A basic definition for a Brushless Motor product is an automatic machine that uses error-correction rountine to correct the motion of the Brushless Motor. The general term Brushless Motor can be applied to systems other than Brushless Motor that use a feedback mechanism such as an encoder or other feedback device to control the motion parameters. Typically when the term Brushless Motor is used it applies to a 'Brushless Motor' but this term is also used as a standard control term with the meaning of a feedback loop to position whatever the product is including a Brushless Motor item.

A Brushless Motor products are unique from other controlled motors in that it is controlled by a time-based derivative commonly referred to as the PID loop. A Brushless Motor products that are used to control position must be capable of changing the velocity of the output shaft because the time-based derivative, or the rate of change of position, is velocity.

A Brushless Motor is utilized in a variety of applications in many different industries. For example some of many applications are Automotive, CNC, Instrumentation, Aerospace, Applicances, Medical, Semiconductor, Consumer, and Packaging Equipment.

The Stator
The stator of a Brushless Motor are similar to an AC motor but the windings are different. The stator of a Brushless Motor has stacked steel laminations, and the windings are placed in the slots that are cut inside the laminations.There are three stator windings in each Brushless Motor connected in either a Delta or star configuration. Each of these windings there are multiple coils that are constructed to connect together to form a winding.There are typically a even number of polls in the Brushless Motor products. Anaheim Automation typically constructs them with six coils per Brushless Motor, which are made into a three-phase winding.

Mainly there two types of stator windings, sinusoidal and trapezoidal. The difference is made on the basis of the interconnection of the coils of the stator windings which results in a different type of back EMF the trapezoidal variant gives its back EMF in the shape of a trapezoid. Each sinusoidal variation gives its Brushless Motor a back EMF that matches with the current. The faulted also is used as the shape of the sinusoid and a trapezoid. The major difference between the two Brushless Motor products is the smoother output torque that you receive from the sinusoidal Brushless Motor than the trapezoidal Brushless Motor. The stator will winding can be wound for multiple folk voltages. This can be customized for almost any distinct applications are speed and torque requirements.

The Rotor
The rotor is constructed with permanent magnets with traditionally between two and eight poles the magnets are bonded onto the rotor core alternating north and south poles. Permanent magnet rotors are typically constructed with Ferrite magnets. For higher power density applications, rare earth magnets are being used more frequently then ferrite magnets that are less expensive but have lower flux density when compared to the rare earth magnets. The cost of rare earth magnets is also moving down. Higher power density means that the Brushless Motor can put out far more torque in a smaller volume which is helpful to manufacturers that are continuously pushed provide smaller and smaller packages.

Rare earth magnet types:
Neodymium (Nd)
Samarium Cobalt (SmCo)
The alloy of Neodymium, Ferrite, and Boron (NdFeB)

At Anaheim Automation you will see that we produce different accessories for our Brushless Motor products. The accessories that we offer include cable, driver, encoder, driver, and a connector.

Because of the Brushless Motor brake is a 24vdc system, it is perfect for any holding applications. They are offered on any Anaheim Automation Brushless Motor, and are already attached to the rear of the Brushless Motor. The Brushless Motor brakes have a low voltage design for applications that are sensitive to weak batter, brown out, or long wiring runs. When electric power is applied to the Brushless Motor brake the armature is pulled by the electromagnet force in the magnet body assembly, which overcomes the spring action. This allows the friction disc to rotate freely. When electrical power is interrupted, the electromagnetic force is removed and the pressure spring mechanically forces the armature plate to clamp the friction disc between itself and the pressure plate.

Brushless Motor cables can be made with the supplied Brushless Motor connector, or can be purchased from Anaheim Automation.

Many Brushless Motor designs today are being made with the housing less design. In this design the laminations are exposed and are sprayed with a paint to prevent the laminations from rusting. Then there are some Brushless Motor types that are still being manufactured in a housed extrusion or aluminum or steel cylindrical housing where the laminations of the stator are inserted and secured inside.

