In part 3, we will explore the structural differences and rotation principles of brushless motors, comparing them with brushed DC motors and AC motors.
Brushless Motor Structure and Rotation Principles
Brushless motors maintain the excellent controllability of DC motors but replace the brushes and commutator with electronic components. This makes them more reliable and efficient, especially in high-speed or high-precision applications.

Brushless Motor Structure

The rotor contains permanent magnets, while the stator houses windings. This is the opposite of the structure found in traditional brushed DC motors. Instead of using physical brushes to transfer current, brushless motors rely on magnetic pole sensors (such as Hall effect sensors) to detect the position of the rotor's magnetic poles. These signals are then used by a drive circuit to control the flow of current through the stator windings, creating a rotating magnetic field that drives the motor.

Brushless Motor Rotation Principles

To understand how brushless motors operate, let’s consider a simplified three-phase, two-pole model. The rotor has north and south poles spaced 180° apart, and the stator windings are arranged 120° apart. Magnetic pole sensors detect the position of the rotor and send signals to the drive circuit, which controls the current flow in the stator coils accordingly. When current flows through a phase coil, it generates a magnetic pole on the inner diameter of the stator. By switching the current between different coils in a specific sequence, a rotating magnetic field is created, causing the rotor to turn.

Brushless Motor Characteristics

Brushless motors have similar speed-torque characteristics to brushed DC motors, but they offer better efficiency and longer life due to the absence of mechanical wear from brushes. However, they require precise control and can be affected by factors like demagnetization if overcurrent occurs. This is why drive circuits often limit maximum current and speed to ensure safe operation.

Brushless Motor Features

Compared to brushed DC motors, brushless motors have no brushes, eliminating maintenance needs and reducing noise. They also offer higher speed accuracy and better reliability. Compared to AC motors, they are more compact, efficient, and can operate on DC power. Brushless motors are widely used in industrial, automotive, and consumer electronics due to their performance and durability. If you're interested in learning more about brushless motor systems, check out our resources or contact us for further details.

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