A brushless DC motor fan is a fan that uses a brushless DC motor as a drive device. According to design differences, DC motor fans are mainly divided into two categories: brushed and brushless. The two have their own characteristics in terms of design principles, performance, and service life. So, what are the differences and advantages of brushless DC motor fans compared to brushed DC motor fans?
- Structural differences
1) The core of a brushed DC motor fan is a DC motor, which consists of three main parts: a stator, a rotor, and a commutator. The stator is fixed to the fan bracket, and the rotor consists of multiple sets of coils. When current passes through the coil, a magnetic field is generated, which interacts with the stator magnetic field to generate a rotational force. The commutator ensures that the current can be continuously powered during the rotation of the rotor to keep the fan rotating continuously.
2) The brushless DC motor fan adopts a more advanced design, with the winding as the stator and the permanent magnet as the rotor. This design eliminates the carbon brushes and commutators in the brushed fan, switches the power-on sequence of the windings through electronic circuits, generates a rotating magnetic field, and drives the rotor to rotate.
- Working Principle
1) Brushed DC motor fans use carbon brushes for commutation, and the current is transmitted to the rotor of the motor through the carbon brushes to drive the rotor to rotate. However, due to the friction contact between the carbon brush and the commutator, the carbon brush will wear after long-term use, resulting in an increase in the failure rate of the fan, and the carbon brush needs to be replaced regularly. In addition, the carbon brush will generate sparks during high-speed operation, which will interfere with the surrounding electronic circuits.
2) Brushless DC motor fans use electronic control circuits to achieve commutation, completely eliminating the mechanical component of carbon brushes. This design not only avoids the failure problem caused by mechanical wear, but also makes the fan perform better in high-load and long-term operation scenarios. The electronic commutation method of brushless fans greatly improves the reliability of the fan and can maintain a high-efficiency working state under various load conditions.
- Life and application
1) Brushed DC motor fans have a relatively short service life due to the wear of carbon brushes. Although it has a simple structure and low manufacturing cost, it has a high maintenance cost in long-term operation. Therefore, brushed fans are more suitable for scenarios that do not require high performance but are sensitive to initial costs, such as household appliances, simple ventilation equipment, etc.
2) Brushless DC motor fans are more suitable for use in industrial, medical equipment, computers and data centers with high requirements for reliability, efficiency and energy consumption due to their high efficiency, low noise and long life. The service life of brushless fans can reach tens of thousands of hours, and the specific life depends on the type of bearings used, such as ball bearings and oil-containing bearings. Ball bearings have longer service life and more stable performance.
Brushless DC motor fans not only significantly improve work efficiency and greatly reduce energy consumption, but also greatly extend service life, thereby effectively reducing maintenance costs. In addition, its significant characteristics such as low noise, wide speed regulation range and high power density provide strong support for various high-precision and high-demand application scenarios. With the continuous advancement of science and technology and the active promotion of the market, the technology of brushless DC motor fans will continue to improve, the cost will be further reduced, and its application range will therefore be more extensive. Nowadays, household brushless DC fans have also begun to circulate in the market and have been warmly welcomed by consumers.
As a leading company in the field of brushless motors, X-TEAM has won the trust of customers with its advanced technology, high-quality products and good market reputation. As market demand continues to grow, X-TEAM will continue to be committed to technological innovation and product optimization to provide customers with more efficient and reliable brushless motor solutions. If you want to know more about “brushless motor”, you can contact online customer service. X-TEAM brushless motor provides OEM and ODM services for a long time to meet the different needs of different customers.