What is the difference between a brushed and brushless motor？

Brushless and brushed motors have the same fundamental purpose of converting electric current into rotational motion.

Brushed motors have been around for over a century, while brushless motors emerged in the 1960s with the development of solid-state electronics that enabled their design. However, it was not until the 1980s that brushless motors began to gain wider acceptance in various tools and electronics. Nowadays, both brushed and brushless motors are utilized globally for countless applications.

Mechanical Comparation

A brushed motor operates by using carbon brushes in contact with the commutator to transfer electric voltage to the rotor, which contains electromagnets. The voltage in turn generates an electromagnetic field in the rotor, resulting in rotational motion as a result of continually flipping the polarity of the magnetic pull. 

However, the structure is simple, but there are some disadvantages:

1. Limited lifespan: Brushed motors have a relatively shorter lifespan due to the wear and tear of the brushes and commutator.

2 Lower efficiency: Brushed motors have lower efficiency compared to brushless motors. The brushes and commutator cause energy loss and electrical current losses, resulting in higher heat generation.

3. Speed limitations: Due to the physical structure of brushes and commutators, brushed motors have limitations on high-speed applications. Friction between the brushes and commutator restricts the maximum speed capabilities of brushed motors, limiting their use and performance in certain applications.

A brushless motor is an electrical vibration motor that operates without the use of brushes and a commutator. Instead, it relies on electronic controllers and sensors to regulate the power sent to the motor's windings directly.

There are a few disadvantages of the brushless design:

1. Higher cost: Brushless motors are generally more expensive than brushed motors due to their more complex design and control system.

2. Electronic complexity: Brushless motors involve complex electronic control systems that require specialized knowledge for repair and maintenance.

3. Limited torque at low speeds: Brushless motors may have lower torque at low compared to brushed motors. This can limit their suitability for certain applications that require a high amount of torque at low speeds.

Which Is Better: Brushed or Brushless?

Both brushed and brushless motor designs have their benefits. Brushed motors are more affordable due to their mass production.

In addition to price, brushed motors have their own advantages that are worth considering:

1.  Simplicity: Brushed motors have a simpler design, making them easier to understand and work with.  This simplicity can also make them easier to repair if any issues arise.

2.  Wide availability: Brushed motors have been around for a long time and are widely available in the market.  This means that finding replacements or spare parts for repairs is usually easier.

3.  Easy speed control: Brushed motors have a simple control mechanism that allows for easy speed control.  Adjusting the voltage or using simple electronics can manipulate the speed of the motor.

In cases where greater control is necessary, a brushless motor may prove to be the superior choice for your application.

The advantages of brushless are:

1.  Greater efficiency: Brushless motors have no commutators that can cause friction and energy loss, resulting in improved energy conversion and less wasted heat.

2. Longer lifespan: Since Brushless motors don't have brushes that wear down over time to increase durability and longevity.

3.  Higher power-to-weight ratio: Brushless motors have a higher power-to-weight ratio. It means they can deliver more power for their size and weight.  

4.  Quieter operation: Brushless motors don't produce the level of electrical noise and mechanical vibrations. This makes them suitable for applications that require low noise levels, such as medical equipment or recording devices.