept proposal, including 3D models to share within a few weeks, and production representative prototypes ready for testing in 10-12 weeks — subject to project complexity.

On site, we have 27 CNC machining centres and lathes, as well as 12 gear cutting machines. Our suite of in-house machining centres comprises of a comprehensive range of CNC mills and lathes, with varying capabilities and capacities to cover the size and complexity variation needed for our diverse customer base.

Our use of automation is applied in three key areas. For manufacturing milled items for bespoke mechanisms, we use robot-loaded 5-axis machining centres, for the production of complex turned parts we use bar-fed/ high-speed fixed/ sliding head lathes and throughout production, a range of automated high-speed CNC gear cutting capabilities.

We’ve designed solutions for a wide range of industries and applications such as prosthetics, laboratory equipment, healthcare and automotive. But just because your industry might not be listed here, doesn’t mean it’s not possible. All industries can benefit from bespoke gearboxes. Get in touch with us today to discuss your design request.

A bespoke mechanism can often appear more expensive than you would expect to pay for an off-the-shelf solution. But the ease of integration and optimised performance can significantly reduce your build cost and give you an edge in the market. A member of the team can assist with a more accurate estimation of cost.

During the concept stage of the design process, you will receive a proposal document, which outlines the basic performance, integration details and CAD models for space envelope testing.

Once a concept has been accepted and prototypes produced, you will then receive a top-level product drawing, which details:

• Overall dimensions of the product
• Customer mounting features
• Details of the Leadwire etc required for powering the motor or sensors
• Materials used
• Motor type and nominal voltage
• Additional product user information

This document in production will become the reference for ensuring consistent product supply, whereby any changes that affect customer experience of the product will need to be pre-agreed. Any changes that do not affect this are down to EMS discretion.

At prototype level, we can be very flexible with last-minute design changes.  However depending on the extent of the change, it could increase cost and lead time. This is because EMS is in a unique position of having both design and manufacturing in the same building.

We recommend letting us know if any parts of the design are at risk of change so we can plan for this accordingly.

As always, it is much easier to proceed with SOP with a full design freeze and it may be more difficult for last-minute changes at production phase. Contact your area sales manager if changes are required and we can advise on the effects this will have.

We will incorporate any supplementary electronic components (encoders, switches, some basic control elements) to allow the customer to integrate this into a larger product.

Most customers typically have a larger system to control and already know how they would like to drive our mechanisms. Therefore, EMS doesn’t typically get involved with the control systems and electronics to drive our drive systems.

However, DC motors from FAULHABER have supplementary standard control electronics, such as speed/ motion controllers, to drive the motors and by extension our mechanisms.

We will provide the specification details for any electronics required to drive the motor.

We mainly stock commercial grade materials for our components, including aluminium, steel, stainless steel, bronze, plastics and brass. However, if there are specific materials for your industry/application, it is likely that EMS can accommodate.

We provide a full aftercare service for all our customers. From the start of the custom design journey, we are on hand until the final sign off and ultimately, until we know you are happy. Our team is always available via email, phone or by filling out the enquiry form. You can find our contact details by clicking here.

Whatever your drive system challenge, we can create a bespoke solution that delivers precision, performance and peace of mind. 

Whether it’s one-off prototypes or full-scale production, we offer a complete bespoke drive system design service, from initial concept to precision manufacturing and quality testing. This includes custom gearbox design for applications with extremely limited space constraints, or where gearboxes with a specific configuration are required. 

Custom gearboxes are manufactured in our 40,000 square foot state-of-the-art facility in Dorset. Our dedicated machine shop is equipped with the latest CNC machine tools and gear cutting suite, for high-quality drive system solutions manufactured in the UK.

Following the company’s founding, we partnered with German drive system specialist FAULHABER to solely distribute its products before exploring the potential manufacturing capabilities in the 1990s. This has since evolved through ongoing investment in CNC gear cutting, high-precision milling, turning and metrology capabilities, to establish EMS as a custom manufacturer of precision gearboxes, as well as a respected distributor of motion control systems.

With over 40 years of experience specifying and supplying high performance motors and drive systems in the UK market, we are positioned to support a wide variety of industries. Key sectors we supply DC motor products to include healthcare, medical technology, factory automation, building automation, robotics, precision measuring and aerospace. Find out how we’ve played a part in various applications by checking out our case studies. 

Our 40,000 ft² headquarters and modern manufacturing facility is located in Poole, Dorset. This facility acts as a hub for our distribution service, supplying drive systems from eight different partners, and for our in-house advanced custom design capabilities. Sales, administration and additional warehousing is located in Aldermaston, Berkshire.

We are committed to quality, with both sites accredited for EN ISO9001:2015 — the international standard that defines the requirements for a Quality Management System (QMS). This demonstrates that we uphold the ability to consistently provide products and services that meet both customer and regulatory requirements.

We also hold Cyber Essentials Plus. Cyber Essentials is a UK Government-backed security certification designed to help organisations protect themselves and their customers’ data from common cyberattacks. It is recommended as the minimum cyber-security standard for any organisation, according to The National Cyber Security Centre (NCSC)

With Cyber Essentials Plus, it means we are independently audited and tested each year by a third party.

We aim for each process to have as little carbon impact as possible. Our Dorset facility is certified carbon neutral, uses only LED lighting and is supported by 117 kW of roof-top solar panels.  Our in-house solvent recovery machine ensures surplus chemicals are appropriately processed and safely reused. Furthermore, we continuously aim to reduce our use of single use plastics and packaging materials and regularly audit our supply chain to ensure the same approach to sustainability is implemented. 

We supply drive system solutions to the UK, Ireland and beyond.

We have partnerships with a number of leading manufacturers of drive systems, including Bühler Motors, Nidec, Kählig Antriebstechnik, Ewellix and MPS Microsystems. We’re also FAULHABER’s exclusive UK and Ireland distributor, offering unique access to the extensive FAULHABER range of high torque DC motors, actuation systems and drive electronics.

With over 30 years of experience specifying and supplying high performance motors and drive systems in the UK market, EMS is positioned to support a wide variety of industries. Key sectors we supply DC motor products to include healthcare, medical technology, factory automation, building automation, robotics, precision measuring, and aerospace. Find out how we’ve helped applications like yours by checking out our case studies. 

Do you have a question we haven’t answered here? Fill out our contact form here and one of our engineers will get back to you as soon as possible.