The use of Hall Sensors makes feedback when rotating the Brushless Motor stator windings that are sequentially energize. The controller needs to know the rotor position in order to understand the next winding to be energized following the correct energizing sequence. The rotor position is sensed by the Hall sensors embedded in the back end cap of the Brushless Motor housing. The Brushless Motor utilizes three Hall sensors. The separation in between them is about 60° or 120°. Hall sensors sense either the rotor magnet or external magnet placed in the back of the shaft, and sends off a signal signifying whether or not a North or South Pole passes the censors. Using each signal from the sensors, the Brushless Motor controller can easily maintain the Brushless Motor velocity. The Hall sensors are normally positioned on a PC board and fixed to the back end cap on the non-driving end of the Brushless Motor.

For low-speed applications it is recommended to use an encoder for the feedback rather than the Hall sensors. The Hall sensor counts for each revolution may only be as good as a number of polls times the quantity of Hall Sensors. The Brushless Motor controller can use this higher count to its advantage when operating the Brushless Motor. The Brushless Motor controller can more precisely control the velocity by using the additional information from the Brushless Motor. The higher the resolution on the encoder to more finely the Brushless Motor controller can control the Brushless Motor. Even though the expense is much greater for encoders when compared to Hall sensors this price can be validated as it can result in very precise control for a much lower cost than alternative technologies such as Servo motors were AC motors or synchronous motors.

The following environmental and safety considerations must absolutely be observed during all phases of operation, service and repair of a Brushless Motor system. Failing to comply with these precautions violates safety requirements of design, manufacture and designed use of the Brushless Motor and controller. Please note that even a well-built Brushless Motor products controlled and installed incorrectly, can be hazardous. Precaution must be observed by the user with respect to the load and operating environment. The customer is ultimately responsible for the proper selection, installation, and operation of the Brushless Motor system.

The atmosphere in which a Brushless Motor is used must be conducive to good standard practices of electrical/electronic equipment. Do not operate the Brushless Motor in the presence of dust, flammable gases, oil, moisture, or vapor. For outdoor use, the Brushless Motor and controller must be protected from the elements by an adequate cover, while still providing adequate air flow and cooling. Moisture can cause an electrical shock hazard and/or induce system breakdown. Due consideration should be given to the avoidance of liquids and vapors of any kind. Contact the factory should your application require specific IP ratings. It is wise to install the Brushless Motor and controller in an environment which is free from vibration, electrical noise, condensation, and shock.

In addition, it is more suitable to work with the Brushless Motor and controller system in a non-static protective atmosphere. Uncovered circuitry should always be properly guarded and/or enclosed to prevent unauthorized human contact with live circuitry. Absolutely no work should be performed while power is applied. Don't plug in or unplug the connectors when power is ON. Wait for at least 5 minutes before doing inspection work on the Brushless Motor system when turning power OFF, because even after the power is turned off, there will still be some electrical energy leftover in the capacitors of the internal circuit of the Brushless Motor controller.

Plan the installation of the Brushless Motor and controller in a system design that is free from debris, such as metal debris from drilling, cutting, welding, and tapping, or any other foreign material that could come in contact with circuitry. Failing to prevent debris from entering the Brushless Motor system can result in damage and/or shock.

The following information is intended as a standard guideline for wiring of the Anaheim Automation Brushless Motor product line. Be aware that when you route power and signal wiring on a machine or system, radiated noise from the nearby relays, transformers, and other electronic devices can be inducted into the Brushless Motor and encoder signals, input/output communications, and other sensitive low voltage signals. This can cause systems defects and communication problems.

WARNING - Dangerous voltages capable of causing injury or death, may be present in the Brushless Motor system. Use extreme caution when wiring, adjusting, testing, and handling during installation, tuning, set-up, and operation. To refrain from mechanical vibration that can lead to failure and/or loss, don't make extreme changes or adjustments to the Brushless Motor system parameters. Once the Brushless Motor is wired, do not run the Brushless Motor controller by switching On/Off the power supply directly. You will decrease the lifetime of the Brushless Motor system by aging the internal components if you frequently switch the power On/Off.

