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Meet the brushless motor

Karol Bryndzák     Reading for 3 minutes   41x read

Do you think the brushless motor is justifiably being used more and more in cordless tools? From the perspective of performance and maintenance, this motor represents significant progress.

To understand the principle of how a brushless motor works, we must first explain how its predecessor—the brushed motor—operates.

 

Operation of a brushed DC motor

Fig. 1. Operation of a brushed DC motor

Brushed DC motor

It consists of two parts - a stator and a rotor. The stator usually consists of permanent magnets, and the rotor consists of coils that create a magnetic field.

The coils are connected to a commutator, into which carbon brushes supply electric current. The coils create a magnetic field, which generates the rotational motion of the rotor itself. The advantage of a brushed motor is that the rotor's rotation speed is directly proportional to the amount of current flowing into the coils. Thus, the higher the current, the higher the RPM, and vice versa. These motors are still used in cordless tools, but they are gradually being replaced by brushless motors.

 

Stator (1), rotor (2), and commutator (3) of a brushed DC motor from the HERMAN AXSP 1800 screwdriver

Fig. 2. Stator (1), rotor (2), and commutator (3) of a brushed DC motor from the HERMAN AXSP 1800 screwdriver

 

 

BLDC motor with sequential current flow through individual coils

Fig. 3. BLDC motor with sequential current flow through individual coils

Brushless DC motor (BLDC)

Similar to a brushed DC motor, the BLDC also consists of two parts - a rotor and a stator. In this case, the rotor is formed by a permanent magnet and the stator by coils. Exactly the opposite of a brushed motor. Since the coil is the stationary part of the motor in this case, it does not need to rotate. Supplying electric current to it is therefore not as complicated as in a brushed motor, where carbon brushes had to be used for electrical transmission.

BLDC does not use them, so there is no sparking or friction. This is very important from a performance standpoint. Control electronics are used for current supply, ensuring that each stator coil creates a rotating magnetic field at the right moment to spin the rotor.

 

BLDC motors are used not only in cordless tools but also in RC models, computers (fans, hard drives), e-bikes, hybrid cars, electric vehicles, etc.

 

Summary:

  Advantages Disadvantages
Brushed motor
  • Time-proven design
  • Low motor service costs with regular maintenance
  • Modern carbon brushes have a long lifespan
  • Need for carbon brush replacement
  • Commutator wear
  • Higher weight, larger dimensions
  • Lower efficiency, higher energy consumption
Brushless motor
  • Higher efficiency, higher torque
  • Significantly lower consumption (up to 50%) – longer working time per single battery charge
  • Almost no heat losses (no sparking, friction)
  • Longer lifespan compared to brushed motors
  • Higher repair costs in case of electronics failure
  • Higher manufacturing costs

 

Sources:
HERMAN internal technical and training materials
https://sk.wikipedia.org/wiki/Elektromotor
https://en.wikipedia.org/wiki/Brushless_DC_electric_motor

Karol Bryndzák

Karol Bryndzák

I have been selling tools at Herman for nine years. I personally tried all the products during the renovation of my parents' house, which helped me to better understand their functionality and advantages. I am glad that I can pass on this practical knowledge to our customers in selling them our products. I am interested in news in the world of tools, and I like to follow the development of new technologies that can make our lives easier. I spend my free time working around my family home, with my family and music.


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  1. Jakub –

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    špecialita ktorá postupne mení svet

    a specialty that is gradually changing the world

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  2. Jakub Borsík –

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    Každy motor má svoje pre aj proti

    Every engine has its pros and cons.

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