The main difference between brushed dc motors and brushless motors is how they switch current. Brushed motors use brushes and a commutator. Brushless motors use electronic motor control. This change affects how well they work, how much care they need, and how loud they are. Brushless motors use sensors or electronics to control the magnetic field. This helps them work better and last longer. Brushed motors need more care because the brushes wear out. These things are important when picking the right brush dc motor for a job. Brushless motors are popular for high-performance motor control because they work better and last longer.
The table below shows how brushed dc motors and brushless motors are different in commutation, control, and performance:
| Aspect | Brushed DC Motor | Brushless DC Motor |
|---|---|---|
| Commutation Method | Mechanical (brushes & commutator) | Electronic (sensors & controller) |
| Efficiency | Lower | Higher |
| Maintenance | More (brushes wear out) | Less (no brushes) |
| Noise | More | Less |
| Lifespan | Shorter | Longer |
| Motor Control | Basic | Advanced (precise speed/torque control) |
| Applications | Simple, low-cost devices | High-performance, long-life systems |
Key Takeaways
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Brushed motors have brushes and a commutator to change current. Brushless motors use electronic controllers and sensors for smoother work.
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Brushless motors work better, make less noise, and last longer. They have fewer moving parts and less rubbing inside.
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Brushed motors need regular care like changing brushes and cleaning. Brushless motors do not need much care.
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Brushless motors cost more at first but save money later. They use less energy and need less fixing.
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Pick brushed motors for easy and cheap jobs. Pick brushless motors for strong, quiet, and long-lasting jobs.
Brushed DC Motors
Key Parts of a Brushed Motor
A brushed motor has many main parts that help it work. The armature, or rotor, spins inside the motor and carries current in its windings. The stator does not move and makes a magnetic field with magnets or electromagnets. The commutator is a switch that changes the current’s direction in the armature windings. Brushes are made of carbon and push against the commutator to send current from the power source. The shaft is attached to the armature and moves energy to the device. Bearings hold the shaft and help it spin smoothly. The motor housing keeps all the parts safe inside. Some brushed motors have a cooling system to stop them from getting too hot.
The table below lists the main parts and what they do in a brushed motor:
| Component | Primary Function |
|---|---|
| Armature (Rotor) | Makes torque by spinning and carrying current |
| Commutator | Changes current direction for steady spinning |
| Brushes | Send current from outside to the commutator |
| Field Magnets | Make a magnetic field that works with the armature |
| Shaft | Moves energy to the thing being powered |
| Bearings | Help the shaft spin with little friction |
| Motor Housing | Keeps and protects all the inside parts |
| Windings | Carry current to make a force with magnets |
| Cooling System | Gets rid of heat to stop overheating (sometimes added) |
How Brushed DC Motors Work
Brushed dc motors turn electricity into movement in a simple way. First, current goes from the power source through the brushes and commutator to the armature windings. The windings make a magnetic field around the coils. This field meets the magnetic field from the stator. The two fields push against each other and make the armature spin. As the armature turns, the commutator switches the current direction in the windings at the right time. This keeps the fields lined up and lets the motor keep spinning. The brushes and commutator work together to keep the current moving and the motor turning.
Brushed motors need care because the brushes wear out as they work. Worn brushes can make bad contact with the commutator, which raises resistance and makes the motor less efficient. Carbon dust from the brushes can build up inside and cause trouble if not cleaned. Changing the brushes and cleaning the commutator helps the motor last longer. The brushes need the right spring tension for good contact and smooth running. Brushed dc motors are still used for simple, cheap jobs because they are easy to use and control.
Brushless Motor
Key Parts of a Brushless Motor
A brushless motor is built differently than a brushed motor. It has a rotor with permanent magnets. The stator has coils that do not move. The rotor spins inside the stator. Brushless motors do not use brushes or a commutator. They use an electronic controller and sensors to control the motor.
The table below shows how brushless motor parts are different from brushed motor parts:
| Component/Feature | Brushed DC Motor | Brushless DC Motor |
|---|---|---|
| Rotor | Armature windings (electromagnets) | Permanent magnets |
| Stator | Permanent magnets | Coils (electromagnets) |
| Commutation | Mechanical (commutator and brushes) | Electronic controller and sensors |
| Brushes | Present | Absent |
| Maintenance | Brushes wear out | Minimal mechanical wear |
| Noise | More noise | Quieter |
| Efficiency | Lower | Higher |
| Size | Bulkier | More compact, needs controller |
| Control | Simple | Advanced electronic motor control |
Brushless motors have fewer moving parts. This makes them more reliable and helps them last longer. The electronic controller does the job of brushes and commutator. This lowers friction and wear.
How Brushless Motors Work
Brushless motors use electronic commutation to control the motor. The controller sends current to the stator coils in a set order. Sensors, like Hall effect sensors, find the rotor’s position. The controller uses this to switch the current at the right time. This keeps the rotor spinning smoothly and well.