Strictly comply with the following rules:
- Follow the Wiring Diagram with each Brushless Motor
- Direct high-voltage power cables independently from low-voltage power cables.
- Segregate input power wiring and Brushless Motor power cables from control wiring and Brushless Motor feedback cables as they leave the Brushless Motor controller. Maintain this separation throughout the wire run.
- Use shielded cable for power wiring and offer a grounded 360 degree clamp termination to the enclosure wall. Enable room on the sub-panel for wire bends.
- Make all cable routes as short as possible.
NOTE: Factory made cables are recommended for use in our Brushless Motor and driver systems. These cables are purchased separately, and are designed to minimize EMI. These cables are preferred over customer-built cables to optimize system performance and to produce additional safety for the Brushless Motor system and the user.

WARNING - To avoid the possibility of electrical shock, carry out all mounting and wiring of the Brushless Motor and controller system prior to applying power. Once power is applied, connection terminals may have voltage present.

The information in the following paragraphs is a basic guideline for installation and mounting the Brushless Motor system properly. WARNING - When voltages reach dangerous levels the Brushless Motor system is capable of causing injury or death. Use extreme caution when testing, set-up, handling, adjusting during installation, and operation. It is very important that the wiring of the Brushless Motor and controller be taken into consideration upon installation and mounting.

Mounting the Brushless Motor system subpanels are installed inside the enclosure, and they must be rigid flat surface that will be free from shock, moisture, vapors, vibration, oil, or dust. Heat dissipation should also be taken into account in the design layout because the Brushless Motor and controller will produce heat during operation. To be sure not to exceed the maximum ambient temperature rating, size the enclosure. It is recommended that the Brushless Motor controller be mounted in position as to provide sufficient airflow. The Brushless Motor ought to be mounted in a stable fashion, secured tightly. NOTE: There must be a minimum of 10mm between the Brushless Motor controller and any other devices mounted in the system/electric panel or cabinet.

NOTE: in order to comply with UL and CE standards, the Brushless Motor system must be grounded in a grounded conducive enclosure offering protection as defined in standard EN 60529 (IEC 529) to IP55 such that they are not accessible to the operator or unskilled person. As with any moving part in a system, the Brushless Motor should be kept out of the reach of the operator. A NEMA 4X enclosure surpasses those standards supplying protection to IP66. To improve the bond between the power rail and the subpanel, construct your subpanel out of zinc-plated (paint-free) steel. In addition, it is strongly suggested that the Brushless Motor controller be protected against electrical noise interferences. Noise from signal wires can cause mechanical vibration and malfunctions.

The establishment of Anaheim Automation as a manufacturer of "turkey" motion control systems took place in 1966. Its' emphasis on R&D has insured the continued introduction of advanced Brushless Motor driver/controller, for instance the Brushless Motor product line. Today, Anaheim Automation ranks high among the leading manufacturers and distributor of motion control products, a position improved by its excellent reputation for quality products at competitive prices. The Brushless Motor product line is no exception to the Company's goal.

Anaheim Automation offers a wide variety of standard Brushless Motor products. Occasionally, OEM customers with mid to large quantity demands prefer to have a Brushless Motor that is custom or modified to meet their exact design requirements. Sometimes the customization for the Brushless Motor is as complex as adjustments to the speed, voltage, and/or torque. Or it can be as simple as a brake, shaft modification, wire colors, oil seal for an IP65 rating, or label. Buyers appreciate Anaheim Automations simplicity of "one-stop shop” and the cost savings of a Brushless Motor custom design while engineers appreciate the creativity, system efficiency, and flexibility that Anaheim Automation features for their Brushless Motor product line.

Anaheim Automation's standard Brushless Motor product line is a cost-effective solution, in that they are known for their durable construction and outstanding performance. Due to dedicated engineering, professional application assistance and friendly customer service, Anaheim Automation often surpasses the customer's expectations for fulfilling their custom requirements. While a good portion of Anaheim Automation's Brushless Motor sales involves special, custom, or private-labeling requirements, the company takes pride in its standard stock base located in Anaheim, California, USA. To make customization of a Brushless Motor affordable, a minimum quantity and/or a Non-Recurring Engineering (NRE) fee is required. Contact the factory for specifics, should you require a custom Brushless Motor in your design.

