Both designs generate torque from the interaction of current and magnetic field. The difference lies in how current reaches the rotating windings, or how the rotating field is produced.
Design and operating principle
| Feature | Brushed motor | Brushless motor |
|---|---|---|
| Magnets | In the housing (stator), armature rotates inside | On the rotor, windings in the stator |
| Current transfer | Mechanical, via carbon brushes and commutator | Electronic, no sliding contact |
| Control | Can run directly on DC voltage | Requires electronic commutation |
| Wear parts | Carbon brushes, commutator | No mechanical contacts in the drive |
Efficiency, maintenance and robustness
Because the brushless motor has no mechanical sliding contact, it typically achieves higher efficiency with lower maintenance, since no carbon brushes wear out and no commutator needs cleaning. The brushed motor, in turn, needs no electronic commutation and can run directly on DC voltage, which simplifies control and replacement. In practice, brushed motors also offer significant overload capacity and start reliably even after long idle periods - a property valued for switching and drive tasks in power distribution.
Which motor type suits which application?
Brushed motors have a decades-long track record in robust industrial drives with high starting torque and occasional, reliable duty - for example in rail, marine, compressor and construction machinery applications. Brushless motors excel where high efficiency, long maintenance-free life, or a dust- or spark-critical environment matter most. JoMo develops and manufactures customer-specific brushed motors, tailored to the load, duty type and installation situation of your application.
Which information helps with the decision?
- Duty type and cyclic duration factor
- Environmental conditions (dust, humidity, cleanroom, temperature)
- Maintenance interval and accessibility requirements
- Control and starting behaviour of the application
- Existing drive electronics or control interface
Frequently asked questions
What is the basic difference between a brushed and a brushless motor?
In a brushed motor, permanent magnets sit in the housing and the armature rotates inside; carbon brushes mechanically transfer current to the commutator. In a brushless motor, magnets sit on the rotor and windings in the stator, and commutation happens electronically with no sliding contact.
Which motor type needs less maintenance?
The brushless motor, since there are no carbon brushes to wear out. Brushed motors require regular inspection of brushes and commutator as part of routine maintenance.
Why are brushed motors still used in industry?
Brushed motors offer significant overload capacity and start reliably even after long idle periods - valuable for switching and drive tasks in rail, marine and construction machinery applications.
When does a brushless motor make more sense?
When high efficiency, low maintenance, or a dust- and spark-free environment - such as cleanrooms or optical applications - are the priority.
Sources (selection): konstruktionspraxis.vogel.de, industrieanzeiger.industrie.de.
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