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WhatsTheDifferenceBetweenBrushDCAndBrushlessDC
Motors?
ElectronicDesign
MatDirjish
MatDirjish
Thu,2012021600:17
Themotorandmotorcontrolmarketsarethrivinginanumberofareas,particularlymedicalandrobotic
applications.Also,thereisarichdemandforsmall,efficient,highandlowtorque,andhighandlowpower
motorsintheautomotivesector.
Theseapplicationscanchoosefrombrushdcmotors,brushlessdc(BLDC)motors,oracombinationof
both.MostmotorsoperateinaccordancewithFaradayslawofinduction(seehere).Still,therearekey
differencesbetweenthesemotorsandintheemploymentopportunitiesthatawaitthem.
TableofContents
1. BrushDCMotors
2. BrushlessDCMotors
3. ToBrush
4. OrNotToBrush
5. TheChoiceLiesInOurApps
6. References
BrushDCMotors
Aroundsincethelate1800s,dcbrushmotorsareoneofthesimplesttypesofmotors.Sansthedcsupplyor
batteryrequiredforoperation,atypicalbrushdcmotorconsistsofanarmature(a.k.a.,rotor),a
commutator,brushes,anaxle,andafieldmagnet(Fig.1)(seeBrushedDCMotorFundamentals).
1.Simpleinconstruction,ageneralpurposedcbrushmotorincludesanarmatureorrotor,acommutator,brushes,anaxle,andafield
magnet.Naturally,abatteryorpowersupplyisrequired.
Related
OptionsEnhancePopularDCMotors
InterfaceCircuitAllowsUsersToControlDCMotor'sSpeed
DCMotorsComeWithPlanetaryGearboxes
MotorDriver/ControllerLineExpands
Themotorspropertiesaredeterminedbythematerialitsmadeof,thenumberofcoilswoundaroundit,
andthedensityofthecoils.Thearmatureorrotorisanelectromagnet,andthefieldmagnetisapermanent
magnet.Thecommutatorisasplitringdevicewrappedaroundtheaxelthatphysicallycontactsthebrushes,
whichareconnectedtooppositepolesofthepowersource(Fig.2).
2.Asplitringwrappingaroundtheaxle,thecommutatormakesphysicalcontactwiththebrushes,whichconnecttooppositepolesofa
powersourcetodeliverpositiveandnegativechargestothecommutator.
Thebrusheschargethecommutatorinverselyinpolaritytothepermanentmagnet,inturncausingthe
armaturetorotate.Therotationsdirection,clockwiseand/orcounterclockwise,canbereversedeasilyby
reversingthepolarityofthebrushes,i.e.,reversingtheleadsonthebattery.
BrushlessDCMotors
Intermsofdifferences,thenameisadeadgiveaway.BLDCmotorslackbrushes.Buttheirdesign
differencesarebitmoresophisticated(seeBrushlessDC(BLDC)MotorFundamentals).ABLDCmotor
mountsitspermanentmagnets,usuallyfourormore,aroundtheperimeteroftherotorinacrosspattern
(Fig.3).
3.Viewedfromthetop,thisbrushlessdc(BLDC)motoremploysfourpermanentmagnetsmountedtothetopofitsrotor,eliminating
theneedforconnections,acommutator,andbrushes.
EfficiencyisaprimarysellingfeatureforBLDCmotors.Becausetherotoristhesolebearerofthemagnets,
itrequiresnopower,i.e.,noconnections,nocommutator,andnobrushes.Inplaceofthese,themotor
employscontrolcircuitry.Todetectwheretherotorisatcertaintimes,BLDCmotorsemploy,alongwith
controllers,rotaryencodersoraHallsensor(seeBrushlessDCMotorControlMadeEasy).
BLDCmotorsaresynchronousmotors,whichmeanstheirrotorsandstatorsturnatthesamefrequency.
Theycomeinsingle,dual,andtriphaseconfigurations(seeBrushlessDC(BLDC)Motor).
ToBrush
Whenitcomestoalooselydefinedrangeofbasicapplications,onecoulduseeitherabrushorbrushless
motor.Andlikeanycomparableandcompetingtechnologies,brushandbrushlessmotorshavetheirpros
andcons.
