How Long do DC Brushless Motors Last?

A brushless motor can last up to 10,000 running hours or more when staying within the manufacturer’s recommended limit for continuous operations

Brushless motors are essential for many electronic devices, from remote-controlled vehicles to computers. They’re also used in some electric vehicles and hybrid cars. But how long do these motors actually last?

The lifespan of a brushless motor depends on a number of factors, including the quality of the motor, the operating conditions, and how frequently the motor is used.

The long lifespan of a brushless motor makes it a great choice for many applications. However, it’s important to note that brushless motors are not maintenance-free. They still require occasional cleaning and inspection to ensure optimal performance.

Why Brushless Motors Last Longer?

As the name suggests, brushless motors, unlike brushed motors, don’t have any brushes. The lack of brushes means there are fewer moving parts that can wear out over time. This contributes to the long lifespan of brushless motors.

On a brushless motor, the outer casing is magnetically charged and rotates while the coils remain stationary. These coils are activated by an external controller to create the magnetic field needed to rotate the casing. Because there are no brushes, there is no friction between moving parts, which further increases the lifespan of the motor.

In addition, brushless motors are typically more efficient than brushed motors. This means that they don’t produce as much heat, and are less likely to overheat and fail. For instance, in a brushed motor, the brushes constantly grind against the casing, which creates friction and heat. This can cause the brushes to wear out quickly, and eventually, the motor will fail.

On the other hand, brushless motors are more efficient because they don’t have any brushes to create friction. In addition, the lack of moving parts means there is less resistance, which further increases efficiency. As a result, brushless motors are less likely to overheat and fail.

Recommended read: “Brushless vs Brushed Motors: Which is Suitable for Your Project?”

What Causes a Brushless Motor to Fail?

While brushless motors can last a long time (up to tens of thousands of hours), operator errors might lead to a decreased lifespan. There are many reasons why a brushless motor fails after only a short time.

The most common reason for early failure of a brushless motor is water or dust contamination, which causes corrosion and eventually leads to bearing failure. Balance issues with bearing load also impact bearing life. In addition, not using the brushless motor in ideal conditions and ignoring the manufacturer’s guidance will lead to early failure. All of these factors will lead to the wear and tear of the bearing.

Other common reasons include the following.

Operating Conditions

In addition to the quality of the motor, the operating conditions also play a role in determining the lifespan of a brushless motor. For instance, if the motor is constantly operated at high speeds, it will experience more wear and tear than if it is operated at lower speeds. As a result, the lifespan of the motor will be reduced.
In addition, sharp stop-and-start cycles can also reduce the lifespan of a brushless motor. These stop-and-start cycles put stress on the motor, and can eventually lead to failure.

Frequency of Use

Another factor that determines the lifespan of a brushless motor is how often it is used. If the motor is used frequently, it will experience more wear and excessive heat. Although they are made to last tens of thousands of hours or more than a year, frequent use can reduce the lifespan of the motor.

External Factors

External factors, such as vibration and shock, can also impact the lifespan of a brushless motor. These factors can cause wear and tear on the motor, and eventually lead to failure. Debris and dust also pose a risk to the motor, as they can cause corrosion and other damage.

Improper Installation

In some cases, brushless motors fail because they were not installed properly. For instance, if the motor is not mounted correctly, it will be subjected to vibration and stress. This can lead to premature failure. In addition, if the wires are not connected properly, the motor will not operate correctly and might eventually fail. It’s always best to follow the manufacturer’s guidelines and recommendations when installing a new brushless DC motor.

Not Following Manufacturer Recommendations

Not following the manufacturer’s recommendations is one of the most common reasons why brushless motors fail. For instance, if the motor is not properly lubricated or cooled, it will experience excessive wear and tear. In addition, if the motor is operated outside of its recommended operating conditions, it will likely fail prematurely. While brushless DC motors are a favorite due to their high torque ability, using more torque or higher RPMs than what is recommended by the manufacturer can cause the motor to fail.

How to Improve the Lifespan of your Brushless DC Motor

There are several steps you can take to improve the lifespan of your brushless DC motor. Inspecting it regularly, keeping it clean, and following the manufacturer’s recommendations are all important steps to take. For instance, always follow the appropriate max torque, rated speed, rated power, and rated current during operation. Doing so will help to prolong the life of your motor.

Additionally, it’s important to keep the motor clean and free of debris. Dust and dirt can cause corrosion, so it’s important to keep the area around the motor clean. In addition, if the motor is regularly exposed to water or other liquids, it’s important to take steps to protect it.

Finally, it’s important to inspect the motor regularly for any signs of damage or wear. If any damage is found, it’s important to have it repaired as soon as possible.

Recommended read: “10 Common DC Motor Failures That You Should Know!”

Assunmotor’s Coreless Brushless DC Motors

If you thought brushless DC motors couldn’t be any more efficient, they can be with the help of coreless DC motors. A coreless electric motor is a type of brushless DC motor that uses wire-wound stators instead of laminated steel, resulting in a more efficient motor. The lack of an iron core also eliminates the need for a mechanical commutator, further improving efficiency.

The coreless design also improves lifespan and reduces the risk of sparks, arcs, and electromagnetic interference.

When it comes to finding a brushless DC motor that will last, you can’t go wrong with a coreless motor from Assunmotor. Our coreless motors are designed for long-term use and can be used in a variety of industries. From healthcare to automotive, to aerospace, our coreless motors are up for the challenge.

Conclusion

Brushless DC motors are incredibly efficient and can last for many years with proper care. However, there are several factors that can contribute to premature failure. Following the manufacturer’s recommendations, inspecting the motor regularly, and keeping it clean are all important steps to take. Additionally, using a coreless brushless DC motor will further improve efficiency and lifespan. Do you think you’d invest in a brushless motor? Share this article to help others experience the many benefits of brushless DC motors today!