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Decoding the Advantages: Brushed vs Brushless Motor Unveiled

Motors are important in electromechanical systems, powering everything from domestic gadgets to industrial gear. Brushed and brushless motors are two significant candidates among the multiple motor types available, each with specific properties and applications.


To comprehend a brushed vs brushless motor, you must differentiate and balance their benefits and downsides. A greater understanding of their operational mechanisms, comparative performance, and real-world application is required.  YD force has the experience to tell you whether to choose a brushed or brushless motor.

Brushed vs Brushless Motor

Table of Contents

Brushed Motors: The Pioneer of Electric Power

Brushless vs. Brushed Motors

Brushed motors, or brushed servo motor, is at the heart of many conventional electrical devices. These components have a long history of functioning as the workhorses of innumerable applications. Their simple design, which consists of a coiled armature and a commutator, allows for a dependable and cost-effective solution for a variety of jobs.


The motor, as the name implies, uses physical brushes to facilitate the flow of electricity and generate motion. Despite their simplicity, brushed motors provide consistent performance, making them a popular choice for various consumer devices such as power tools, household appliances, and automotive systems.

Pros and Cons of Brushed Motors

While the brushed servo motor has intrinsic advantages such as low cost and ease of maintenance, they have some restrictions. The friction caused by the brushes causes wear and tear, reducing the motor’s lifespan. Furthermore, the brushes must be replaced regularly, increasing long-term operational costs.


Moreover, brush contact with the commutator frequently causes electromagnetic interference and lower efficiency, making brushed motors unsuitable for applications requiring high precision and low electromagnetic noise.

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Brushless Motors: Revolutionizing Efficiency and Performance

Brushless motors, or the brushless servo motor, on the other hand, represent a current advance in motor technology, employing electronic commutation to eliminate the need for physical brushes.


This ground-breaking design provides smoother operation, lower maintenance, and increased efficiency, making brushless motors the preferred choice for applications requiring precision and longevity.


Brushless motors have become vital components in robotics, aerospace, and electric cars, where high performance and dependability are critical. They do this by utilizing sophisticated control systems and permanent magnets.

Pros and Cons of Brushless Motors

The lack of physical brushes in brushless servo motor decrease not just wear and tear but also electromagnetic interference, improving operational efficiency and lifespan. Furthermore, the precise control made possible by electronic commutation promotes smoother and more accurate motor operation, resulting in increased performance in crucial applications.


Brushless motors have a streamlined and compact design with fewer mechanical components, making them a perfect alternative for applications where space is limited. In addition, their exceptional thermal management capabilities and high power-to-weight ratio reinforce their position in demanding industrial and commercial situations.

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Brushed vs Brushless Motor: Difference Between the Two

Auto Machinery Electric Brushless Dc Motor

Brushless and brushed motors both serve the same purpose. They transform alternating current into rotating motion.


Brushed motors have been available for almost a century, but brushless motors first appeared in the 1960s, when solid-state electronics enabled their creation. Brushless motors were not widely used in tools and electronics until the 1980s. Both styles are now used all over the world for a variety of purposes.

Mechanical vs Electronic Function

The comparison between a brushed vs brushless motor varies primarily because brushed motors are mechanically operated, whereas brushless motors are electronically powered.


The stator (stationary part) of brushed motors comprises permanent magnets, whereas the rotor (moving part) contains electromagnets. Moreover, the electric voltage is transferred to the commutator in the rotor by carbon brushes in direct contact with it.


This voltage produces an electromagnetic field within the rotor. The commutator is utilized to consistently reverse the polarity of the magnetic attraction to generate a spinning motion. Also, the design is uncomplicated. However, there are some disadvantages:


  • Lower efficiency
  • Hotter
  • Life expectancy is decreasing
  • More upkeep is required

Brushless motors enable the rotational movement of various objects. The stator generates the electromagnetic field, whereas the rotor houses the permanent magnets. Also, the motor’s coils are driven sequentially by an electronic controller, which creates a variable current in three phases, as opposed to the use of brushes.


This procedure generates a rotating magnetic field in the stator, which drives the rotation of the rotor’s magnets. A few disadvantages are associated with the brushless design as well:


  • An electronic controller is required
  • Greater cost
  • More difficult to operate
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Advantages and Disadvantages of Brushed and Brushless Motors

There are several reasons why you would prefer a brushed vs brushless motor, depending on your application.

