There are a variety of motors available today, ranging from large AC motors to small DC brushless and stepper motors. To select the proper motor for the job, users must have a complete understanding of the application factors, including power, speed, torque, physical size, efficiency, lifetime expectations, and other criteria. Each of these elements has been the topic of books and defining them all adequately in a short post would be difficult.
So, in this article, we’ll look at some of the critical distinctions between DC brushed and brushless motors to help you decide which is best for your application. Many machines today, for example, function in a clean environment rather than in a demanding industrial setting. Therefore, long life and low noise would become important characteristics for drives used in these applications.
Characteristics of DC Motors
Finding out what voltage is readily available for the application and what physical size the motor needs are two essential criteria for picking a DC motor. After these first two factors have been calculated, speed and torque can be evaluated.
- Voltage availability is an important consideration when choosing a motor. Many rack-mounted equipment and tools, for example, are powered by a 24V power source, whereas batteries power remote applications or portable devices. Depending on the power required, DC motors can operate at voltages as low as 1.5V and as high as 48V.
- Because more and more applications, such as desktop 3D printers, portable medical devices, and hand tools, have smaller footprints, physical size is generally one of the limiting criteria in motor selection. Choosing which engine to utilise and the available area it needs to fit into is frequently a compromise. Efficiency becomes a top priority when you need to think about power consumption to maximise battery life in a surgical device.
- As previously stated, torque and speed impact the size of the motor frame. More mounting hardware and housings may be necessary because high-torque motors are frequently more prominent than their low-torque counterparts. For example, a larger engine is required to rotate the magnets in an MRI than operate the windows in a car’s doors. Although speed and torque are separate requirements in many applications, the speed decreases typically — assuming the voltage remains constant when the torque increases. The speed/torque curve slope is used to make this relationship.
- The motor duty cycle of many semiconductor production machines could be one of the most significant indicators. Intermittent operation reduces motor wear and tear and increases motor life and allows for the use of a smaller motor size without sacrificing the machine’s favorable attributes.
Brushed or non-brushed
According to key characteristics, Brushless motors, which rely on a mechanical connection for functioning, last far longer than brushed motors. Brushless motors are also significantly faster. However, if you’re utilising a brushless motor for reliability, you won’t want to throw in a gearhead. Because of the mechanical nature of a gearhead, it will have a shorter life cycle. When a gearhead is paired with a brushless motor, the combined system’s longevity is negated, and the machine’s longevity is reduced as a result. However, there are situations when recommended using a gearhead with a brushless motor. For instance, if the environment is such that noise is a worry or if the climate is such that, If noise is a concern or more torque is required, a gearhead will suffice.
Brush motors should not be speeded up with gearheads. Using a gearhead with a brushed motor has little effect on the life cycle. Both are mechanical components that will wear out over time. The competence of the machine builder is a severe concern when deciding between brushed and brushless motors. Brushless motors are available with built-in or external electronics to control the motor. Custom electronics, which many machine builders prefer to provide, need some knowledge. However, if you sell a lot of stuff, the expenditures are readily recouped.
On the other hand, brushed motors don’t require any electronics to operate, giving the designer a plug-and-play option. This means that a brushed motor will save money on the overall cost of the system if the machines are expected to be sold in small quantities. The motors’ power requirements are a final worry. When working with a motor manufacturer, make sure they offer a wide range of power ratings, such as up to 250W for brushed enigne and 400W for brushless motors.
Brushless motors are being used by numerous machine manufacturers whenever practical. These motors can be used in various applications due to their long life and high speeds.x`