All Sales for a customized or modified Brushless Motor are Non-Cancelable-Non-Returnable, and a NCNR Agreement must be signed by the customer, per each request. All Sales, including a customized Brushless Motor, are created pursuant to Anaheim Automation's standardized Terms and Conditions, and are in lieu of any additional expressed or implied terms, including but not limited to any implied warranties. Anaheim Automation has a wide range of customers for the Brushless Motor product line: companies running or developing automated machinery or processes that involve food, medical packaging, special filming and projection effects, inspection and security devices, assembly, labeling or tamper-evident requirements, cosmetics, medical diagnostics, conveyor, pump flow control, robotics, equipment upgrades, and metal fabrication (CNC machinery). We often put a "private-label" for many OEM customers that request it so their customers stay loyal to them for replacement, servicing, and repairs.

PLEASE NOTE: Technical assistance regarding its Brushless Motor product line, as well as all the products manufactured or distributed by Anaheim Automation, is offered at no charge. This assistance is offered to help the customer in choosing Anaheim Automation products for a specific application. However, any selection, quotation, or application suggestion for a Brushless Motor, or any other product, offered from Anaheim Automation's staff, its' representatives or distributors, are only to assist the customer. In all cases, determination of fitness of the custom Brushless Motor in a certain system design is solely the customers' responsibility. While every effort is made to offer solid advice regarding the Brushless Motor product line, as well as other motion control products, and to produce technical data and illustrations accurately, such advice and documents are for reference only, and subject to change without notice.

Some of the advantages of a Brushless Motor, but are not limited to are:
• Higher speed range
• High dynamic respons
• Long operating lif
• Better speed versus torque characteristic
• Noiseless operatio
• High efficienc


Disadvantages for a Brushless Motor
• High cos
• Additional system wiring is required to power the electronic commutation circuitr
• Motion controllers/drivers electronics needed to operate a Brushless DC Motor are more complx

Brushless motors have electronic commutation systems, no brushes and no mechanical commutators. This allows the motor to operate at higher speeds. There can be a different amount of poles on the stator for each motor.

When selecting a Brushless Motor, you want to ask yourself a few questions. Such as, what is my application? What are my specifications? How much do I want to spend? What controller/driver and I going to use/need? These are some of the questions you want to think about to narrow down your selection. You will definitely want to do your research.

The type of application will need to be determined for your motor. You will then need to determine all specifications, known ones along with possible ones. For example, do you need a specific frame size, weight, power, speed, length, etc. Once you have determined all those things, you will need to take into consideration on what controller/driver you will be using. This goes hand in hand with the selection of the motor. Keep in mind there are many different motors and driver/controllers to choose from, therefore it is wise to do detailed research.

The Brushless Motor has the physical appearance of a 3-phase permanent magnet that is stationary which is located on the outside, which is known as the Stator. The rotating armature is located inside and is also called the rotor. Brushless Motors can be constructed in many different physical configurations. One configuration is known as the “Inrunner” type where the permanent magnets are a part of the rotor and three stator windings are surround the rotor. Another configuration is the “Outrunner” type, where the radial-relationship between the coils and magnets is reversed. The stator coils form the core of the motor, while permanent magnets spin within an overhanging rotor surrounding the core.

Brushless motors also known as BLDC Motors, are synchronous electric motors that are DC (Direct Current) powered. They are electronically commutated without brushes making them “Brushless”. A Brushless Motor consists of a fixed armature along with permanent magnets that rotate, hall sensors, stator windings, rotor magnet North and South, hall sensor magnets, an accessory shaft, and a driving end of the shaft.

A Brushless Motor varies in price. It can be anywhere from twenty dollars or less to several hundred dollars, possibly more. It just depends on the size and capabilities of the brushless motor itself.

Brushless Motor Products are quickly growing in popularity and are being used in many industries. Some of the industries are:

• Instrumentation
• Medical
• Appliances
• Consumer
• Automotive
• Industrial Automation Equipment
• Aerospace
• Military

It is said that Brushless Motor has been in commercial use and possible since 1962, although the first Brushless Motor appeared during the 1800s. This was made possible by the conversion of electrical energy into mechanical energy by electromagnetic means, which was demonstrated by a British scientist by the name of Michael Farady in 1821. A Hungarian physicist by the name of Ányos Jedlik began experimenting with devices he called electromagnetic self-rotors in 1827. At the time, they were only used for instructional purposes. In 1828, he demonstrated the first device to contain the three main components of practical direct current motors; the rotor, commutator, and stator. The magnetic fields of both the revolving and stationary components were produced solely by currents flowing through their windings and the motors did not contain permanent magnets in those times. In 1832, William Sturgeon, also a British scientist invented the first commutator-type direct current electric motor capable of turning machinery.

