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Nightmare flaunts its big ol’ brushed motorĪ word of caution regarding budget friendly hobby motor ratings: Or, you could just be one of those gutsy competitors who leaves it all hanging out. In combat robots with a fixed weight budget, the size reduction also leverages additional weight savings because less armor required to protect the motor. These factors compound such that a brushless motor can typically do the same job as a brushed motor in half the weight.Ĭomparison of Perm 132 brushed motor and TP100 brushless motor: It’s even easier to dispose of the waste heat because a brushless motor has the heat generating windings on the outside where it can be directly synced to the environment, whereas a brushed motor’s heat path has to travel through magnets. Motor efficiency is also improved by being able to dynamically adjust when the phases are energized (motor timing) for optimum performance which results in less waste heat. Without the brushes, heating comes primarily from winding resistance I2R losses (milliohms), oversaturating the iron stator with magnetic flux at extremely high winding currents, and parasitic eddy current losses generated from spinning fast. The only real limits are those set by thermal factors (magnet wire insulation burns, magnets demagnetize) or mechanical factors (magnets flung into oblivion from spinning at 50,000rpm, which isn’t an uncommon speed). One of the main benefits of eliminating brushes is that it allows the motor to handle more peak current and spin much faster. The elimination of mechanical brushes, which are often the weak link in a motor, has a number of benefits:ġ.) Brush housing assemblies are mechanically complex and prone to fail from big shock loads.Ģ.) Brushes are made from soft carbon alloys which wear out and need to be replaced on a regular basis.ģ.) Spring loaded brushes bounce in big impacts which can cause arcing.Ĥ.) Brushes arc when transitioning between commutator bars which limits their operating speed.ĥ.) Extra electrical resistance from the carbon brushes and friction from sliding contact increases heat buildup and lowers motor efficiency. In order to know when to pulse each winding, most motor controllers measure the voltage generated by the magnet spinning across the windings to determine the magnet’s position. As the copper windings spin in the motor, the commutator directs current to different windings.Ī brushless motor does away with the brushes and instead has its windings electronically pulsed. In a brushed motor, this is done mechanically using spring loaded brushes rubbing against a spinning “commutator”. In order to achieve continuous rotation or “commutation”, the wire coils have to be turned on and off in a precise sequence.
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Let’s take a closer look at the differences in these motors, their merits, as well as some rules of thumb on selecting the right motor for the job.īrushed and brushless motors both belong to the category of “permanent magnet direct current” motors where coils of wire attract and repel against magnets.