Brushless vs Brushed Motor

Brushless vs Brushed Motors: Which is Suitable for Your Project?

When comparing brushed motors with brushless ones, we tend to lean towards one being better than the other. But the truth is neither of these options is technically “better”.

It all depends on the project you are equipping, and how you plan to increase the efficiency of your build. Brushed and brushless motors are respectively ideal for different projects, which is why it’s so important to learn the difference between and the purpose of each.

Today we’re going to discuss the intricate differences between brushed and brushless motors, and guide you in selecting the right one for your current project.

The Main Differences Between Brushed & Brushless Motors

If an untrained eye looked at a brushless motor next to a brushed one, they probably wouldn’t be able to tell the difference between the two. Although both deliver a similar result, they are designed to function differently.

How Brushed Motors Function

As you’ve probably guessed, brushed motors derive their name from having brushes within their internal structure. These brushes are what charge another device within the motor called the commutator.

The commutator gets charged with electricity from the brushes. In fact, the brushes are the sole provider of energy that directly results in the rotor turning.

How Brushless Motors Function

Brushless motors are void of the above-mentioned brushes because they derive their energy elsewhere. Hall-effect sensors detect magnet pole positions inside the device, which drives the current to a dedicated phase of the winding coil. This turns the magnet based on Fleming’s left-hand rule.

Is One Better than the Other?

These differences are neither good nor bad. The nature of your project will determine which of these is the best fit for you. Since one is cheaper, you may not need the features of the other. But if you do, it’s best you choose the one that fits your requirements

Yes, brushed motors are cheaper than brushless motors, but there is still an important role to play for brushed motors in today’s technological arena.

Here’s a breakdown of when you should choose one over the other.

Projects Conducive to Brushed Motors

Due to the design of brushed DC motors, some aspects may either encourage or discourage you from using them. Bear the following in mind:

  • Brushed motors are more inclined to wear & tear 
  • They are cheaper than brushless motors
  • They require slightly more energy to run
  • They are noisier than brushless motors

Brushed motors will save you money on the following projects:

Projects with an Expiry Date

There is a higher probability of wear & tear on brushed motors. They require periodic maintenance, part changes, or brush replacements. If you’re working on a project that will likely end within a few years, it’s best not to spend more on your DC motors than what you need to.

Many machinery projects are temporary, which is why brushed motors are still so widely used. And considering the size of some of these projects, it makes good sense to go with a cheaper option that’s adequately efficient.

Projects Where Noise is Not an Issue

Because brushed motors are noisier than brushless ones, they are more often used in machinery where noise is considered non-disruptive. Factory machinery can be equipped with brushed motors because factories are more inclined to save money on equipment that doesn’t necessarily need to run quietly.

Projects with a Tight Budget

It goes without saying that brushed motors are the route to take if you don’t have a large budget for your project. For large projects, the decision to opt for brushed motors can have a significant decrease in the entire project’s expenditure.

As you’ve seen, brushed DC motors may be the best route to follow. But if you’re looking for something more streamlined, take a look at these ideal brushless motor projects.

Special NoteAssun Motor’s DC Brushed & Brushless motors are coreless / ironless. That makes the price between brushed and brushless almost no difference.

Projects Conducive to Brushless Motors

The basics of how brushless motors function are rooted in their construction. There is no commutator to carry the current to the rotor. Instead, this is where the aforementioned amplifier comes in—which triggers the rotor to move more smoothly.

Here in a nutshell is what you need to know about brushless motors:

  • They last longer than brushed motors because there is less wear & tear
  • The initial cost layout for brushless motors is significantly higher
  • Brushless motors deliver a quieter sound because they need less power to function

Here are the types of projects well fitted to brushless DC motors.

Projects that Are Long Term

The initial layout of any machinery project is going to be expensive. But you never want to lay that money out twice, do you? Going for brushless motors will mean less maintenance and less likelihood of eventual breakdowns and replacements.

If your project is long term, it’s advisable to opt for brushless motors. Maintenance will be easier and less frequent.

Projects that Necessitate Quiet

There are several cases where noise is a disruption to a working environment where machinery is used. Brushless motors provide a solution to laboratories, workshops, and factories that necessitate quiet while working. Because power is conducted without brushes, there is less movement noise during functionality.

Medical research centers, laboratories, and universities often opt for brushless motor devices so that noise disruption is at its lowest.

Meticulous Projects

Some projects call for extreme precision and reliability. While brushed motors are adequately efficient for repetitive projects, precise projects are best managed by machinery equipped with brushless motors. Movement is seamless, giving more control over the finer aspects of your machinery.

Projects that Are Time Sensitive

It’s true that brushless motors have the capability of working more efficiently over a shorter span of time. That’s because the technology behind brushless motors makes them use less power while increasing energy output. Brushless motors are simply more efficient because of this aspect, and they can endure faster movement because of it.

Your Selection Process

Choosing the right type of motor for your project depends on these aspects. So don’t write off brushed motors just yet. They have a lot to offer and still fill an important role in the manufacturing world we live in.

Make an educated choice based on your budget, time frames, and the nature of your project. Get the most out of your project with either brushed or brushless motors and find a good balance between your pocket and your product line.



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