Americans, Thomas and Emily Davenport built a commutator-type direct current electric motor with the intention of commercial use in following Sturgeon’s work and patented in 1837. The motors were used for a printing press and powered machine tools. They were said to have ran up to 600 revolutions per minute (RPM). The Brushless was commercially unsuccessful due to the high costs of the primary battery power, also there was no practical commercial market for the motors at that time.

A modern Brushless motor was accidently invented in 1873, when a dynamo was to a similar motor driving it as a motor by Zénobe Gramme. He then created the Gramme Machine, it was the first electric motor that was successful in the industry. A non-sparking motor capable of constant speed under variable loads was the first practical Brushless motor was invented in 1886 by Frank Julian Sprague.

The Brushless Motor has and continues to rise in popularity for many different applications. Although a Brushless Motor may cost a little more than a DC Brushed Motor, they have far more advantages than disadvantages. Many industries have turned to the Brushless motor for their applications. For specific Industries, please check the “What Industries is the Brushless Motor used in” section.

All Brushless Motor Products are permanent magnet motors. There are also two basic types labeled as a Trapezoidal Motor and the other as a Sine Wave Motor. The Trapezoidal Motor is said to be a DC servo motor and the Sine Wave Motor has close resemblance to an AC synchronous motor.

Most Brushless Motor Products need a controller/driver to run. There are many different types of controllers/drivers that are manufactured around the world for different applications. Many come with different options and can be custom made. Most are referred to as Electronic Speed Controller (ESC).

In a Brushless Motor Controller/Driver, either a Hall Effect Sensor or the Back EMF (Electromotive Force) is used to run the motor. The Hall Effect uses three hall sensors within the motor to help detect the position of the rotor. This method is primarily used in speed detection, positioning, current sensing, as well as proximity switching. The magnetic field changes in response to the transducer that varies its output voltage. A feedback is created by directly returning a voltage since the sensor operates as an analogue transducer. The distance between the Hall plate and a known magnetic field can be determined with a group of sensors, in this case, three, and the relative position of the magnet can be deduced. A Hall sensor can act as an on/off switch in a digital mode when combined with circuitry.

The Back EMF, also known as the Counter-Electromotive Force is caused by a changing electromagnetic field. In a Brushless Motor, the back EMF is a voltage that occurs where there is motion between the external magnetic field and the armature of the motor. In other words, the voltage is developed in an inductor by and alternating current or pulsating current. At every moment, the polarity of the voltage is the reverse of the input voltage. This method is commonly used to measure the motor’s position and speed indirectly.

The brushless Motor has become popular amongst the medical industry for its long-lasting design. Used in medical equipment, a DC brushless motor has a life expectancy of 10,000 hours, versus the 2,000-5,000 hour lifespan of the brushed motor. The brushless motor also has a top speed that is not limited by a large number of poles. It wasn't until the cost of these brushless motors decreased, that they became a viable option for most medical applications. A brushless motor can provide a more efficient, reliable, and compact motor that can be used in a variety of ways.

Basically, a brushless motor is a synchronous electric motor that is powered by a DC power source. An electric commutation circuit replaces the standard commutator and brush assembly found in the brushed DC motor. A brushless motor and a brushed DC motor are essentially polar opposites. While the windings of a brushed motor rotate around the rotating shaft or armature, the brushless motor has windings that are attached to the motor housing. The magnets of the brushed DC motor attach to the motor housing, while the brushless motor magnets are affixed to the rotor.

Commutation is the process of reversing the polarity of the phase currents in the windings of the motor at an exact time that will produce continuous rotational torque. If commutation did not occur, the magnets and magnetic fields would lock the rotating shaft in place by aligning themselves. The appropriate reversal time is crucial; the brushless motor shaft must continue spinning, and it does so as a result of the changing polarity of the windings.

