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My first experience with DC motors was for a small elevator project in school. I had no idea that day would be the beginning of my journey with motors. The motor worked well during testing, but it failed when it really mattered. I built the elevator shaft from wood and used a pulley system with strings to lift a cardboard box. (Back then, I didn’t know about gear ratios, so my elevator was more like an ejector seat than a real one.) For control, I used a battery, a switch, and a DC motor. In short, I forgot to change the battery before the presentation, and it ran out just as I needed it. Fortunately, someone saw it work and vouched for me, so I passed the class.
That was my first encounter with a DC motor. Can you guess which type I used? We’ll come back to that later.
There are two main types of DC motors: brushed and brushless. Both are permanent magnet DC motors because they use a segmented permanent magnet rotor. The key difference is in how they commutate their windings—brushed motors use brushes, while brushless ones don’t. These motors are commonly used for speed control applications.
Brushed DC motors are self-commutated, meaning they can operate without a drive circuit. Brushless DC motors, on the other hand, require a driver circuit that uses transistors to direct current to different winding coils.
Understanding their design helps explain how they function. In a brushed motor, the commutator and brushes are inside the motor. The commutator rotates with the rotor, while the stator remains stationary. When power is applied, specific electromagnets in the rotor are energized, attracting and repelling the stator’s magnetic poles. As the rotor turns, the brushes mechanically switch to the next set of coils, repeating the process until the power is turned off.
In a brushless motor, the permanent magnets are on the rotor instead of the stator. This allows the stator’s winding coils, which generate the most heat, to dissipate it more efficiently. A driver circuit monitors feedback from the motor using Hall Effect sensors, which detect the position of the rotor’s magnets. This data is used to electrically excite the stator poles, rotating the rotor without physical brushes.
The image shows a brushless motor with 6 stator poles and 4 rotor poles. The Hall Effect IC sends signals to the driver, which controls the timing of phase excitation. This feedback also helps regulate motor speed.
Most of our brushless motors now have 10 poles, providing 30 pulses per revolution with three Hall Effect sensors. Some models, like the BXII Series, include encoders for even higher resolution.
Brushless motors require feedback to function properly, unlike brushed motors. This feedback allows for precise speed control and features like torque limiting, which is useful in tensioning applications. While brushless motors may cost more upfront, their benefits make them ideal for many modern applications.
Both brushed and brushless motors offer similar speed-torque performance. However, brushless motors use a driver to optimize performance, ensuring consistent results. Their excitation sequence must speed up to increase motor rotation.
Here's a comparison chart summarizing the differences between brushed and brushless motors:
[Image: Brushed vs. Brushless Motors Comparison Chart]
Brushed motors are simpler and cheaper but require regular maintenance due to brush wear. They can also cause sparks, limiting their use in sensitive environments. Brushless motors, on the other hand, are quieter, last longer, and offer higher efficiency. They are also more compact and provide precise speed control, often within ±0.2% or better with encoders.
As technology advances, brushless motors are becoming more popular. While brushed motors are still common in household appliances, brushless motors are preferred in a wide range of applications, from conveyors to automated guided vehicles (AGVs).
For more information, check out this short article comparing brushless, brushed, and AC motors.
[Image: Brushless DC Motor vs. AC Motor vs. Brushed Motor]
Enjoy this video about our brushless motors:
[Embedded Video: Brushless Motors Overview]
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