In the world of motors, brushless motors and brushed motors are two common and important types that play an indispensable role in various fields.
1、Brushed motor
The structure of a brushed motor is relatively simple, mainly composed of components such as stator, rotor, brush, and commutator. The stator is usually a permanent magnet or electromagnetic winding that generates a fixed magnetic field. There are coils wound around the rotor, and when current flows into the rotor coils through brushes and commutators, the energized coils generate torque under the action of the stator magnetic field, causing the rotor to rotate.The advantages of brushed motors are low cost, simple control, and good starting and speed regulation performance. It has been widely used in early fields such as electric tools, household appliances, and toys. However, due to mechanical friction and contact resistance between the brush and commutator, brushed motors suffer from issues such as wear, electrical sparks, high noise, frequent maintenance, and relatively low efficiency. As the usage time increases, the electric brush will gradually wear out and need to be replaced regularly, which not only increases the cost of use but also limits the service life of the motor.
2、Brushless motor
Brushless motor is a type of motor that uses electronic commutation technology. It does not have electric brushes or commutators, but rather uses a controller to timely switch the direction of current in the stator winding based on the signal from the rotor position sensor, so as to maintain a certain angle between the stator magnetic field and the rotor magnetic field, thereby generating continuous torque to drive the rotor to rotate.Brushless motors have many significant advantages. Firstly, due to the absence of friction between brushes and commutators, brushless motors have minimal wear, long service life, and high reliability. Secondly, brushless motors have high efficiency and can effectively save energy.
In addition, brushless motors have low noise and minimal electromagnetic interference during operation, making them suitable for situations with high requirements for noise and electromagnetic compatibility. Due to these advantages, brushless motors have been widely used in high-end power tools, electric vehicles, aerospace, industrial automation, medical equipment and other fields.However, brushless motors also have some shortcomings. Its cost is relatively high, the control circuit is complex, and the performance requirements for the controller are high. In addition, brushless motors experience relatively large torque fluctuations during low-speed operation, which may affect the performance of certain applications.
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3、Application Fields
Brushed motors, due to their cost advantage, are commonly used in price sensitive applications such as small electric toys, electric shavers, egg beaters, and other household appliances, as well as some simple electric tools that do not require high precision and performance.Brushless motors are widely used in fields that require high performance and high reliability due to their advantages of high efficiency, long life, and low noise. For example, in the drive system of electric vehicles, brushless motors can provide efficient power output and long range; In the joint drive of industrial robots, brushless motors can achieve precise position control and high-speed motion; In the power system of drones, brushless motors can provide stable power and lightweight structure.
4、Development Trends
Brushless motors and brushed motors each have their own advantages and disadvantages, and they play their respective roles in different application scenarios. With the continuous advancement of technology, the performance of brushless motors continues to improve, the cost gradually decreases, and their application scope will continue to expand. According to Grandview Research and other data, from 2014 to 2019, the global market size of brushless DC motors showed an upward trend year by year. In 2015, the global market size of brushless DC motors was about 12.6 billion US dollars, but just four years later in 2019, it dominated the precision motor market with a market size of about 16.3 billion US dollars. In the following three years, which is 2022, the global market size of brushless DC motors will be approximately 19.7 billion US dollars, maintaining a sustained and stable growth trend. With the rapid development of information technology and the increasing awareness of energy conservation and environmental protection, the global demand for brushless DC motors is showing a continuous growth trend. It is expected that by 2027, the global market size of brushless DC motors will reach $27.2 billion, with a compound annual growth rate of 6.5%.
In short, both brushless motors and brushed motors have their own advantages and disadvantages. Brushed motors will not be eliminated in the short term, but will emit light and heat in their respective fields.