Changzhou Joinbrain Motor Co., Ltd.

There are significant differences between brushed DC motors and brushless DC motors in terms of structure, performance, maintenance requirements and use environment

First of all, from the perspective of structure and working principle, the brush motor includes stator windings, rotors (including iron core and armature), commutator and carbon brush assembly. The power supply is supplied by a carbon brush to the armature windings, creating a rotating magnetic field that drives the rotor to rotate. The commutator of the brushed motor works in conjunction with the carbon brush to continuously change the direction of the current during the rotation of the motor to ensure that the torque is continuously generated and the motor is continuously rotated. In contrast, brushless motors abandon mechanical commutation systems and employ electronic commutation technology, which mainly consists of a permanent magnet rotor, a multiphase winding stator and a position sensor or non-inductive control algorithm. The external electronic controller switches the current direction in each stator winding in real time according to the rotor position, and realizes precise control and continuous operation of the motor, hence the name "brushless".

In terms of performance and maintenance requirements, brushless motors have higher efficiency and power density due to the absence of friction losses from carbon brushes and commutators, and can convert electrical energy into mechanical energy more efficiently. The lifespan of a brushless motor is often determined by the durability of the bearing, which is much higher than that of a brushed motor and requires less maintenance. Due to the contact friction between the carbon brush and the commutator, the brush motor will produce a certain amount of noise and electromagnetic interference, and it will also cause a certain degree of vibration. Because the brushless motor eliminates this mechanical contact link, the work is smoother, and the noise and vibration are less. In addition, brushed motors require regular replacement of worn carbon brushes and commutators, increasing maintenance costs and complexity，Brushless motors, on the other hand, eliminate the need for such maintenance, reducing long-term operating costs.

In terms of the use environment, the commutator and carbon brushes of the brushed motor may generate sparks when operating at high speeds, which may not be suitable for applications that are sensitive to electromagnetic interference or require a spark-free environment. Brushless motors are more suitable for occasions with high requirements for electromagnetic compatibility, such as medical equipment, precision instruments, etc., due to their non-sparking and low electromagnetic interference characteristics.

In summary, brushless DC motors have obvious advantages in terms of efficiency, lifespan, maintenance requirements and use environment, especially for application scenarios with high performance and reliability requirements. Because of its simple structure and low cost, brushed DC motor still has certain application value in some occasions with low performance requirements.