Ontheproside,brushmotorsaregenerallyinexpensiveandreliable.Theyalsooffersimpletwowire
controlandrequirefairlysimplecontrolornocontrolatallinfixedspeeddesigns.Ifthebrushesare
replaceable,thesemotorsalsoboastasomewhatextendedoperationallife.Andbecausetheyneedfew
externalcomponentsornoexternalcomponentsatall,brushmotorstendtohandleroughenvironments
reliably.
Forthedownside,brushmotorsrequireperiodicmaintenanceasbrushesmustbecleanedandreplacedfor
continuedoperation,rulingthemoutforcriticalmedicaldesigns.Also,ifhightorqueisrequired,brush
motorsfallabitflat.Asspeedincreases,brushfrictionincreasesandviabletorquedecreases.
However,torquemaynotbeanissueinsomeapplicationsandcouldactuallybedesirable.Forexample,
electrictoothbrushesrequirehigherspeedswithdecreasingtorque,whichisgoodforthebrushandyour
teethandgums.
Otherdisadvantagesofbrushdcmotorsincludeinadequateheatdissipationcausedbytherotorlimitations,
highrotorinertia,lowspeedrangeduetolimitationsimposedbythebrushes,andelectromagnetic
interference(EMI)generatedbybrusharcing.
OrNotToBrush
BLDCmotorshaveanumberofadvantagesovertheirbrushbrothers.Forone,theyremoreaccuratein
positioningapps,relyingonHalleffectpositionsensorsforcommutation.Theyalsorequirelessand
sometimesnomaintenanceduetothelackofbrushes.
Theybeatbrushmotorsinthespeed/torquetradeoffwiththeirabilitytomaintainorincreasetorqueat
variousspeeds.Importantly,theresnopowerlossacrossbrushes,makingthecomponentssignificantly
moreefficient.OtherBLDCprosincludehighoutputpower,smallsize,betterheatdissipation,higherspeed
ranges,andlownoise(mechanicalandelectrical)operation.
Nothingisperfect,though.BLDCmotorshaveahighercostofconstruction.Theyalsorequirecontrol
strategiesthatcanbebothcomplexandexpensive.And,theyrequireacontrollerthatcancostalmostas
muchasifnotmorethantheBLDCmotoritgoverns.
TheChoiceLiesInOurApps
Thebottomlinesformakingachoicebetweencomponentsofanytypearethetypeofapplicationandthe
costcutofffortheendproduct.Forinstance,atoyrobottargetingthesixtoeightyearoldmarketmay
requirefourtoninemotors.Theycanallbebrushorbrushlessdccomponentsoramixtureofboth.
Ifthisrobotonlyperformsbasicmovementsorispartofanintroductorykit,theresnoneedtogowith
longlifeBLDCsthatcostmorethanbrushedcounterparts.Thetoyorkitwillprobablyendupinthe
recyclingbinwellbeforethebrushmotorshaveburnedout.
Typicalbrusheddcmotorapplicationsincludemotorizedtoys,appliances,andcomputerperipherals.Auto
makersenlistthemforpowerwindows,seats,andotherincabindesignsbecauseoftheirlowcostand
simpledesign.
BLDCmotorsaremoreversatile,mainlybecauseoftheirsavvyinthespeedandtorquedepartments.They
alsocomeincompactpackages,makingthemviableforavarietyofcompactdesigns.Typicalappsinclude
computerharddrives,mechanicalbasedmediaplayers,electroniccomponentcoolingfans,cordlesspower
tools,HVACandrefrigeration,industrialandmanufacturingsystems,anddirectdriveturntables.
TheautomotiveindustryalsoputshigherpowerBLDCmotorstoworkinelectricandhybridvehicles.These
motorsareessentiallyacsynchronousmotorswithpermanentmagnetrotors.Otheruniqueusesinclude
electricbicycleswheremotorsfitinthewheelsorhubcaps,industrialpositioningandactuation,assembly
robots,andlinearactuatorsforvalvecontrol.
References
1. FaradaysLaw
2. MichaelFaraday(17911867)
3. ZnobeThophileGramme
4. Condit,Reston,BrushedDCMotorFundamentals
5. Yedamale,Padmaraja,BrushlessDC(BLDC)MotorFundamentals
6. Brown,Ward,BrushlessDCMotorControlMadeEasy
7. BrushlessDC(BLDC)Motor
SourceURL:http://electronicdesign.com/electromechanical/whatsdifferencebetweenbrushdcand
brushlessdcmotors