Brushed Vs Brushless Motors – Which Do You Need?

Many motion control applications use permanent magnet DC motors. Since it is easier to implement control systems using DC motors compared to AC motors, they are often used when speed, torque, or position needs to be controlled. There are two types of commonly used DC motors: Brushed motors, and brushless motors (or BLDC motors). 

Brushed motors and brushless motors are two different types of electric motors, each with its own advantages and applications. Here's a comparison between brushed and brushless motors to help you understand the differences and determine which one you need:

1. Construction:

   - Brushed Motors: Brushed motors have a rotating armature (the rotor) and a stationary set of brushes that come into contact with the commutator to switch the current direction in the rotor. They typically have fewer components and are simpler in design.

   - Brushless Motors: Brushless motors have a stationary armature (the stator) and a rotating magnet on the rotor. The commutation is done electronically using sensors or a controller, eliminating the need for brushes and commutators.

2. Efficiency and Performance:

   - Brushed Motors: Brushed motors generally have lower efficiency due to the friction and voltage drop caused by the brushes. They also experience more wear and tear on the brushes and commutator, which can affect their lifespan and performance.

   - Brushless Motors: Brushless motors are more efficient because they eliminate the energy losses associated with brushes. They offer higher power-to-weight ratios, faster acceleration, and smoother operation. Brushless motors also tend to have a longer lifespan and require less maintenance.

3. Control and Speed:

   - Brushed Motors: Brushed motors provide simple speed control by varying the applied voltage. However, they are generally less responsive to rapid changes in speed and have limited speed ranges.

   - Brushless Motors: Brushless motors offer more precise control of speed and direction using electronic commutation. They can provide a wider range of speeds and better response to changes in load conditions.

4. Maintenance:

   - Brushed Motors: Brushed motors require regular inspection and maintenance, mainly due to the wear on brushes and commutators. Brushes may need to be replaced periodically, and commutators should be kept clean and free of debris.

   - Brushless Motors: Brushless motors require less maintenance since they don't have brushes or commutators that can wear out. However, the electronic control components may need attention in case of any failures.

5. Cost:

   - Brushed Motors: Brushed motors are generally less expensive compared to brushless motors due to their simpler construction.

   - Brushless Motors: Brushless motors tend to be more expensive initially, but their higher efficiency and longer lifespan can result in cost savings over time.

For the past 32 years, our company has specialized in the research and manufacturing of various types of motors. Keli motor is China’s most reliable brushless motor manufacturer and supplier. Our team has extensive experience in introducing solutions with brushless DC motors for our clients.