Brushless motors are advantageous for many reasons. The lack of a brush means that there is less sparking, smoother operation, reduced noise, and extended operational life. These advantages do depend upon a brushless motor being properly-suited to an application, so while it is possible to find many commercial, off-the-shelf models from general suppliers, custom brushless DC motors sourced from a dedicated brushless DC motor manufacturer can be a better option for highly specific and critical applications.
One of the most common and critical applications of these motors is on aircraft and various aerospace equipment. Aerospace BLDC motors are used to perform many automated and mechanical functions on airplanes, helicopters, spacecraft, and more. One of the key features of aerospace brushless motors is that they are made to operate safely and reliably even at temperature extremes. When manufactured properly, using the right materials for the housing, writing, insulation, etc., they can be used as high-performance, high-temperature motors.
Frameless BLDC motors are also in demand for specific industrial applications, specifically those that require a stator and rotor assembly that will fit into housing already designed for a specific piece of equipment. This is a versatile solution for manufacturers of unique tools and equipment, like motorized medical devices, automated technologies, industrial appliances, and more.
Instead of being made of carbon like brushed motors, brushless motors generate power through the incorporation of magnets. This means they do not generate friction and don’t heat up as quickly. As a result, they perform better and do not wear out as quickly as a motor with a brush.
A DC brushless motor features 3 wires that are connected and wound in a way that a magnetic field is created when DC current passes through two of the connections. The rotor will then turn once this magnetic field is active. A speed control will then alter which two of the three wires is active.
Brushed DC motors contain a brush made of carbon while a brushless DC motor contains magnets. One of the chief differences between these two types of motors is their operational efficiency. Brushed motors will deliver between 70 and 80 percent efficiency, while brushless motors will provide between 85 and 90 percent efficiency. That means the output of a brushless motor is somewhat greater. Brushless motors also do not generate as much heat, friction, and vibration. This means they run smoother, cooler, and quieter.
Brushless electric motors do not wear out in the same way as a brushed motor. Since they do not contain a brush, that component doesn’t need to be replaced. However, all motors will wear down and need repair or replacement at some point but brushless motors will typically run longer and smoother than brushed motors when used in the appropriate application.
The longevity of a brushless motor can vary greatly depending upon a number of operational and maintenance factors. In general, brushless motors will typically run for tens of thousands of hours before replacement is needed. In comparison, a brushed motor will often provide 1,000 to 3,000 hours of runtime before the brush begins to wear out.
When a brushless motor is properly sealed and in the proper watertight housing, it can be submerged in water. These motors are sometimes used in submersible pumps and processing applications that are regularly subjected to moisture and various liquids. Waterproof motors often cannot be paired with other components that are not water-resistant, such as various sensors and switches.