Differences between Ordinary DC Brushed Motors and DC Brushless Motors: Technological Innovation Leading the Future

In today's rapidly developing era of science and technology, as the core power components of numerous devices, the performance of motors directly affects the operation efficiency and service life of these devices. Among the various types of motors, the differences between ordinary DC brushed motors and DC brushless motors are particularly remarkable. Dongguan Tern Power Technology Co., Ltd., with its cutting-edge research and breakthroughs in the field of brushless DC motors, is leading the technological innovation in this field.

First，structural Differences: The Transformation from Tradition to Innovation The structure of ordinary DC brushed motors is relatively simple, mainly consisting of a stator, a rotor, brushes, and a commutator. The contact between the brushes and the commutator allows the current to be conducted to the rotor, thus enabling the motor to operate. However, this structure also brings about many problems. The mechanical friction between the brushes and the commutator will lead to brush wear. Not only does it require regular brush replacement, increasing the maintenance cost, but also when the motor is running at high speed, the friction will generate sparks, posing a safety hazard. At the same time, it will also reduce the operation efficiency of the motor. In contrast, the DC brushless motors that Dongguan Tern Power Technology Co., Ltd. focuses on adopt a more advanced structural design. It eliminates the brushes and the commutator, and realizes the conduction of the current through electronic commutation technology. This design not only eliminates the problem of brush wear, greatly reducing the maintenance cost, but also improves the operation efficiency and reliability of the motor. The rotor of a brushless DC motor usually uses a permanent magnet, and the stator is composed of windings. Under the precise control of the electronic controller, the current flows into the windings in a specific order, generating a rotating magnetic field to drive the rotor to rotate. This contactless current conduction method makes the motor run more smoothly and quietly, and is not limited by mechanical friction, enabling higher rotation speeds and more precise speed control.

Second，performance Comparison: A Model of High Efficiency, Energy Conservation, and Precise Control In terms of performance, the differences between ordinary DC brushed motors and DC brushless motors are even more obvious. Due to the friction between the brushes and the commutator, brushed motors have relatively large energy losses and lower efficiency, usually around 70% - 80%. Moreover, as the rotation speed of the motor increases, the friction loss will further increase, resulting in a more significant decrease in efficiency. In addition, the speed regulation performance of brushed motors is also limited to a certain extent. Although speed regulation can be achieved by changing the armature voltage or the exciting current, within a wide speed regulation range, the speed regulation accuracy and stability are poor, making it difficult to meet the requirements of some high-precision devices. The DC brushless motors produced by Dongguan Tern Power Technology Co., Ltd., however, have achieved a qualitative leap in performance. The efficiency of brushless DC motors generally can reach 85% - 90% or even higher. This means that with the same input power, brushless motors can output more mechanical energy, thus achieving higher work efficiency and energy-saving effects. For some devices that need to run for a long time, this can not only reduce energy consumption but also cut down on operating costs. In terms of speed regulation performance, brushless motors, with the help of advanced electronic control systems, can achieve wide-range and high-precision speed regulation. Whether running at a low speed or a high speed, they can maintain a stable rotation speed and torque output, meeting the needs under various complex working conditions. For example, in some precision medical devices, industrial automation equipment, and the aerospace field, the precise control ability of brushless motors can ensure the efficient and stable operation of the devices, providing reliable power support for these high-end devices.

Third，application Fields: Expansion from Traditional Industries to High-end Technologies Due to the limitations of their structure and performance, ordinary DC brushed motors are mainly applied in some traditional industrial fields where the requirements for motor performance are not high and cost is a sensitive factor, such as simple household appliances and small electric tools. These devices have relatively low requirements for the rotation speed, accuracy, and reliability of the motor, and brushed motors can meet the basic usage needs. However, with the continuous progress of science and technology, more and more industries have put forward higher requirements for motor performance. The DC brushless motors of Dongguan Tern Power Technology Co., Ltd., with their excellent performance, have gradually emerged in various high-end application fields. In the new energy vehicle field, as the core component of the power system, brushless motors can provide efficient and powerful power output, while having good acceleration performance and battery life, providing strong support for the development of new energy vehicles. In the field of drones, the high efficiency, high rotation speed, and lightweight characteristics of brushless motors enable drones to achieve longer flight times, higher flight speeds, and more stable flight postures, greatly expanding the application range of drones. In addition, in fields such as robots, aerospace, and high-end medical devices, brushless motors have also become the preferred power solution due to their advantages such as precise control, high reliability, and long service life. 

Dongguan Tern Power Technology Co., Ltd.: The Leader in Brushless Motor Technology In the promising field of DC brushless motors, Dongguan Tern Power Technology Co., Ltd., with its profound technical accumulation and innovative spirit, has become a leading enterprise in the industry. The company is located in Changping Town, Dongguan City, which is known as the manufacturing capital. Here, there are numerous excellent manufacturing enterprises, with a complete industrial chain and rich industrial resources. Relying on its advantageous geographical location, Tern Power Technology Co., Ltd. can quickly integrate various resources and achieve efficient transformation from research and development to production. The company focuses on cutting-edge research and breakthroughs in brushless DC motor technology and has an excellent technology-oriented team. They keep up with the international advanced technological trends, constantly explore and innovate, and are committed to providing customers with high-performance and high-quality brushless motor products. The company relies on advanced manufacturing equipment and testing equipment to ensure that every product production process meets strict quality standards. With mature manufacturing processes and rich manufacturing experience, the company has reached the leading level in the production and manufacturing of brushless motors in the industry. Whether it is OEM (Original Equipment Manufacturer) or ODM (Original Design Manufacturer) according to customers' customized requirements, Tern Power Technology Co., Ltd. can meet various needs of customers with its strong technical strength and flexible production mode. Solving customers' pain points is the unremitting pursuit of Tern Power Technology Co., Ltd. The company serves every customer attentively, deeply understands customers' needs and pain points, and provides the most suitable solutions for customers through technological innovation and product optimization. Whether in terms of product performance improvement, cost control, or after-sales service, the company strives for perfection and has won high recognition from customers and the market. Its products are sold all over the world and have become the preferred partner of many high-end equipment manufacturers.

With the continuous development of science and technology, motor technology will also face more opportunities and challenges. Dongguan Tern Power Technology Co., Ltd. will continue to adhere to technological innovation as the core, continuously increase research and development investment, and deepen the research and development of brushless DC motor technology. The company will be committed to exploring more efficient, energy-saving, and intelligent motor solutions and contributing to the development of the motor industry. In the future, the application fields of brushless motors will be further expanded. From traditional industrial manufacturing to emerging intelligent technologies, from civil devices to high-end military equipment, brushless motors will play an important role in all these areas. Dongguan Tern Power Technology Co., Ltd. will keep up with the trend of the times, actively expand its business areas, and cooperate with customers around the world to jointly create a bright future for brushless motor technology.