Electronic commutation means there are no sliding contacts. This lowers friction and stops brush dust. Brushless motors are quieter and make less electrical noise. They can spin faster and work more efficiently. Only the bearings wear out, so brushless motors last longer than brushed motors.
Advanced motor control lets brushless motors change speed and torque exactly. The controller can use pulse width modulation to adjust how the motor works. This makes brushless motors good for jobs that need high efficiency, quiet running, and long life. Many new devices, like drones, electric cars, and computer fans, use brushless motors because of these good features.
Important Factors for the Difference
Better Efficiency
Efficiency is a big reason why these motors are different. Brushless motors work better because they do not have friction from brushes. They use electronic commutation, which helps control the current exactly. This means less energy is wasted and the motor works better. Brushless motors also have fewer moving parts. This means you do not need to fix them as much and they use less electricity.
The table below shows how efficient each motor type is:
| Motor Type | Average Efficiency (%) |
|---|---|
| Brushed DC Motor | ~80 |
| Brushless DC Motor | 85 - 90 |
Brushless motors are about 5% to 10% more efficient than brushed motors. They waste less energy as sound and heat. This makes them use less electricity and work better. Because of this, brushless motors can run longer and use less power in many things.
Some reasons why brushless motors are more efficient are:
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No friction or energy loss from brushes and commutators
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Electronic commutation instead of mechanical switching
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Exact control of current in the windings
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Fewer moving parts, so less fixing and less power used
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Less noise and shaking when running
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Better speed and torque control for good performance
Maintenance Needs
How much care a motor needs is important when picking one. Brushed motors need regular checks and fixing. You have to look at and change the brushes, clean the commutator, oil the bearings, and check wires. Big motors need this every few months. Small motors need it less often. Brushed motors can have problems like worn brushes, dust, sparks, and commutator damage. Checking and cleaning them often helps stop problems and keeps them working well.
Brushless motors need much less care. They do not have brushes or commutators, so there are fewer things to break. You mostly just keep them clean, use them the right way, and protect them from dust, water, and shaking. You do not need to change parts often. This means they work better and last longer.
Here is how their care needs compare:
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Brushed motors need lots of hands-on care, like changing brushes and commutators.
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Brushless motors only need simple cleaning and protection, with no regular part changes.
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Brushed motors need more checks, but brushless motors only need a little care when needed.
Noise and Heat
Noise and heat matter for how well a motor works. Brushed motors are louder because the brushes rub on the commutator. This rubbing also makes heat, which can hurt the inside parts and make the motor less efficient. Brushed motors can get too hot if they work too hard or do not cool down.
Brushless motors are much quieter. They use electronic commutation, so there is no rubbing noise. Many have fans or special ways to move air and keep cool. This helps them stay at a safe temperature even when running for a long time. Less noise and better cooling help brushless motors work better and use less energy.
Tip: Brushless motors are best for things that need to be quiet and cool, like medical machines or computer fans.
Lifespan and Durability
Brushless motors last longer and are tougher than brushed motors. If you take care of them, brushless motors can run for over 10,000 hours. They do not have brushes, so there is less rubbing, less sparking, and less heat. This makes them very reliable and helps them last a long time. They also have fewer parts that wear out.
Brushed motors do not last as long because the brushes and commutators wear down. Rubbing and sparks hurt these parts, so they break more often and need more fixing. Oiling, checking, and cleaning can help brushed motors last longer, but they still do not last as long as brushless motors.
Things that help motors last longer are:
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For brushless motors: no brushes, good cooling, clean place, and good setup
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For brushed motors: changing brushes, oiling, and keeping out dust and water
Cost Comparison
How much a motor costs and how hard it is to use matters too. Brushed motors cost less because they are simple and easy to make. They use basic controls, like a rheostat, which keeps the price low. People pick brushed motors when they want to save money.
Brushless motors cost more at first. They need special electronic speed controllers, which makes them more expensive. But they work better, use less energy, and need less fixing over time. They last longer and do not need as many repairs, so you save money in the long run. The table below shows how they compare:
| Aspect | Brushless DC Motors (BLDC) | Brushed DC Motors |
|---|---|---|
| Maintenance Requirements | Very low; almost maintenance-free due to no brushes or commutators | High; frequent brush and commutator replacements needed |
| Wear Components | None (no brushes or commutators) | Brushes and commutators wear out and require regular replacement |
| Service Life | Longer service life due to reduced mechanical wear and heat loss | Shorter service life due to friction and arcing damage |
| Downtime and Failure Rate | Lower failure rate and reduced downtime | Higher failure rate and more frequent maintenance downtime |
| Long-term Ownership Cost | Lower despite higher initial cost due to reduced maintenance and replacement | Higher due to ongoing maintenance and part replacement costs |
Typical Uses
Brushed and brushless motors are used for different things because of how they work. Brushed motors are found in things like electronics, car parts, and machines. They power things like electric toothbrushes, fans, toys, car seats, wipers, belts, and pumps. They are cheap and easy to use, so people use them for simple jobs.