The primary way a brushless motor and a brushed DC motor differs is in their methods of commutation. Brushed DC motors use brushes and a commutator that acts as an electromechanical switch to connect the windings in the proper polarity. In the brushless motor, electronic switches take the place of the mechanical switch, controlling the timing of the polarity-reversal by an electrical circuit. Usually, a brushless motor senses rotor position and controls the electronic drive of the motor by using Hall-effect devices (HFD). However, because of the ability to monitor motor back-EMF, HFD can be eliminated to create a sensorless brushless motor drive. These motors are far less expensive, and are a primary reason they appeal in medical equipment design.

Sleep Apnea can also be treated with the help of a brushless motor. Treatment for the disorder requires the use of Positive Airway Pressure (PAP) respirators. The PAP respirator is attached to a special breathing mask that the patient must wear to breathe through while sleeping. Within the respirator is a blower fan that pressurizes the air mask, according to the patient's breathing pattern. As the patient inhales, the blower fan speeds up, allowing more air to reach the lungs. Oppositely, when the patient exhales, the blower fan slows down to reduce the amount of air the patient breathes out. A brushless motor never needs to operate underneath the minimum threshold speed of the drive, so they are the perfect power source for blower fans. Furthermore, there is no risk for any sudden changes in load.

Low-noise-level standards force hospital equipment to be as quiet as possible, thus making the brushless motor a prime candidate due to how silent they are in operation. The brushless motor can operate at high speeds with accuracy, and yet maintain a silent sound. Therefore, they can be used both in hospitals, and in the patient's home. It is the absence of a commutator and brushes in the brushless motor that removes even more of the motor noise.

Consumer Electronics Although a Brushless motor may perform the same functions originally fulfilled by brushed DC motors, cost and control complications prevent a Brushless motor from completely replacing brushed motors. However, the Brushless motor has monopolized many areas of the consumer electronics industry, and are used in many different locations, including computer hard drives and CD/DVD players. A Brushless motor is used to operate the small cooling fans that are located in electronic equipment as well. Cordless power tools also utilize a Brushless motor because the need for increased efficiency of the Brushless motor allows for long periods of use before needing to recharge the battery. Furthermore, direct-drive turntables for ?analog? audio disks use a low-speed, low-power Brushless motor.

Transport Electric and hybrid vehicles use a high power Brushless motor that are essentially AC synchronous with permanent magnet rotors. A Brushless motor is used in Segway and Vectrix-Maxi-Scooters also. Electric bicycles sometimes build a Brushless motor into their wheel hubs, with the stator solidly fixed to the axle and magnets attached to and rotating with the wheel. These electric bicycles have a standard bicycle transmission with pedals, sprockets, and chain that, if needed, can be pedaled along with or without the use of the Brushless motor.

Heating and Ventilation It has become a popular trend to switch from AC motors to a BLDC motor (EC) because of the dramatic reduction in power needed o run them, versus the typical AC motor. Although shaded-pole and permanent split capacitor motors were the primary fan motor of choice, many fans today are being run by a BLDC motor. Some use a BLDC motor simply to increase system efficiency as a whole. Certain HVAC systems use ECM motors (electronically commutated BLDC motors). Particularly these are the HVAC systems that feature load modulation and/or variable-speed. A BLDC motor does not only have higher efficiency, but also a built-in microprocessor that allows for better airflow control, programmability, and serial communication.

Model Engineering and Hobbyists The most popular motor choice for model aircraft today is the BLDC motor. The BLDC motor is available in a wide array of sizes, and have a favorable power to weight ratios. A BLDC motor has transformed the market of electric-powered flight. The introduction of the BLDC motor has displaced the use of almost all brushed electric motors in model aircraft and helicopters. Modern batteries and BLDC motor products allow model airplanes to vertically ascend, versus gradually climb. Small glow fuel internal combustion engines that were used in the past are no comparison to the silent and clean BLDC motor products.

BLDC motors have also increased in popularity among the Radio Controlled (RC) cars, buggies, and trucks, where sensor-type BLDC motors allow the position of the rotor magnet to be detected. Many BLDC motors feature upgrades and replaceable parts like sintered neodymium-iron-boron (rare earth magnets), replaceable motor timing assemblies, and ceramic bearings. As a result, these BLDC motors are quickly ascending to the top of the list as far as preferred motor types for electric on and off-road RC racers. BLDC motors have low-maintenance, high reliability and power efficiency ~ most BLDC motors with an efficiency rating of 80% or more.

