The motor and motor control markets are thriving in many areas, particularly automobile and robotic applications. Also, there is a rich demand for motors with miniature size yet efficient performance. Different applications can choose from brush motors, brushless motors, or a combination of both. Most motors operate in accordance with Faraday’s law of induction. Still, there are key differences between brushless motor vs brushed motor (driven by direct current) in the employment opportunities that await them.
Brushless Motor VS Brushed Motor (Direct Current)
What is Brushed Motors?
A brushed motor provides needed control of speed, driven by a direct current. The brush DC motors is an internally commutated electric motor designed to be run from a direct current power source. It often consists of six different components: the axle, armature/rotor, commutator, stator, magnets, and brushes. The brush DC motor offers stable and continuous current, using rings to power a magnetic drive that operates the motor’s armature. Brushed DC motors can be varied in speed by changing the operating voltage or the strength of the magnetic field. Depending on the connections of the field to the power supply, the speed and torque characteristics of a brushed motor can be altered to provide steady speed or speed inversely proportional to the mechanical load. Since the brushes wear down and require replacement, brushless DC motors using power electronic devices have displaced brushed motors from many applications.
What is Brushless Motor?
A brushless motor (BLDC motor or brushless DC electric motor), also known as electronically commutated motor (ECM or EC motor) and synchronous DC motors, are synchronous motors powered by direct current (DC) electricity. The brushless motor’s journey to prominence began in the early 1960s with the arrival of a power dimmer. However, it was not until the 1980s that the brushless motor really got off to a good start. The greater availability of permanent magnets combined with high-voltage transistors has allowed this type of motor to generate as much power as brushed motors. Improvements to the brushless motor have continued unabated over the last three decades. This has transformed the way drill manufacturers produce efficient drilling tools. In turn, customers are taking advantage of key benefits associated with variety and reduced maintenance requirements.
- Features: Brushed VS Brushless DC Motor
- Its simple construction results in no need for an expensive controller;
- Understandable design technology facilitates the ease of use and quick application;
- If the field is created by permanent magnets, a brush DC motor is said to be a “permanent magnet DC motor” (PMDC), which is cost-effective and reliable.
- Compared with brushless DC (BLDC) motors, it obtains a relatively low amount of mechanical power, in return for the electrical power that you use.
- Blushless motors are considered more energy efficient than brushed motors since it can convert more electrical power into mechanical power than a brushed motor, mostly due to the absence of friction of brushes. The enhanced efficiency is greatest in the no-load and low-load region of the motor’s performance curve.
- For the same mechanical work output, the brushless motor will usually be smaller than a brushed motor, and always smaller than an AC induction motor owing to its far superior thermal characteristics. It uses less raw material for construction, contributing to environment protection.
- Compact size for convenient applications;
- Higher speed range and lower electric noise generation;
- Service life is even longer. The absence of brushes eliminates problems associated with overheating and breakdowns. The service life of the brushless motor is therefore related only to the bearings;
- The cost of a brushless DC motor is comparatively higher as compared to brushed DC motor and the electronic controller also increases the cost of overall setup.
- Applications: Which is Suitable for Your Project?
When comparing the difference between brushed and brushless motors, we tend to lean towards one being better than the other. But the truth is that there is no standard answer. It all depends on the project you are equipping, and how you plan to increase the efficiency of your build. Brushed and brushless motors are respectively ideal for different projects, which is why it’s so important to learn the difference between and the purpose of each.
Projects with Brushed Motors:
- Projects with an Expiry Date: Many machinery projects are temporary, which is why brushed motors are still so widely used. Based on the size of some of these projects, it makes good sense to go with a cheaper option that’s adequately efficient;
- Projects Where Noise is Not an Important Issue at a Tight Budget: The brushed motors are noisier than brushless ones. Factory machinery that are more inclined to save money on equipment can be equipped with brushed motors because the equipment there doesn’t necessarily need to run quietly.
Projects with Brushless Motors:
- Projects with Long Term: In the long term projects, going for brushless motors will mean less maintenance, and less likelihood of eventual breakdowns and replacements;
- ProjectsWhere Noise is Unacceptable: Because power is conducted without brushes, there is less movement noise during functionality. Medical equipment, automobiles and robots often opt for brushless motor devices so that noise disruption is as its lowest;
- Projects that Are Time Sensitive: Brushless motors can work more efficiently over a shorter period. That’s because the technology behind brushless motors makes them use less power, while increasing the energy output. Brushless motors are simply more efficient.
ZHAOWEI manufactures gears for both brush motors and brushless motors to reduce speed and increase torque and provides custom service according to requirements of customers.