Brushless motors are used when you need high performance and efficiency. Cars use them for power steering, brakes, and electric engines. Other uses are drones, computer fans, HVAC blowers, and medical machines. Brushless motors are better because they are quiet, last longer, and work well, so they are picked for tough jobs and new technology.
| Application Sector | Brushed DC Motors | Brushless DC Motors |
|---|---|---|
| Automotive | Power seats, wipers, windows | Electric power steering, braking, powertrains |
| Consumer Electronics | Toys, fans, toothbrushes | Computer fans, drones, advanced appliances |
| Industrial Machinery | Conveyor belts, pumps, robots | Robotics, CNC machines, HVAC systems |
| Medical Devices | Diagnostic tools, life-saving machines | Surgical robots, ventilators, imaging equipment |
| Renewable Energy | Clean energy components | Wind turbines, solar tracking systems |
Note: Brushless motors are used most in places that need high efficiency, great performance, and strong reliability.
Choosing the Right Motor
Key Considerations
Picking the best motor depends on many things. You need to think about how you will use the motor. The place where the motor works is important too. You also need to know what the device needs. The table below shows how brushed and brushless motors are different:
| Factor | Brushed Motor Characteristics | Brushless Motor Characteristics |
|---|---|---|
| Efficiency | Medium efficiency due to friction and commutator losses | High efficiency with minimal energy waste due to no brushes |
| Maintenance | Requires regular maintenance because of brush wear | Minimal maintenance, no brushes to replace |
| Noise and Vibration | Medium noise and vibration from brushes and commutator | Low noise and vibration due to electronic commutation |
| Cost and Complexity | Lower cost, simpler design | Higher cost, requires electronic controllers |
| Design and Operation | Mechanical commutator and brushes | Electronic control with hall sensors and driver circuits |
| Speed and Torque | Limited speed and torque range | Wide speed and torque range with precise control |
| Safety | Sparks generated due to brushes | No sparks, safer operation |
| Electrical Consumption | Medium power consumption | Lower power consumption |
You should also think about where the motor will be used. Dust, water, and heat can hurt both kinds of motors. Brushed motors need more cleaning and can break from dust or water. Brushless motors do better in tough places but still need care for the controller and wires. If it gets too hot, both motors can lose power and not last as long. Good cooling helps keep motors working well.
If your device uses a battery, pick a motor that does not use much power. This helps the battery last longer. Brushless motors are good for this because they use less power and last longer. If your device is small or light, size and weight are important. Make sure the motor works with the battery or power supply you have.
Tip: For things you use every day, like toys or small fans, brushed motors can work fine. For things that need to work better and last longer, like electric cars or hybrid cars, brushless motors are a better choice.
Brushed and brushless DC motors are not built the same way. Brushed motors have brushes and a commutator. Brushless motors use an electronic controller and sensors. Brushless motors work better and use less energy. Brushed motors are not as efficient. Brushed motors need more fixing and care. Brushless motors do not need much maintenance. Brushed motors make more noise when running. Brushless motors are much quieter. Brushed motors do not last as long. Brushless motors have a longer life.
| Aspect | Brushed DC Motors | Brushless DC Motors |
|---|---|---|
| Construction | Brushes, commutator | Electronic controller, sensors |
| Efficiency | Lower | Higher |
| Maintenance | Frequent | Minimal |
| Noise | Louder | Quieter |
| Lifespan | Shorter | Longer |
You should pick a motor based on what you need. Think about how you will control it, how much it costs, and what you will use it for. If you want to learn more, check out the Association for Advancing Automation or Monolithic Power Systems.
FAQ
What makes brushless motors last longer than brushed motors?
Brushless motors do not have brushes that wear out. The electronic controller reduces friction and heat. This design helps the motor run longer and need less maintenance.
Can someone replace the brushes in a brushed DC motor?
Yes, a person can replace worn brushes in a brushed DC motor. Regular replacement keeps the motor running well. Always use the correct type of brush for the motor.
Why do brushless motors cost more at first?
Brushless motors need an electronic controller and special parts. These add to the price. Over time, lower maintenance and longer life help save money.
Which motor type works better for quiet devices?
Brushless motors work better for quiet devices. They do not have brushes that make noise. Many people use them in computers, fans, and medical tools.
Do both motor types need cooling?
Both motor types can get hot during use. Brushed motors make more heat from friction. Brushless motors stay cooler but still need airflow or fans for best performance.
Written by Jack Elliott from AIChipLink.
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