Brushed Versus Brushless Motors

When you're searching for a motor for your product designs, you may be wondering which is a better choice — brushed or brushless. Let's review five parameters that may be helpful in your decision-making process. 

Motor Performance

For each type of motor, there are different performance levels that depend on size, voltage, flow and impedance. Due to their simple design, brushed motors typically have higher air performance than brushless motors. They also work only as an open loop system, while brushless motors can be designed as open or closed loop systems.

Brushed motors are designed to work with a single voltage such as 110V for the blower. If you require a higher air performance, you must increase the voltage or change the winding. Conversely, brushless motors can provide consistent performance across a voltage range between 108-230V.

Control

Let's think about your requirements. Do you need to be able to control the airflow, or have it change speeds after a certain amount of time? If so, consider a brushless motor solution for your project.

In brushless motors, there is a digital control board inside the unit that allows it to be programmed to give you ultimate control over your project. Brushless blowers are designed for complex air moving applications.

However, if you need only constant air flow, a brushed motor may be your best solution. Brushed motors provide a steady airflow and performance for your product.

In addition to providing consistent air flow, they can also help keep your costs low.  Since the brushed motor is more rugged, it can be placed in harsher conditions, than brushless blowers, allowing greater flexibility and less worry about issues when the motor will be used in rugged environments.

Motor Life 

Makers of brushed and brushless motors have found many ways to increase their life spans. Brushed motors can now be outfitted with infinity curved brushes to enhance the life of the blower up to 3,000 hours. Brushless motors do not have any contacting parts, increasing their life usage to 20,000-25,000 hours.

When considering both brushed and brushless motors, ask yourself what the design life of your project will be. Does it need to last for several years, or will it only need to last for a short period?

By considering the life span, you have taken another step in the right direction when choosing the correct motor for your application.

Also, as you consider the life of the blower, think about the amount of time the motor will be running. If it is meant for continuous duty, you may want to use a brushless blower, but if you only need short bursts of time for the motor to run, a brushed motor may be a better option. 

Motor Size

Next, take size into consideration. Does your final product need a small motor solution? Perhaps you have size constraints for the result. By knowing the space you have available, you can make an calculated decision about what works best for you.

Size and weight may play an important role, especially if you are developing a product that is meant to be portable. You'll want to consider smaller options and different sizes of motors that may have performance ratings similar to what you need.

Cost

When you are searching for a motor, whether brushed or brushless, it's important to understand the differences in cost effectiveness and how those relate to your final product. In other words, you don't want to spend more on a component than the cost of your final product.

Brushed motors are very cost effective due to their simplistic nature. The majority of brushed motors provide a cost-effective solution for products where the motors are also cost-effective, although they don't offer as many features as a brushless motor.

Brushless motors are designed to provide more control, life and performance than traditional brushed motors, making their pricing higher. These blowers are designed to last longer and can provide you with ultimate control over your motor and system.

Conclusion

Overall, the decision lies with you when choosing a brushed or brushless blower. Take some time to think about these five parameters. When you're ready to purchase a motor/blower, you'll already have a great start sourcing your perfect solution. AMETEK Dynamic Fluid Solutions manufactures both brushed and brushless blowers for many different applications and interests. 

At AMETEK Dynamic Fluid Solutions, we understand you’re looking for more than just an off-the-shelf part or one-time solution. You need a true technology partner who understands your engineering challenge that is focused on you, providing customized, collaborative solutions. We’ll also provide you with excellent customer service for a great total experience.