A Ukrainian customer urgently needed a reliable drive motor for an outdoor AGV robot cart. Their AGV was used in open industrial areas, transporting materials over long distances and operating for prolonged hours every day. They required a high-torque, long-life, weather-resistant worm-gear BLDC motor, and their previous supplier failed to deliver on time and could not meet outdoor requirements.
The customer contacted BG Motor and requested urgent production. The initial requirement was 48VDC and 60N·m torque for long-term outdoor operation. After successful field testing, the customer placed a second repeat order for mass production.
(1) Outdoor environment with long operation hours
The AGV needed to work outdoors under dust, humidity, and temperature changes, and often ran for long periods (S1 continuous duty). It also required short-time heavy load operation (S2) and frequent start-stop cycles (S3). This demanded strong sealing, long motor life, and stable output under all running modes.
(2) Required torque between 60N·m–300N·m
The first prototype required only 60N·m, but the customer planned a larger AGV model needing 100–300N·m in the future. They wanted a motor platform that could scale up without changing the entire system.
(3) Stable low-speed control
The AGV required smooth output between 30–400RPM for outdoor road surfaces, obstacle avoidance, and heavy-load starting. Their previous motor had unstable speed under changing loads.
(4) Urgent delivery
The customer needed fast engineering confirmation, shaft customization, gearbox assembly, testing, and rapid shipment. Delay would affect their AGV delivery schedule.
In response to the above questions from customers, BG Motor gave them answers that far exceeded the industry level：
(1) Outdoor-enhanced worm-gear structure
To withstand outdoor conditions, we upgraded the sealing structure to IP54–IP65, added moisture-resistant grease, improved corrosion protection, and used reinforced bearings. The worm-gear design also provided self-locking capability for safety on slopes.
(2) High-efficiency BLDC motor design
The motor used low-heat windings, high-efficiency magnetic circuits, and a brushless structure, supporting up to 20,000 hours of lifetime. It maintained stable torque even when battery voltage fluctuated at 48V.
(3) Accurate low-speed performance
We optimized the motor winding and worm-gear ratio to ensure stable operation from 30RPM upward, giving smooth, quiet movement and high torque at low speed.
(4) Urgent production support
BG Motor arranged priority machining, quick gearbox assembly, fast winding production, and accelerated aging tests. The motors were completed and shipped earlier than the planned delivery date.
The diameter of this AGV trolley motor is 130mm, there are 48vdc, 72vdc, 96vdc, 310vdc and other voltage options, support 1000W-3000W,support S1/S2/S3 running mode,rated torque from 26.25N.M to 300N.M, welcome to browse the specific details of this 130mm high-performance worm geared motor
The AGV passed outdoor working tests under rain, dust, and temperature changes.
The motor showed stable 60N·m output, low heat at long S1 operation, low noise, and smooth low-speed performance.
The customer confirmed that the AGV could run for long hours outdoors without motor issues.
After two weeks of testing, the customer placed another repeat order for mass production and requested development of a higher-torque 150–200N·m version for a larger AGV model.
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