The difference between the two
1. When a brushed motor is working, the coil and commutator rotate, while the magnet and carbon brush do not rotate. The alternating change of the direction of the coil current is accomplished by the commutator and brushes that rotate with the motor.
2. A brushless DC motor consists of a motor body and a driver, and is a typical mechatronic product. Because a brushless DC motor operates in a self-controlled manner, it does not require an additional starting winding on the rotor like a synchronous motor that starts under heavy load with frequency conversion speed regulation, nor will it experience oscillation or loss of synchronism during sudden load changes.
3. Brushed motors are traditional products with relatively stable performance. Brushless motors are upgraded products with better lifespan and performance than brushed motors. However, their control circuits are more complex, and the requirements for component aging screening are more stringent.
4. Brushless motor equipment can be used in: dairy industry, brewing industry, meat processing industry, soy product processing industry, beverage processing industry, pastry processing industry, pharmaceutical industry, precision electronics factory, and other cleanrooms with higher requirements. For example, the brushless motor (DIHOUR) hand dryer produced by Dior Electric is widely used in factories.
5. Carbon brush motors are only suitable for areas with less stringent requirements, such as various restrooms, and cannot be used in cleanrooms and explosion-proof workshops!
6. Service life: Brushless motors can operate continuously for approximately 20,000 hours, with a typical service life of 7-10 years. Carbon brush motors: can operate continuously for approximately 5,000 hours, with a typical service life of 2-3 years.
7. In terms of energy saving, relatively speaking, the power consumption of a brushless motor is only 1/3 that of a carbon brush.
I. Performance Comparison of Brushless and Brushed Motors
1. High friction, high wear.
Some users often encounter this problem when using brushed motors: after using the motor for a period of time, they need to open the motor to clean the carbon brushes, which is time-consuming and laborious, and the maintenance intensity is no less than a major house cleaning.
2. High heat generation, short lifespan
Due to the structure of brushed motors, the contact resistance between the brushes and the commutator is very high, resulting in a high overall resistance of the motor and making it prone to overheating. Since permanent magnets are heat-sensitive elements, if the temperature is too high, the magnets will demagnetize, causing a decrease in motor performance and affecting the lifespan of the brushed motor.
3. Low efficiency and low output power
The overheating problem of brushed motors mentioned above is largely due to the fact that the current does work on the internal resistance of the motor, so a large amount of electrical energy is converted into heat energy. Therefore, the output power of brushed motors is not high and the efficiency is not high.
II. Advantages of brushless motors
1. Brushless, low interference
The most direct change from brushless motors is the elimination of electrical sparks generated during the operation of brushed motors, which greatly reduces the interference of electrical sparks on remote control wireless devices.
2. Low noise and smooth operation
Brushless motors, without brushes, experience significantly reduced friction during operation, resulting in smoother running and much lower noise. This advantage greatly enhances the stability of the model's operation.
3. Long lifespan and low maintenance costs
Without brushes, the wear and tear on brushless motors mainly occurs on the bearings. From a mechanical point of view, brushless motors are almost maintenance-free motors, requiring only dust removal maintenance when necessary.
A comparison reveals the advantages of brushless motors over brushed motors. However, nothing is absolute. Brushed motors have superior low-speed torque performance and high torque, characteristics that brushless motors cannot replace. Nevertheless, considering the ease of use of brushless motors, the decreasing cost of brushless controllers and the development and market competition of brushless technology both domestically and internationally have greatly promoted the development of brushless motors in China.
Third, in terms of trends, brushless motor gearing may replace brushed geared motors.
1. Scope of application:
Brushless motors are typically used in equipment with high control requirements and high speeds, such as model airplanes and precision instruments. These devices require strict control of motor speed and can reach very high speeds. In addition, the most advanced hand dryers currently have very high-cost motors and controllers, so they are only used in higher-end equipment.
Brushed motors: Brushed motors are commonly used in power equipment, such as hair dryers, factory electric motors, and household range hoods. In addition, series-wound motors can also reach very high speeds, but due to the wear of carbon brushes, their service life is not as good as that of brushless motors.
2. Service life
Brushless motors typically have a lifespan in the tens of thousands of hours, but the lifespan can vary greatly depending on the bearings used.
Carbon brush motors: The continuous working life of brushed motors is usually several hundred to more than 1,000 hours. When they reach the limit of use, the carbon brushes need to be replaced, otherwise it will easily cause wear on the bearings.
3. Usage effect
Brushless motors: They are usually digitally frequency-controlled, highly controllable, and can easily achieve speeds from a few revolutions per minute to tens of thousands of revolutions per minute.
Brushed motors: Brushless motors generally operate at a constant speed after startup, and speed adjustment is not easy. Series motors can also reach 20,000 rpm, but their service life is relatively short.
4. Energy conservation and environmental protection
Comparatively, brushless motors controlled by frequency conversion technology are much more energy-efficient than series-wound motors, most notably in variable frequency air conditioners and refrigerators.
5. Future maintenance
Carbon brush motors require carbon brush replacement; failure to replace them in time can damage the motor. Brushless motors, on the other hand, have a much longer lifespan, typically more than 10 times that of brushed motors. However, they do require replacement if they break down, but routine maintenance is generally unnecessary.
6. Noise level
Noise levels are not related to whether it is a brushed motor or not; they mainly depend on the fit between the bearings and the internal components of the motor.
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