Brushless Motor
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Brushless motor operation: efficiency and precision supporting Industry 4.0
The brushless motor, literally “motor without brushes,” is an electric motor that includes a permanent magnet rotor. Unlike a brushed motor, it does not require sliding electrical contacts, or brushes, on the rotor shaft to operate.
Brushless motor: what it means
Brushless motor literally means a motor without brushes. It refers to a direct current (BLDCM, Brushless Direct Current Motor) electric motor with a permanent magnet rotor. The brushless motor therefore uses electronic commutation. The commutation of the current flowing in the stator windings: the variation of the orientation of the magnetic field they generate occurs electronically. This results in lower mechanical resistance, reduced likelihood of spark formation, and also reduced need for periodic maintenance.
In a brushless motor, the permanent magnets are positioned on the rotor and are made with special materials. This allows for very low rotor inertia and high dynamic response with extremely precise speed control. Furthermore, brushless motors, being synchronous, can reverse their direction of rotation in just a few tenths of a second.
The brushless motor is ideal for performing the following tasks:
meeting energy efficiency requirements;
improving the performance of applications using asynchronous motors;
more stably controlling speed.
Brushless motor: where it is used
The brushless motor is dominating the global electric motor market. They are integrated into many different contexts because they can be designed for the most varied applications. Their energy efficiency exceeds 96%, which is why they have earned the nickname “green motors.” The brushless electric motor is widely used in industrial settings because it is employed in automatic machines that require precise and fast movements with compact and versatile dimensions. For example, due to limited energy consumption and small size, it is indispensable in professional battery-powered devices, such as screwdrivers, drills, or angle grinders.
A very popular sector today that relies heavily on brushless motors is the production of electric and hybrid cars. Another important sector for brushless technology is in the production of washing machines and air conditioners.
How a brushless motor is powered
In a brushless motor, the field produced by the rotor permanent magnets is rotating, and the rotating field produced by the currents flowing in the three stator windings is maintained, on average, at 90 electrical degrees from the action of the control on the inverter that powers the motor.
Therefore, to achieve this result, the stator windings are powered by an inverter or servo drive: the solid-state switches within it are commutated by a control system based on the logical signals provided by a position sensor. In this way, the distribution of stator currents changes along with the rotor's position. Thus, the rotating stator magnetic field is 90 electrical degrees ahead of the rotor's in any operating condition.
The main advantages of brushless motors
The brushless motor, or motor without brushes, offers a series of competitive advantages. Here are some:
reduced malfunctions; generally, brushes are the most wear-prone element in single-phase brushed motors, and the brushless motor significantly extends their lifespan;
quieter operation; brushes, by rubbing against rotating elements, cause noise. The adoption of a brushless motor significantly reduces device noise during operation;
less frequent maintenance interventions; with the use of brushless motors, the device no longer contains critical parts subject to wear during operation;
increased device efficiency; the elimination of mechanical resistance allows the device to reach higher speeds and improve torque performance. Furthermore, the brushless motor consumes less current compared to brushed motors;
greater workplace safety; classic drives produce dangerous sparks for the operator, which does not happen with brushless motors, allowing their use in flammable and explosive environments.
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