DC Motor Types and Applications: Pancake, BLDC, and Wheel Hub Motors

DC Motor Types and Applications: Pancake, BLDC, and Wheel Hub Motors

Wuxi Speedup Power Co., Ltd. is a DC motor manufacturer established in 2018, specializing in the design and production of pancake motors, BLDC motors, wheel hub motors, and other DC motor solutions for industrial and civil applications. With a 10,000 m² facility and an annual output of 30,000 pieces, the company serves a global customer base, exporting 90% of its products to the EU and USA.

The global brushless DC (BLDC) motor market was estimated at USD 20,990.5 million in 2024, with China accounting for approximately 39.8% of global revenue. The electric wheelchair market was valued at USD 4.49 billion in 2024, projected to reach USD 9.05 billion by 2030. These figures underline the growing demand for efficient, compact DC motors in mobility, medical, and industrial equipment.

What Makes a DC Motor Right for Your Application?

Selecting the correct DC motor involves matching voltage, power, torque, speed, dimensions, and environmental protection to the specific end‑use. Key questions include: Does the application require a gearbox? Is an electromagnetic brake needed? Should the motor be brushed or brushless? What is the allowable diameter and weight? The following sections break down the choices using real product examples from Wuxi Speedup Power.

Industry Background and Verified Data

According to Grand View Research, the BLDC motor market reached USD 20.99 billion globally in 2024. The medical device motor market was valued at USD 4.25 billion by MarketsandMarkets. These statistics reflect the increasing electrification of mobility aids, floor cleaning machines, and industrial robots—all key segments for DC motors.

Detailed Solution: Product Lines

Wuxi Speedup Power Co., Ltd. offers four main DC motor families:

1. Pancake Motors (Brushed DC)

The flat, disc‑shaped design (printed armature) delivers high power density in a thin profile. Examples include model 150SN‑A (36 V, 300 W, 3500 RPM) for floor washing machine brush drives, model 150SN‑B (24 V, 350 W, 3000 RPM) for burnishers, and model 120SN (24 V, 75 W) for welding machine drives. Materials are aluminum alloy, copper, and magnet. Axis length and performance profiles are customizable.

2. Pancake BLDC Motors

Model DD03 is a 24 V, 100 W external‑rotor BLDC motor with a diameter of 106 mm and length of 51 mm. It provides direct‑drive operation with big torque at low speed, suitable for brush drives in cleaning machines or rotary tables.

3. Wheel Hub Motors (Brushed and Brushless)

Integrated motor‑in‑wheel designs eliminate external drivetrains. Brushless versions include the 8‑inch model 1DY‑E5S (36 V, 300 W, 150 RPM, 1:20 gearbox, EMB brake) and the 12‑inch model SA06 (24 V, 300 W, 150 RPM, IP54). Brushed options include model 1DY‑E3 (24 V, 180 W) and the heavy‑duty 6DY‑A (24 V, 300 W, 40 Nm). All hub motors carry CE, EMC, and RoHS certifications.

4. Geared Hub Motors with Electromagnetic Brake

Models like 6DY‑A1 (magnesium alloy, 24 V, 200 W, 28 Nm, 1:40 gear ratio) and 6DY‑A4 (12‑inch, 24 V, 200 W, 70 RPM) integrate a built‑in electromagnetic brake. They are designed for electric wheelchairs, mobility scooters, hospital carts, and robots, offering high starting torque and low‑speed commutation.

Step‑by‑Step Selection Guide

1. Define operating voltage: Choose 24 V, 36 V, or 48 V based on battery system.
2. Determine power and torque: Use rated torque (Nm) and speed (RPM) to calculate required power.
3. Select motor type: Pancake for thin space, BLDC for efficiency and low noise, brushed for simple control.
4. Add gearbox if needed: Reduction ratios from 1:4.5 to 1:40 are available.
5. Safety features: Electromagnetic brake (EMB) or electronic brake (EABS) for holding and stopping.
6. Environmental protection: IP54 waterproof rating for outdoor or humid environments.
7. Customize: Shaft length, double/single shaft, special OEM configurations.

Use Cases

• Medical equipment: The 6.5‑inch brushless hub motor model SA05‑6 (24 V, 200 W, IP54, EABS) powers electric wheelchairs and hospital transport beds in Germany, Czech Republic, Netherlands, USA, and UK.
• Floor scrubber machines: The 150SN‑A pancake motor drives the brush in low‑to‑medium speed, high‑load, humid environments across Europe (Germany, Switzerland, Netherlands, UK, Italy).
• Electric scooters and shopping carts: The 8‑inch brushed hub motor 1DY‑E3 (180 W, EMB brake) is widely used for mobility scooters and shopping carts in Europe.
• AGV/Robot: The spoke brushless hub motor SA05 (24 V–48 V, 100 W–500 W) fits custom‑plate wheels for automated guided vehicles.

Comparison of Key DC Motor Variants

Frequently Asked Questions

Conclusion

Choosing the right DC motor—whether pancake, BLDC, or wheel hub—directly affects the performance, safety, and cost of your end product. Wuxi Speedup Power Co., Ltd. offers a broad range of certified, customizable DC motors backed by a 10,000 m² factory and 30,000‑unit annual capacity. For a complete overview of products and capabilities, download the company brochure or contact the team to discuss your next project.

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