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Compare the actions of a brushed vs brushless motor 

Brushed motors inherently generate some degree of sparking and carbon dust flying off the surfaces where the brushes meet the commutator, as seen in the video on the left.  Dust builds up over time, causing shorts. This only gets worse if the motor is VIBRATED, leading to frequent faults and fast motor failures. 

(See brushed motor failure at bottom left)




Advanced VSR stopped using brushed motors in 1999.   Since then we have used either brushless low-slip or PM sync motors.  This has extended motor life several-fold. 
Our slowest vibrator can go 2000 RPM faster than our closest domestic competitor, while our fastest (12,000RPM) has twice the speed. More speed means greater workpiece range.



All the independent research work states that both resonance and sub-resonance can be effective, but that:




. . . . either gauged on how much stress is relieved, or how long it takes to relieve stress (i.e., resonance is faster).  The EPA has also weighed in on this issue, stating clearly that resonance is the most effective means of stress relief :    EPA link


These works can be seen in the Advanced VSR Technical Library: 

  -  Dr. William Hahn, Vibratory Residual Stress Relief and Modifications in Materials to Conserve Resources and Prevent Pollution
  -  Dr. S. Shankar, Vibratory Stress Relief of Mild Steel Weldments
  -  Drs. Y. P. Yang, G. Jung, and R. Yancey Finite Element Modeling Of Vibration Stress Relief After Welding


Bonal console has 6.5" touchscreen (similar to automotive / back-of-seat video monitor)  mounted in NEMA 1 (nominal protection from dust or moisture) grade enclosure. 

Advanced VSR Console's display is FOUR TIMES LARGER, making it easier for the operator to see critical data.


Advanced VSR Model 7.5 Console

A-VSR Model 7.5 Console is NEMA 4 / IP 65 enclosed (no dust, dirt or sprayed water entry), features 15" / 380 mm touchscreen industrial PC with solid state HD.  Uses Allen-Bradley 3 HP / 2.2 kW drive with external heat sink (waste heat exits outside of enclosure).   Motor temperature reported on VSR OS Main Screen (bargraph at top / middle).  VSR charts, tagged with PN and SN of workpiece, are archived in PDF format, with user-friendly software.  Lid closes for full protection during storage.

Advanced VSR VS9 vibrator has a spindle-grade brushless motor, 16 kN output potential, and features variable unbalance over a 20:1 range, a max speed of 9000 RPM, and a 1.5 kW motor designed to operate continuously .  Unbalance adjustment takes one minute, using standard hex keys. Sensors in motor windings supply temperature data to console. Hardened inserts in feet assure good clamping quality. Through holes in feet can be used for bolts, ideal for fixtured applications, or when using an adapter plate.

Below is the 12000 RPM Model VS12 vibrator.

Or Vibe beaut pic Aprl 2023.jpg
Advanced VSR heavy duty strain relief

Advanced VSR only uses industrial-grade vibrator cable connectors with die-cast aluminum housings and coiled spring strain reliefs, mounted on fully shielded servo-grade cable.  Vibrator socket located on right front of operating panel, within easy reach of the operator.

Bonal worn-out plastic strain relief

Bonal uses a soft-plastic housed vibrator cord connector.  On this two year unit the affixing collar threads were stripped.   SO-grade electrical cable. Clamp collar is the only strain relief.   Connector on back of unit, outside immediate reach of operator.   Note circuit breakers on back of unit, for mains, motor field and armature.   This is protection against short-circuiting, not motor protection (overload or over-temperature).  

Advanced VSR stopped using brushed motors in 1999.

Force vs. speed / RPM of both the Advanced VSR and Bonal vibrators.   Both units have adjustable unbalance, but the A-VSR vibrators have both more force and speed.  Workpieces that have resonances above Bonal's 6000 RPM limit (imposed by their brushed motor design) could not receive effective stress relief. 

Brushed DC motor failure

Closeup of the surface motor brushes ride upon, called a "commutator". These can suffer overheating and rupture, such as the one shown, if a combination of heat and mechanical loading, including vibration, lasts too long.  Also, esp. if vibrated, the carbon brushes produce a cloud of carbon dust that clings to the motor interior, leading to shorts / faults.  It is for this reason that Advanced VSR abandoned brushed motors for AC and DC brushless motors roughly twenty years ago.   DC brushed motors and the drives that power them remain the cheapest form of variable speed, but their reliability for high-speed apps is questionable.   

Also, a brushed motor has less speed / RPM range than a brushless motor, which is apparent from the chart on the upper right.

In the VSR Chart above, peak growth of ~ 30 percent can be seen (red peak above original green peak), with almost no peak shifting.   This poses an interesting question:

If an operator was monitoring treatment progress while tuned off the peak (i.e., subresonance) how could he tell when he was finished ?

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