DC Brushless Motor 57BLF02

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Brushed DC motors have been in use since 1879, but did not become commercially viable until 1962.[1][citation needed]

Brushed DC motors develop a maximum torque when stationary, linearly decreasing as velocity increases.[2] Some limitations of brushed motors can be overcome by brushless motors; they include higher efficiency and a lower susceptibility to mechanical wear. These benefits come at the cost of potentially less rugged, more complex, and more expensive control electronics.

Brushless motors offer several advantages over brushed DC motors, including high torque to weight ratio, more torque per watt (increased efficiency), increased reliability, reduced noise, longer lifetime (no brush and commutator erosion), elimination of ionizing sparks from the commutator, and overall reduction of electromagnetic interference (EMI). With no windings on the rotor, they are not subjected to centrifugal forces, and because the windings are supported by the housing, they can be cooled by conduction, requiring no airflow inside the motor for cooling. This in turn means that the motor's internals can be entirely enclosed and protected from dirt or other foreign matter.

Brushless motor commutation can be implemented in software using a microcontroller or microprocessor computer, or may alternatively be implemented in analogue hardware, or in digital firmware using an FPGA. Commutation with electronics instead of brushes allows for greater flexibility and capabilities not available with brushed DC motors, including speed limiting, "micro stepped" operation for slow and/or fine motion control, and a holding torque when stationary.

The maximum power that can be applied to a brushless motor is limited almost exclusively by heat;[citation needed] too much heat weakens the magnets[3] and may damage the winding's insulation.


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