Have you ever thought about why brushed DC motors are still used so much, even with new motor types available? These motors have been around for a long time but are still important in many fields. Why is that? It’s because they are dependable, simple, and cheap. They are easy to make, low-cost, and can do many jobs.

Look at cars, for example. Over 10 million electric cars were registered in 2022. This shows brushed DC motors are still useful in electric vehicles. Also, new technology has made them last longer and work 30% better. From running conveyor belts to powering home appliances, brushed DC motors prove their value every day.

Key Takeaways

• Brushed DC motors are strong, cheap, and simple to fix. This makes them common in cars and home gadgets.

• These motors give high power and speed. They are used in car windows and machines like washers.

• Brushed DC motors are still used a lot. But brushless motors are becoming more liked because they last longer, work better, and are quieter.

• Brushed DC motors are great for tough jobs. They are used in planes and medical tools where they must work well.

• As tech improves, people prefer brushless motors. These save energy and work better in things like air systems and robots.

1. Automotive Industry

Uses in starter motors and power windows

Brushed DC motors are found all over cars. They are used in starter motors, power windows, cooling fans, and wipers. Why? They are simple, reliable, and cheap. In 2018, they were the most used motors in cars. Their basic design, with a commutator and brushes, makes them great for these jobs.

For example, power windows need high torque at low speeds. This helps them move smoothly and steadily. Starter motors need a quick burst of power to start the engine. The commutator and brushes work together to give the needed torque and speed.

Why brushed DC motors are popular in cars

Brushed DC motors are popular in cars for good reasons. They are affordable and easy to install. Their simple design makes them easy to maintain. They also provide high torque and speed, which many car systems need.

Cooling fans, for instance, keep the engine cool by moving air. Windshield wipers use the commutator-brush system to work well, even in bad weather. These motors are cheap, strong, and work well, making them a top choice for cars.

Switch to brushless motors in electric cars

Even though brushed DC motors are common, cars are moving to brushless motors. Brushless motors are more efficient and last longer. They don’t have brushes or a commutator, so they wear out less. This makes them perfect for electric cars, which need to save energy and last a long time.

Still, brushed DC motors are important in regular cars. They give high torque and speed at a low cost. This ensures they will stay useful in the car industry for years.

2. Industrial Machinery

How they help conveyor systems and machines

Think about machines in factories. Conveyor belts and tools come to mind. These machines often use brushed DC motors to work well. Conveyor belts use these motors to move items on assembly lines. The motors give steady power and speed for sorting and packing. Tools like drills and presses also use these motors. They need strong power to work precisely and reliably.

Why industries still use them

Why do factories still pick brushed DC motors? It’s because they are cheap and simple. These motors cost less, which helps businesses save money. Their design is basic, with brushes and a commutator. This makes them easy to set up and fix. You don’t need special skills to keep them working. They are great for jobs like cranes and hand tools where low cost and ease are key.

Moving to brushless motors for better performance

Brushed DC motors are common, but brushless motors are growing popular. Brushless motors are more efficient and last longer. They don’t have brushes, so they wear out less. This means less fixing and a longer life. They also use less energy and make less noise. This is good for companies that care about the environment. Brushed DC motors are still useful, but brushless motors are the future for factory machines.

3. Consumer Electronics

How they work in home appliances and tools

Ever think about what makes your blender spin or drill work? Brushed DC motors are the hidden helpers in many gadgets. They power washing machines, fridges, and blenders to keep them running well. In tools like drills and saws, they give the strength and speed needed for good performance.

Here’s a simple breakdown of their uses:

Brushed DC motors are flexible and widely used in electronics.

Why they’re affordable and easy to fix

Brushed DC motors are popular because they’re cheap and easy to fix. They don’t cost much to make or repair, which is great for homes. The brushes wear out over time, but replacing them is quick and cheap. This makes sure your tools and appliances keep working without costing too much.

• These motors are simple and low-cost to use.

• Brushes need replacing sometimes, but it’s an easy fix.

Their low price and easy repairs keep them in demand.

Moving to brushless motors for less noise

Brushed DC motors are reliable but can be noisy. The brushes rubbing against the commutator make a humming or grinding sound. This noise can be a problem for quiet devices like smart gadgets or medical tools.

Brushless motors solve this issue. Without brushes, they don’t make friction noise, so they’re much quieter. They also vibrate less, with noise only from air movement. This makes them ideal for modern electronics where quietness matters.

• Brushed motors make noise from brushes rubbing the commutator.

• Brushless motors are quieter and work more efficiently.

As technology improves, brushless motors are becoming more common, especially for quiet devices.

4. Aerospace and Defense

How they work in actuators and control systems

Brushed DC motors are important in aerospace and defense. They are used in actuators, pumps, and engine starters. These motors handle tough conditions, making them reliable for critical tasks. They run on 18–32 VDC and give power from fractional to 12 HP. With speeds up to 30,000 RPM, they provide the needed torque and speed for precise movements.

What makes them special? They work well in high heat and have extra features. These include EMI protection, fault monitoring, and sealed bearings. These features help them work smoothly in harsh conditions. They can also be customized. You can add electronics, gear heads, or special mounts to fit specific needs.

Why they are trusted for tough jobs

Brushed DC motors are known for their reliability. They work in extreme environments, from freezing cold to very hot. For example, they can handle temperatures from -55°C to +125°C. That’s pretty amazing, right?

Here’s why they’re so dependable:

These qualities make brushed DC motors a top choice for aerospace and defense.

Moving to better motor technologies

Brushed DC motors are great, but new motors are improving. Brushless motors are more precise and efficient. They don’t use brushes, so they last longer and need less fixing. This makes them perfect for jobs needing long-term reliability.

