High power brushless motor are used in everything from household appliances to drones. They offer higher performance, efficiency, and reliability than their brushed counterparts.
BLDC motors use Hall sensors to identify the rotor’s position, then power MOSFETs to switch current into the appropriate windings. These switches are controlled by gate drivers, which can be integrated or discrete components such as IGBTs or GaN.
Energy Efficiency
Unlike their brushed counterparts, brushless motors don’t have brushes and commutators that wear out over time. As such, they offer greater energy efficiency, ranging from 80-95%. They can also produce more torque than their brushed counterparts, resulting in reduced power consumption.
A key factor in determining brushless motor efficiency is copper losses, which are produced by the windings’ resistance to current flow. However, these losses are mitigated by smart controller software High power brushless motor that automatically varies the windings’ resistance to fit the motor’s specific operating conditions.
As a result, the ability of brushless motors to operate at lower torque and current settings while still achieving full power potential contributes significantly to their impressive efficiency. This fact makes them particularly favourable for cordless tools, RC vehicles, heating and cooling systems, and even drones and electric aircraft. The robust design of brushless motors also supports their longevity in industrial applications, allowing them to deliver consistent performance in conveyor belt systems and robotic arms. In fields where accuracy and efficiency are non-negotiable, like satellite gyroscopes and drone propulsion systems, brushless motors’ responsive control and power-to-weight ratio ensure unwavering performance.
Less Noise
As the name implies, a brushless motor is free from the sliding brushes that are used in brushed DC motors. Instead, they use electronic commutation to transmit current in the motor windings. This results in less friction and wear, as well as no abrasion of the commutator plates. This increases the lifespan of the motor.
The absence of abrasion also reduces electrical noise. This is especially important for servo motors that are used in sensitive applications like medical equipment and 3D printers. In addition, a lack of electrical noise eliminates the potential for sparks that can ignite flammable materials.
Allied Motion offers a wide range of brushless brushed DC motors including standard geared options for high torque applications. The KinetiMax HPD series of outer-rotor brushless motors offers frameless part sets for optimum performance in various applications. They are available in six frame sizes with three stack lengths per size to allow for a perfect fit. These motors offer a very high torque density and are suited for demanding speed and positioning tasks. Learn more about them here.
Less Maintenance
The absence of carbon brushes and commutators means that brushless motors do not require frequent replacement or maintenance. Instead, an electronic sensor constantly monitors the motor’s position and signals to switch current on or off as needed. This eliminates friction and rubbing that is associated with the brushes contacting the commutator, extending its lifespan and ensuring optimal performance.
BLDC motors are used in modern cordless power tools, including string trimmers, leaf blowers, circular and reciprocating saws, drills and drive units. Their lighter weight, increased efficiency and ability to operate in varying temperatures are key benefits. The lack of emissions and mechanical noise also helps in meeting regulatory requirements for certain types of model aircraft, which rely on them for operation.
Brushless DC motors are also frequently used in commercial and industrial applications such as centrifugal automotive air purifiers, electrically powered side windows in cars, and CNC machines and linear motors. They are even used to control the motions of robots in manufacturing processes, steel processing and welding. In addition, BLDC motors are often more durable than their brushed counterparts, meaning they can handle harsh operating conditions and environments.
Longer Lifespan
While brushed motors are inexpensive and easy to use, they require maintenance and have short service lives due to brushes that wear out over time as they rub against the commutator plate. This process also generates sparks that can cause damage to components. Brushless motors don’t have these same issues, and they last much longer.
BLDC motors are also more efficient than their brushed counterparts and produce higher amounts of torque per watt. Additionally, they have a higher power density and operate much quieter since they communicate via an electric circuit rather than through the mechanical interaction between commutator plates and brushes.
BLDC motors are often used in cordless power tools, like string trimmers, leaf blowers, saws (circular and reciprocating), and drills/drivers. They provide a high torque to weight ratio and have a simple speed control.
Lower Cost
Brushless motors cost more up-front than brushed motors, but their lower maintenance costs and longer lifespan offset this upfront expense. They also consume less energy, reducing operating costs. This makes them ideal for industrial automation applications that demand high precision, quiet operation and long life.
For instance, the inner rotor brushless DC motors (BLDC) are used in robots for medical aspirators, operating beds and other equipment because of their lightning-fast acceleration, superior accuracy and low noise. They are also widely used in cordless power tools such as brush cutters, hedge trimmers and High power brushless motor supplier cordless drills because of their efficiency and ability to run longer on a single charge than brushed motors.
In addition, brushless DC motors are also used in drones because of their light weight, wide speed range and fast acceleration capabilities. While they may not be as powerful as nitro motors, which are commonly used in racing drones, they can easily handle the most demanding tasks. They also offer an optimal power-to-weight ratio and feature efficient heat dissipation for cool operation. Moreover, they can be controlled using a variety of analog and digital systems to match the application’s requirements.