Brushless power tools are bringing innovative technology to the world of power tools.
You may have heard of power tools that now come with brushless motors. You can learn what all the fuss is about. Brushless motors have been around for over 50 years in industrial and manufacturing conveyor belt motors. It wasn’t until the 2000s that power tool manufacturers began producing brushless power tools. In 2009, Makita released a brushless three-speed impact driver. Other top-quality power tool brands such as DeWalt and Milwaukee also have lines of brushless power tools.
Brushed motors consist of four main parts: an armature, a commutator, magnets and carbon brushes. The armature is a copper component which carries the main electrical current. The commutator is attached to the armature. It’s used to reverse the direction of the electric current. A commutator makes a direct current.
As the motor becomes energized, an electrical current goes through the brushes. Brushes carry the current between stationary and moving parts in the motor. The brushes make contact with the commutator, delivering the current to the copper armature. These components power the tool in use.
Brushed motors are typically more reliable and fairly inexpensive. Power tools with brushed motors are also considered more durable. They don’t need any external components. If you have a tool with replaceable brushes, you can increase the lifespan of the motor. However, there are some cons for brushed power tools. As you use more speed, the brushes create more friction, decreasing the amount of torque you can produce.
Brushless motors don’t have brushes or a commutator. The magnet is on the conventional motor shaft, while the copper armature is around the shaft. The magnet is on the outside of brushed motors. For a brushless motor, the magnets are on the inside. A small circuit board takes the place of the commutator and brushes, directing the energy to the copper windings of the armature.
Brushless power tools and their motors have many advantages. The lack of brushes causes less friction, saving energy. This creates a longer life for the motor, making it efficient and cost-effective. This also gives the motor more power. The brushless motor does not require airflow to cool down; it’s cooled by conduction. This means the motor can be fully encased in the power tool, and protected from harmful debris, such as dirt. Brushless motors are also less noisy than brushed motors. They also produce more torque per weight, and per watt.
Brushless power tools are more expensive than power tools with brushed motors. However, their power and long motor life can be worth the cost.