In modern power tools, robots, drones and other equipment, hollow cup motors are widely used in the industry as an important power source. According to the design and working principle of the motor, hollow cup motors can be divided into brushed hollow cup motors and brushless hollow cup motors. Understanding the difference between the two will help us better choose the motor that suits our needs and improve the performance and reliability of the equipment.
- The basic principle of brushed hollow cup motor
The brushed hollow cup motor (Brushed Hollow Cup Motor) is a traditional type of motor. The “brush” in its name refers to the use of brushes (carbon brushes) inside the motor to work with the commutator. The current is transmitted to the commutator of the motor through the carbon brush, and then the current direction is changed to drive the rotor to rotate.
The advantages of this motor are simple structure and low cost. It is suitable for cost-sensitive applications that do not require high load and high-precision control. However, due to the friction between the brush and the commutator, it is easy to wear, resulting in reduced motor efficiency and limited service life. At the same time, the electromagnetic interference generated by friction may also affect the stability of the equipment.
- Basic Principle of Brushless Hollow Cup Motor
The brushless hollow cup motor does not use carbon brushes, but uses an electronic commutation system to control the direction of current flow to drive the rotor to rotate. There are sensors or electronic controllers inside the brushless motor to detect the angle of the rotor and adjust the current direction in time to achieve smooth motor operation.
Compared with brushed motors, brushless motors are more complex in structure, but they have significant advantages such as high efficiency, longer service life, lower noise and less electromagnetic interference. Since there is no friction between the brush and the commutator, the operation of brushless motors is smoother and more efficient, especially in occasions that require long-term operation or high-precision control.
- The difference between brushed hollow cup motors and brushless hollow cup motors
1) Different working principles:
The brushed hollow cup motor relies on the friction between the carbon brush and the commutator to change the direction of the current, while the brushless motor uses electronic control to achieve commutation. This makes the working process of the brushless motor smoother and more stable.
2) Efficiency difference:
Brushless hollow cup motors have no friction of brushes when working, so their energy loss is lower and their efficiency is higher. In contrast, brushed motors have lower efficiency and generate more heat due to the contact between the brushes and the commutator, which will cause power loss.
3) Service life:
Because there are carbon brushes and commutator friction inside brushed motors, the carbon brushes will wear out after long-term use and need to be replaced regularly. In contrast, brushless motors have no carbon brushes and less friction, so their service life is significantly longer than brushed motors.
4) Cost difference:
Brushed motors have a simple structure and low manufacturing cost, which makes them suitable for cost-sensitive applications. Brushless motors require additional electronic control systems and are more expensive, so they are mostly used in occasions with higher performance requirements, such as high-end drones, high-precision mechanical equipment, etc.
5) Maintenance requirements:
Brushed motors need to be regularly inspected and replaced due to the wear of carbon brushes, and the maintenance work is relatively complicated. Brushless motors require almost no maintenance and are more durable due to their high efficiency and stability.
6) Noise and electromagnetic interference:
Due to the friction between the brush and the commutator, the brushless motor will generate greater noise and electromagnetic interference, while the brushless motor runs more smoothly with less noise and electromagnetic interference.
- Applicable scenario analysis
1) Brushless hollow cup motors are suitable for applications that are more cost-sensitive and have low efficiency requirements. For example, low-power devices, electric toys, low-load home appliances, etc. Due to its simple structure and low price, brushless motors perform better in some devices that do not need to run continuously for a long time.
2) Brushless hollow cup motors are widely used in occasions that require high efficiency, long life and low noise. For example, high-end drones, robots, power tools, medical equipment, etc. Especially in equipment that requires long-term high-load operation and precise control, the advantages of brushless motors are more obvious.
Brushless hollow cup motors and brushless hollow cup motors have their own advantages and disadvantages. Which motor to choose depends on the needs of the specific application. If the budget is limited, and the load of the equipment is not large and the working time is not long, using a brushless motor is a cost-effective choice. If you need a high-efficiency, low-noise, long-life motor and have a certain tolerance for cost, a brushless motor is undoubtedly a better choice.
If you want to know more about “coreless motors”, you can contact online customer service. X-TEAM brushless motors provide OEM and ODM services for a long time to meet the different needs of different customers.