In a brushed motor, the coils and commutator rotate while the magnets and carbon brushes remain stationary. The alternating change in the direction of the coil current is accomplished by the commutator and brushes, which rotate with the motor. In the electric vehicle industry, brushed motors are categorized into high-speed and low-speed brushed motors. There are many differences between brushed and brushless motors; as the names suggest, brushed motors have carbon brushes, while brushless motors do not. Brushless motors are an upgraded product with better lifespan and performance than brushed motors. However, their control circuitry is more complex, requiring stricter aging screening of components. Although the motor has a longer lifespan, the control circuit is more prone to failure. Therefore, selecting a brushless motor requires rigorous reliability testing to ensure quality. However, with continuous technological advancements, brushless motor technology has become quite mature.
In actual production, brushed geared DC motors are high-speed motors with small, easily worn gear teeth, but they offer great power and strong climbing ability. Brushless DC motors, on the other hand, eliminate the need for carbon brush replacement every two to three years. However, controlling brushless motors requires extremely high precision, and brushless motor controllers are also more expensive. In contrast, while brushed gearless DC motors do require carbon brush replacement, this process is very easy, and the motor control is simpler, resulting in smoother operation and a higher safety factor.
Brushed motors use direct current (DC) input, and their speed is adjusted by the controller providing varying current levels. Brushless motors, on the other hand, are three-phase AC motors. The controller converts DC to AC and uses Hall effect sensors to initiate commutation, ensuring proper operation. In short, brushless motors have a longer lifespan, stronger acceleration, and are more energy-efficient than brushed motors, but their controllers are more expensive. Currently, brushless controllers are the standard, and brushed controllers are largely obsolete. The electric vehicle controller is the core component that controls the motor's start, operation, forward and reverse movement, speed, and stop, as well as other electronic devices. It's like the brain of the electric vehicle, a crucial part of its design.
