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Lifting and Hoisting Industry

Why BLDC is Replacing Induction Motors in Lifting Systems: 
A Total Cost & Safety Analysis

Yenshen’s custom BLDC solution redefines lifting and hoisting performance by addressing the critical flaws of traditional induction motors.

  • System Weight: 50% lighter for easier installation
  • Energy Efficiency: 50% lower starting current, reducing electrical grid stress.
  • Advanced Safety: Dual-layer "Electronic + Electromagnetic" braking architecture.
  • Cost Advantage: Up to 30% reduction in Total System Cost.

Technical Comparison: Yenshen BLDC vs. Induction Motors

To understand why industry leaders are transitioning to Brushless DC technology, we must look at the fundamental efficiency gaps between traditional induction motors and Yenshen’s optimized BLDC systems. While induction motors have been the legacy choice, they often struggle with energy spikes and mechanical complexity. The following comparison highlights how our custom solutions simplify these systems while maximizing output. 

Feature
 Yenshen Customized BLDC
 Traditional Induction Motor
 Business Value
Gearbox Ratio
 1:150 (High Efficiency)
1:210 (Complex)
 Simpler mechanics; less heat loss
Starting Current
 Low (~50%)
High (Inrush spikes)
 Lower-rated breakers; longer grid life
Speed Range 400–2400 rpm
Fixed ~1650 rpm Higher flexibility; shorter cycles
Safety Protection
 Electronic + Electromagnetic
Mechanical Only Zero-slip during power failures
Control Box Cost Lower (>50% savings)
Higher
 Significant CAPEX reduction
Protection
 IP67 Rated
Limited
 Ideal for medical/harsh environments

Key Takeaway from the Comparison:

The most significant advantage shown above is the 50% reduction in starting current. In practical hoisting applications, this means your electrical infrastructure—from wiring to circuit breakers—can be downsized, leading to an immediate 30% to 50% saving in control box component costs. Furthermore, our 1:150 gearbox ratio isn't just a number; it represents a more streamlined mechanical path that generates less heat, directly extending the service life of your equipment in high-frequency environments.

Core Engineering Advantages

Wide Speed Range & High Torque Performance Integrated Dual-Brake Safety System Overcoming the "High Current" Barrier Industrial-Grade Environmental Protection

Wide Speed Range & High Torque Performance

Our BLDC motor provides a wide speed range from 400 to 2400 rpm (over 6× speed ratio). This allows for lower gearbox reduction ratios, simplifying mechanical design and reducing system cost.


Integrated Dual-Brake Safety System

In hoisting, "Uncontrolled Descent" is the critical failure point. Yenshen integrates a Dual-Safety Logic: our patented controller provides active electronic braking for precise stopping, while the electromagnetic brake serves as a fail-safe.


Overcoming the "High Current" Barrier

Yenshen’s solution leverages High Torque Density, starting under full load with 50% less current than induction motors. This eliminates the need for expensive, high-rated power components and reduces grid impact.

Industrial-Grade Environmental Protection

An IP67 waterproof and dustproof design ensures reliable operation in high-humidity, outdoor, or medical wash-down environments.


Real-World Applications: Delivering Value Across Industries

Case 1: Smart Medical Lifting Bed

In high-end medical lifting bed applications, motor heat dissipation and compact size are key design challenges. A leading international medical equipment manufacturer adopted Yenshen’s customized BLDC motor solution to replace traditional induction motors.


Results:

Installed inside the bed and surrounded by cushioning materials, the motor cannot use fan cooling without increasing noise. Yenshen’s high-efficiency BLDC design reduces motor size and heat generation, preventing thermal buildup and eliminating uncomfortable heat transfer to patients. The solution significantly improves safety, reliability, and patient comfort, meeting the strict requirements of medical environments.

Case 2: Suspended Platform Hoisting System

A suspended platform equipment manufacturer faced persistent challenges related to insufficient torque, frequent maintenance, and operational safety risks under heavy-load lifting conditions. To address these issues, the company adopted Yenshen’s high-torque customized BLDC system, integrated with intelligent sensing and electromagnetic braking, optimizing the gearbox ratio from 1:210 to 1:150.


Results:

The upgraded system achieved an approximately 50% reduction in starting current and a 20% increase in load capacity. Under heavy-load operation, the intelligent braking logic significantly reduced the risk of uncontrolled descent, enhancing operational safety while accelerating return on investment (ROI) and improving overall operational efficiency.

Result: A Smarter, Safer Lifting System 

By replacing legacy induction systems with Yenshen’s customized BLDC solution, equipment manufacturers achieve higher efficiency, improved safety, and up to 30% lower total system cost. From medical care to heavy-duty hoists, we provide the precise, stable performance that modern industry demands.

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We offer full-spectrum technical support and training to ensure our partners maximize the potential of our motor systems.

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