Brushed vs Brushless – What’s The Deal?

There is a lot of marketing hoopla (dare we say propoganda?) out there these days about the virtues of brushless motors in power tools so I thought it was about time I put something together on the differences and benefits of each motor type used.

How Do Brushed Motors Work

Warning sciency content – Brushed motors are the traditional motor type and are made up of four major parts. These parts are a commutator and armature which both rotate together and magnets and carbon brushes which remain stationary. Power runs through the carbon brushes to the commutator and on to the armature magnetising it in the process and causing it to repel against the stationary magnet and spin making your drill bit go round.

How Do Brushless Motors Work?

Warning a bit more sciency content – Brushless motors as the name suggest do away with the carbon brushes and also the commutator. They differ in that the magnets and copper windings that drive the armature are reversed. The magnets are mounted to the armature and the wire bundles that are charged surround them. The commutator is replaced by electronics controlling the power delivery of the tool.

What’s Better – Brushed or Brushless?

‘Sweet’ you say less parts, less to go wrong right? Yep you are correct but there is more to it than that, lets have a quick look at the pros and cons of each system

Brushless Motors

Pros less moving parts = less to break no carbon brushes to replace longer runtime as there are less moving parts and greater control of the power delivery from the battery Higher motor power when compared to a similar brushed motor runnig the same battery system Cooler tool operation as there is less friction in the motor assembly

Cons Higher cost to manufacture means higher purchase prices Motor assemblies can be heavier and change the weight and balance characteristics of the tool

Brushed Motors

Pros Cheaper to manufacture in comparison to brushless tools Easier to repair as there is less electronic circuitry

Cons Carbon brushes need replacing when worn Generate more heat when running less ‘grunt’ less battery runtime

Looking at the above it is easy to see then benefit of the brushless motor and you may suspect that all the new cordless power tools on the market will come out with brushless motors. Well, not exactly yet. The price barrier is the main issue as these brushless motors and associated electronics are much dearer to manufacture. You will see brushless drills and brushless impact drivers but the less popular tools will remain brushed for some time to come.

But Which One Should I Buy?

The general guideline is pretty simple. If you’re a tradie and you use the tool most of the day no question get the brushless impact driver or brushless drill. You’ll get longer battery life and better performance and be able to show it off at site and get maximum kudos.

If you’re a tradie but you don’t use the tool regularly then make the call based on how much you’re willing to spend. if you can afford the brushless and like having the best toys – buy it. If not get the brushed cordless and save some coin for the boys weekend coming up.

If you’re a DIY’er I’d recommend the brushed cordless rather than the brushless unless you really like having the best toys to show off in the man cave.

Check out our range of quality brushed and brushless powertools at Direct2Trade from quality manufacturers Dewalt and Hitachi 

Cheers
Liam @ Direct2Trade