Still, brushed DC motors are useful in many areas. They give high torque and speed at a lower cost. As technology grows, both brushed and brushless motors will be used in aerospace and defense systems.

5. Medical Devices

Uses in portable medical tools and pumps

Brushed DC motors are key in medical tools like pumps. They are used in infusion pumps, ventilators, and blood pressure monitors. These motors give the right torque and speed for accurate work. For example, infusion pumps need steady flow to deliver medicine safely. Brushed DC motors are great at keeping this steady flow.

Their simple design, with brushes and a commutator, makes them reliable. These motors also give high torque at low speeds. This is perfect for tools needing controlled movements. Whether it’s running a small pump or a portable tool, brushed DC motors work smoothly and efficiently.

Small size and low cost

Brushed DC motors are small and affordable for medical tools. They are light and fit easily into portable devices. Here’s why they are so useful:

• Quick acceleration

• Good performance

• Lightweight design

• Can be customized

• High power for their size

These features make them a smart choice for balancing cost and performance. Their small size doesn’t reduce their power. They give the needed torque and speed without taking up much space.

Switch to brushless motors for better hygiene

Brushed DC motors are good, but brushless motors are becoming popular. Why? Hygiene and long life are very important in healthcare. Brushless motors don’t have brushes, so they wear out less. This means less fixing and a longer life.

Here’s a simple comparison of the two:

Brushless motors are quieter, which helps patients feel comfortable. They also make less heat, which is safer for medical tools. While brushed DC motors are cheaper, brushless motors are now preferred for advanced medical devices.

6. Robotics

How they help in simple and cheap robots

Brushed DC motors are important in robotics, especially for beginners. If you’ve made a robot kit or seen school projects, you’ve likely seen these motors. Why are they used? They’re easy to use, dependable, and affordable. For example, they move small wheels, arms, or sensors in basic robots. They give steady power and speed for tasks like moving, turning, or lifting light things.

In low-cost robots, these motors are great because they save money. Whether it’s a toy robot or a DIY project, they balance cost and performance well.

Easy to use and budget-friendly for testing

When testing a robot, you need something simple and cheap. Brushed DC motors are perfect for this. Their design uses brushes and a commutator to control power and speed. This makes them easy to work with when trying out ideas.

Here’s why they’re great for testing:

• They cost less, which helps with small budgets.

• Their simple design makes them easy to set up or fix.

• They’re reliable, so you can focus on improving your robot.

If you’re new to building robots, these motors are a good choice. They let you try ideas without spending too much or dealing with hard setups.

Moving to brushless motors for better robots

As robots get more advanced, they need to be more precise and efficient. Brushless motors are becoming popular for this reason. They don’t use brushes or a commutator, so they last longer. They also give more power for their size, making them great for high-tech robots.

More companies now use brushless motors in advanced robots. These motors last longer, need less fixing, and work better. For things like factory robots or drones, their benefits are worth the extra cost. While brushed motors are still used for simple robots, brushless motors are leading the way for future robotics.

7. HVAC Systems

How they work in fans and blowers

Ever think about how your AC or heater works? Brushed DC motors help run HVAC systems. They power fans that move air around your house. They also drive blowers that push hot or cold air through vents. This keeps your home at a comfy temperature.

The brushes and commutator in these motors give steady power. For example, when you change the fan speed, the motor adjusts to match. This makes them a great choice for HVAC systems.

Why they’re affordable and easy to fix

Brushed DC motors are popular because they’re cheap and simple. They cost less to make and install than other motors. If they break, fixing them is easy and doesn’t cost much. You can replace brushes or fix the commutator quickly.

Their basic design means fewer problems during repairs. You don’t need special tools to keep them working. This makes them a smart choice for homes and businesses.

Moving to brushless motors for saving energy

Brushed DC motors are good, but brushless motors are better for saving energy. Brushless motors don’t have brushes, so they waste less power and last longer.

Here’s why this change is happening:

Smart home devices are also making brushless motors more popular. These motors are quieter, save energy, and are better for the planet. While brushed motors are still used, brushless ones are the future of HVAC systems.

Brushed DC motors are still used in many areas. You can find them in cars, factories, and home gadgets. Why are they so common? They are simple, cheap, and dependable. These motors can change speed and power easily. Their brushes and commutator help them work smoothly.

However, brushless motors are becoming more popular now. They are better because they last longer and need less fixing. With new technology, brushless motors save energy by changing speeds. This is changing industries like robotics and HVAC systems.

What’s ahead? Motor technology is improving fast. Industries want more accuracy and better performance. Whether it’s brushed or brushless, the best motor depends on the job.

FAQ

How are brushed and brushless motors different?

Brushed motors use brushes and a commutator to work. Brushless motors use electronic controllers instead. Brushed motors are cheaper and simpler. Brushless motors last longer and are more efficient. Pick one based on your needs and budget.

Why are brushed motors still popular?

They are cheap, reliable, and easy to fix. Industries like cars and electronics use them for simple tasks. For jobs that don’t need high precision, brushed motors work well.

How do you take care of a brushed motor?

Change old brushes and clean the commutator often. Watch for overheating or strange sounds. Regular care keeps the motor working longer. It’s easy and doesn’t need special tools.

Are brushed motors good for high-performance jobs?

Not really. They’re fine for simple tasks but not for precision. Brushless motors are better for robots or electric cars. They are more durable and efficient for advanced uses.

Can you switch a brushed motor to a brushless one?

Yes, but it can be tricky. Brushless motors need electronic controllers. You might need extra wiring or changes. Make sure your system can handle the upgrade.