Acoustic Noise

You can start the battle by comparing the brushed vs brushless motor in their acoustic noise. Brushed motors are “hard switched,” which means that current is abruptly transferred from one winding to another.


The torque produced fluctuates with the rotation of the rotor when the windings are turned on and off. It is feasible to control the winding currents of a brushless motor so that the current smoothly transitions from one winding to another.


Torque ripple, a mechanical energy pulsing onto the rotor, is reduced. Vibration and mechanical noise are caused by torque ripple, particularly at low rotor speeds.


The inclusion of more advanced electronic components in brushless motors results in a greater overall expenditure for brushless drives compared to brush motors. Due to the absence of brushes and a commutator, brushless motors are simpler to manufacture than brushed motors, even though brushed motor technology is relatively mature and production costs are low.


As brushless motors acquire popularity, this characteristic is evolving, especially in high-volume applications like automotive motors. Moreover, the decreasing cost of electronic components, including microcontrollers, further enhances the attractiveness of brushless motors.

Electrical Noise

Brushes and commutators combine to make a type of electrical switch. As the motor rotates, the switches open and close, and considerable current flows through the inductive rotor windings. This process causes arcing at the contacts.


Also, this movement produces a lot of electrical noise, which can get into sensitive circuits. Arcing can be reduced by connecting capacitors or RC snubbers across the brushes, but the commutator’s fast switching always causes some electrical noise.


As stated previously, one disadvantage of brushed motors is the mechanical deterioration of the brushes and commutator. Particularly sacrificial are carbon brushes, which are intended to be replaced frequently as part of the maintenance program for many motors.


Additionally, the brushes erode the commutator’s malleable copper over time, ultimately resulting in the motor ceasing operation. Brushless motors do not experience this degradation due to the absence of moving contacts.

Speed and Acceleration

Lastly, the comparison between the brushed vs brushless motor can also be seen in their speed and acceleration. The bulk of the rotor, the commutator, and the brushes may constrain brushed motor rotational speed. At high velocities, brush-to-commutator contact can err, and brush arcing becomes more pronounced.


A laminated iron core in the rotor of the majority of brushed motors provides them with a high rotational inertia. This characteristic limits the acceleration and deceleration rates of the motor. To reduce rotational inertia, brushless motors may be constructed with extremely potent rare earth magnets affixed to the rotor. This process increases the cost.

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Make the Right Choice

The debate between the brushed vs brushless motor has many factors to consider. Numerous critical variables, including the operational needs of the application, financial limits, and long-term maintenance considerations, determine the suitable motor type.


Brushed motors are a useful and cost-effective choice for simpler, cost-sensitive applications with less demanding performance requirements. Brushless motors, despite their somewhat larger initial investment, emerge as the preferred choice for complicated, high-precision activities that require enhanced efficiency, durability, and precise control.


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Are brushed motors superior to brushless motors?

What is A Brushless Motor

Brushed motors are simple and cost-effective for less demanding applications, whereas brushless motors are more efficient, durable, and precise, making them vital for high-performance activities in key industries.


The superiority of any motor type is determined by the intended application’s specific operating needs, performance expectations, and budget limits.

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Do brushless motors outlast brushed motors?

Brushless motors have a longer lifespan than brushed motors because the lack of actual brushes lowers wear and tear, enhancing durability and longevity.

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Why are brushed motors preferable?

Because of their simplicity, cost-effectiveness, and ease of maintenance, brushed motors are commonly used when complex control and great precision are not required. They are widely used in consumer electronics, power tools, and automotive applications where their adequate performance satisfies the needs of everyday chores at a reasonable cost.

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What are the advantages of a brushed vs brushless motor?

Brushed motors are more appropriate for applications where advanced control and precision are not required, such as consumer electronics, power tools, and automotive. Brushless motors, on the other hand, provide benefits such as increased efficiency, durability, and precise control.


These DC servo motor features make them necessary for high-performance activities in critical industries such as robotics, aircraft, and electric cars. Their outstanding performance in demanding applications is due to their streamlined design, decreased wear and tear, and little electromagnetic interference.

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