In our daily life, we often see machines and tools using brushed DC motors and brushless DC motors to provide rotational motion. While these two types of motors may look similar on the outside, they have significant differences in their design and operating principles. Let’s delve into the intriguing differences between these two! With curiosity in our hearts, let’s follow Annie on this exploration! Together, we’ll unveil the mysterious veil of brushed and brushless motors and discover their unique features.

What Is A Brushed DC Motor?

A brushed DC motor is a traditional and straightforward type of DC motor. It consists of a stator (permanent magnet) and a rotor (coil). They generate torque through electromagnetic induction between the brushes and the rotor. Brushed motors achieve commutation by mechanically switching the winding instead of controlling the current through a controller. The brushes reverse the polarity of the commutator (also known as the armature), causing the rotor to rotate (More about metal brushes and carbon brushes). When the rotor winding is energized, the resulting magnetic attraction and repulsion keep the rotor rotating. The rotation of the rotor continually changes the sequence of winding energization, enabling the rotor to keep rotating within the stator’s magnetic field. The armature, commutator and brushes can be seen below:

Brushed motors generally come in two types: the hollow-cup motor and the iron-core motor. The hollow-cup motor is named after its coil’s cup-like shape. If you need more information, please visit https://ineedmicromotors.com/micro-dc-motor/

What Is A Brushless DC motor?

A brushless DC motor (BLDC motor) is an advanced type of small electric motor, unlike brushed DC motors, does not use traditional brushes and commutators. Instead, BLDC DC motors employ an electronic controller to manage the commutation process, thereby controlling the rotation of the rotor. The motor consists of a stator with coils that generate a magnetic field and a rotor with permanent magnets or permanent magnet coils that respond to the stator’s magnetic field and rotate accordingly.
In a BLDC motor, the electronic controller adjusts the current flow based on the rotor’s position and speed, ensuring that the permanent magnets or coils on the rotor stay synchronized with the stator’s magnetic field, enabling smooth rotation of the rotor. This commutation method eliminates issues such as friction and sparks, resulting in improved motor efficiency and reliability. Depending on their structure, BLDC motors can be classified as either inner rotor or outer rotor. Click here to know more:

Usually, brushless motors utilize three-phase drive coils and a dedicated sensor to track the rotor’s position. When the sensor tracks the rotor’s position, it sends a reference signal to the controller. The controller, in turn, activates the coils in a structured manner, one phase after another.

What Applications Are Brushed and Brushless DC Motors Used In?

Today, brushless DC motors are indeed becoming more common and are used in various applications, just like brushed DC motors. Both types of motors have their unique advantages and are employed in a wide range of industries, from home appliances and kid toys to industrial applications, medical equipment, robots, drones, electric cars, power tools, and more. Each type of motor has its own strengths and suitability for specific applications, making them valuable choices in different scenarios.

Due to their reliability and longer lifespan, brushless DC motors have expanded their usage in many applications. They have become quite common across various industries, including electric vehicles, hybrid vehicles, electric bicycles, industrial applications, drones, washing machines, fans, pumps, and blowers, among others. Their efficiency, lower maintenance requirements, and improved performance have made them a popular choice in these diverse fields.

Annie hopes this article has helped you understand the differences between brushed DC motors and brushless DC motors, which have only a few distinctions. If you have any inquiries or wish to further discuss our products, please do not hesitate to contact us! We are experts in what we do and aim to ensure you find the best solution tailored to your application. We look forward to assisting you!

The Difference Betweent Brushed DC Motor and Brushless DC Motor

You already know the definition of brushed and brushless motors, but you still not sure which one to choose, right? No problem! Annie will present the ultimate showdown table of brushed and brushless motors, highlighting their main advantages and disadvantages. You can refer to this table to help you decide which one to choose based on your application.

Summany

Overall, brushed DC motors and brushless DC motors have their applicable scenarios. Brushed motors are still common in some simple, low-cost applications, but in many high-performance, long-lasting, and efficient applications, brushless motors have become the preferred choice. Therefore, when selecting a motor, it is essential to consider the application requirements comprehensively to make the most suitable choice.

FAQ

1. Which is better brushless vs brushed motor?

When comparing brushless motors to brushed motors, the consensus tends to favor brushless motors. According to Consumer Reports, brushless motors are considered better due to their higher energy efficiency. They can often operate on battery power for up to 50 percent longer compared to brushed motors. The absence of brushes in brushless motors eliminates energy loss caused by friction, resulting in a longer battery life for tools and devices powered by these motors. Many brushless motor models can run for extended periods, making them a preferred choice for various applications.

2. What are the disadvantages of brushless DC motors?

Higher power requirements for controller: One drawback of brushless motors is that they require an electronic controller to operate. This controller consumes additional power, which can reduce the overall efficiency of the system compared to brushed motors, which don’t require such complex controllers.

Electromagnetic compatibility issues: Brushless motors can generate electromagnetic interference (EMI) during their operation, which may affect the proper functioning of other electronic devices located in close proximity. This interference can potentially lead to issues in sensitive electronic systems, and proper measures need to be taken to mitigate EMI problems.

Resource:

https://en.wikipedia.org/wiki/Brushed_DC_electric_motor

https://en.wikipedia.org/wiki/Brushless_DC_electric_motor