Fundamentally, all electric motors use electromagnetic rules to transform electrical energy into rotational kinetic energy. However, these physical laws have led to a wide range of motor topologies that offer a variety of performance traits. The two most popular motor types, brushed and high-efficiency brushless motors, are explained in this article. When most people consider high-efficiency motors, they consider the energy and financial savings that would result from using them. Your operating costs will decrease if you use energy-efficient motors, but it is just one of several advantages. Choosing to utilize an energy-efficient machine is certainly a no-brainer when you weigh all the benefits. Brushed DC MotorsA stator and a rotor are the main components of a brushed motor. A fixed ring of permanent magnets makes up the stator. The stator's interior part, the rotor, comprises a ring of electromagnetic windings, the ends of which are coupled to a commutator. Brushes fixed on the commutator's opposite sides are in constant contact with them. The electromagnetic windings in the rotor generate a magnetic field when direct current is applied to them, and this magnetic field causes the rotor to revolve until it lines up with the stator’s magnetic field. Brushless DC MotorsBrushes are not used in BLDC motors; the motor is commuted electronically. In brushless motors, an electronic circuit senses the rotor's position about the stator. Then it supplies current through the three-phase pairs of the stator windings while maintaining a 120° phase offset between each to ensure smooth rotation and low torque ripple. The invention of solid-state electronics in the 1960s allowed for the development of brushless motors, a relatively new type of motor. Although brushless motors' electronics are fairly straightforward by modern standards, they constitute a significant change from the mechanical commutation methods used in brushed motors. Brushless motors now have surprising benefits due to this design modification. Less Operational NoiseBrushed motors produce significant motor noise due to friction and electrical arcing between the brushes and commutator plates. An electronic circuit performs the function of commutation in brushless motors, resulting in a significantly quieter operation. Higher Motor EfficiencyThis is a feature of brushless motors that is very significant. A brushed motor's noise and heat are essentially power losses from the machine that depletes energy from the rotor, which would otherwise be used to drive the load. Brushless motors are substantially more efficient since they produce significantly less noise and heat. Better Power-to-Weight Ratio of a MotorBrushless motors have less mass than brushed motors because they have fewer mechanical parts. The end consequence is that compared to brushed motors, brushless motors have better power-to-weight and torque-to-weight ratios. Longer Motor LifeSince brushed motor brushes are always in touch with the commutator, they gradually lose their effectiveness with use and ultimately need to be replaced. This issue is not there in brushless motors, which greatly decreases maintenance requirements and makes a variety of applications possible where brush replacement would be problematic, such as in satcom equipment used in space. Less Heat Production of the MotorIn a brushed motor, friction between the commutator plates and brushes results in heat production in addition to sound. This could be an issue for many applications. The only friction that exists with brushless motors is in the rotor bearings. As a result, brushless motors have significantly less of a problem with heat production. Final WordsExcept for a few outdated applications, all these benefits make high-efficiency brushless motors the best choice for modern applications. To learn more about our motors, get in touch with a member of the BMC Motor's staff.
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