BLDC Motors: Applications, Advantages & Differences With Brushed Motors

One of the most useful types of motors on the market today is called a brushless motor. Here’s what you need to know about BLCD motors, the different types, their applications, their advantages, and their differences vs brushed motors. As you are about to discover, these motors can do some pretty amazing things.

What is a Brushless DC Motor and How Does it Work?

Unlike conventional motors, which use a set of metal coils to generate power, a brushless DC motor uses electricity to send signals through a set of electromagnetic coils. These signals cause the coils to spin, which in turn causes a shaft to spin. The shaft can be used to power equipment or to transfer power to other machinery.

The design of brushless DC motors is often called the “open circuit” design because when the motor isn’t running the coils are open and don’t generate power.

Traditional DC motors are often referred to as “brushed” DC motors because they contain a series of copper brushes on the inside of the motor which help to transfer current from the power source to the electromagnets. In contrast, brushless DC motors contain no brushes and instead use permanent magnets to transfer power.

Understanding BLDC Motor Basics

Brushless motors have similar characteristics to the traditional brushed DC motors, but one apparent difference is exactly what the name implies: The BLDC motor model doesn’t have any brushes. What this change means for you is that the BLDC motors are more reliable because there is less equipment to deal with.

Without the use of brushes, the BLDC motor is also more durable and has a longer longevity than brushed motors, which, in turn, allows your company to save money on additional expenses related to future maintenance or full replacement of that equipment. As the brushes can also wear out during the course of operating the motor, this can cause sparking and may lead to fire hazards, additional concerns, and expenses for your company.

The BLDC motor efficiency over that of a traditional brushed motor is another benefit of using a brushless motor. Brushless motors have an overall higher speed and torque and produce less noise than traditional brushed motors. They also run more efficiently and have little or no power loss, which is a problem that can accompany brushed motors due to increased friction caused by the brushes. BLDC motors have reportedly hit 85 to 90 percent efficiency margins, which is higher than the standard brushed motors at 75 to 80 percent.

Brushless DC motors must also be electronically commutated, which means the motor is regulated by a control mechanism. That feature allows the 3-phase BLDC motor to change speeds at varying degrees along with the ability to quickly accelerate and decelerate to provide for the most efficient use of power and productivity when it comes to output. BLDC motors also typically weigh less than a brushed motor, but they have the ability to provide similar power outputs.

BLDC Motor Types

There are two types of BLDC motors: fixed-frequency and variable-frequency. Fixed-frequency BLDC motors have a constant frequency of rotation. Variable-frequency BLDC motors have a variable frequency of rotation. Both types come in different RPM ranges for use with different applications.

Fixed RPM: A fixed RPM BLDC motor has a rotational frequency that is constant throughout each speed setting. These are common in applications that don’t require speed control, including outdoor equipment.
Variable RPM: A variable RPM BLDC motor has a rotational frequency that can be increased or decreased via a control system. These are common in applications that require speed control, including industrial equipment.

Advantages of BLDC Motors

Variable Load Speed Range

Brushed motors require what’s called a commutator, which alters the magnetic phase within the motor to keep the armature moving. In a DC motor with a brushless design, the commutator is replaced by an electronic control function that operates the rotation of the armature. The most widely used motor for DC brushless designs are three-phase motors, which allow the speed of the motor to vary at different rates. That level of control further enhances the different applications in which a DC brushless motor can be used.

Outstanding Continuous Torque Range

Due to our DC brushless motors being electronically controlled, they have the ability to produce different torque and power outputs. TelcoMotion provides a variety of DC brushless motors with both NEMA and Metric frame sizes. Some features of our motor line include:

Sizes range from .5 to 3.4 inches
Output power of up to 660 watts
Incredible longevity
Compact size
High speed and high efficiency

Customizable Options

While traditional DC brushed motors are incredibly responsive and easy to control, they rely on direct contact between the brushes and the commutator. On the opposite side of the spectrum, brushless motors typically have a longer lifespan and require very little or even no maintenance at all. Telco’s motor with DC brushless design is an obvious choice for all of your application needs.

Where are the Applications of BLDC motors?

Brushless motors are used for a wide variety of applications in the commercial and industrial world thanks to their capability to provide high-speed performance and efficient operation. Moreover, most modern devices have incorporated BLDC motors, making them a clear choice above traditional brushed motors.

For example, they are commonly used for industrial positioning applications that require a great deal of precision such as the construction of a PC hard drive and other electronic hardware like DVD players and Blu-ray recorders. Other applications of BLDC motors include:

Heating, Ventilation, and Air Conditioning
Electrical vehicles
Pumps
Laboratory equipment
Fuel Controls
Dental Surgical Tools
Respirators
Robotics and Model Airplanes

With so many applications, it’s easy to see that a brushless motor is a good thing to have. The trick is to know where to find it. Telco has a strong reputation for building some of the best brushless motors ever made.

Choosing Between a Brushed Motor and a Brushless Motor

To choose the best motor for your needs, you’ll need a basic understanding of the differences between brushed and brushless motors. The primary difference between brushed and brushless motors is that the former is equipped with a brush and commutator while the latter does not have a brush. Brushless motors don’t need brushes because they rely on electromagnetism.

So which one is more advantageous to have? Brushless motors are widely considered to be superior to brushed motors because they’re more efficient. A brushless motor is generally 10%-15% more efficient than the average brushed motor.

Brushless motors are also safer to use as brushed motors have a bad habit of generating more sparks which can be hazardous.

Find the Best Brushless DC Motors Right Here at Telco!

Need brushless DC motors for your business? Then you’ll want to get in touch with Telco. We have a vast selection of BLDC motors and a reputation for excellence that others simply cannot compete with.

Find the best brushless DC motors for your business today at Telco!