The key dissimilarity between brushless motor, also known as a Brushless motor, and their predecessors is the process of commutation. Newer Brushless motor products are electrically commutated; this is accomplished with Hall elements, by counter EMF, or encoder feedback.

A Brushless motor is very useful and cost-effective by their design and construction. However, there are some factors that can negatively affect the life expectancy of the Brushless motor:

Key Points to Remember -
• Bearing failure and lack of lubrication are major factors when it comes to a Brushless motor failing. As a result, manufacturers now use industrial grade components so that a Brushless motor now has the ability to last lifetimes in excess of 20,000 hours or more! Integrated into the BLDC motor are permanently lubricated ball bearings that use special grease, thus eliminating the need for re-lubrication. IMPORTANT NOTE: Non-approved lubricants are not recommended for the Brushless DC motor components because they could potentially shorten the life of the Brushless motor.

• Temperature also plays a key role in the lifespan of the Brushless motor. The motor casing in particular must ensure that the heat generated in the BLDC motor windings must be dispelled. A Brushless motor could face severe damage if it exceeds the Brushless DC motor specification with respect to heat. Brushless motor performance has a direct correlation with the maximum possible rotor temperature, ambient temperature, and duty cycle. As temperature increases, the winding resistance increases, and magnetic forces decrease, ultimately causing the Brushless motor to perform less efficiently.

• When a Brushless motor runs at high continuous loads, heat sinking and forced air-cooling can considerably lower operating temperatures. Therefore, it is highly recommended that all of these factors be taken into consideration when designing and installing motion control systems that include a Brushless motor.

The key dissimilarity between bldc motor products and their predecessors is the process of commutation. Newer Brushless motor products are electrically commutated; this is accomplished with Hall elements, by counter EMF, or encoder feedback.

Factors That Affect Brushless Motor Life

Bearing failure is a major factor when it comes to Brushless motor products failing. As a result of using industrial grade components, some Brushless motor products have the ability to last lifetimes in excess of 20,000 hours or more. Integrated into these systems are permanently lubricated ball bearings that use special grease, thus eliminating the need for re-lubrication. Non-approved lubricants are not recommended for the motor components because they could potentially shorten the life of the Brushless motor.

Temperature also plays a key role in the lifespan of a Brushless motor. The motor casing in particular must ensure that the heat generated in the motor windings must be dispelled. The motor may face severe damage if it exceeds the specification regarding heat. The motor's performance has a direct correlation with the maximum possible rotor temperature, ambient temperature, and duty cycle. As temperature increases, the winding resistance increases, and magnetic forces decrease, ultimately causing performance to dwindle. When running at high continuous loads, all of these factors must be taken into consideration. Heat sinking and forced air-cooling can considerably lower operating temperatures.

Although the 12V DC Motor has been overshadowed by the brushless motor, the 12V DC Motor is still used in a wide range of applications. Just because we may not see Brush Motors very often, they really are everywhere ranging from toys to cellular phones to Jacuzzi pumps. Most automatic car windows and automatic seat adjustments are operated by Brush Motors. The 12V DC Motor has been an automotive industry favorite because of their relatively low cost and simple design. Brush Motors come in all different sizes all with different torque and speed specifications; so whatever your application may be there most likely is a 12V DC Motor that will meet your demands.

The 12V DC Motor is one of the earliest of all electrical motor designs. It is usually the motor of choice for the majority of torque control and variable speed applications. This Tech Tip discusses the advantages and disadvantages of using a DC Brush motor in machinery and processes. Advantages of the 12V DC Motor • The 12V DC Motor has a simple construction, therefore requiring a cheap drive design • Understandable design/technology facilitates in quick application of a 12V DC Motor. • The design of the 12V DC motor is quite simple, in that a permanent magnetic field is created in the by either of two means: • Permanent magnets • Electro-magnetic windings • If the field is created by permanent magnets, a 12V DC Motor is said to be a permanent magnet DC motor (PMDC). If created by electromagnetic windings, the brush motor is often said to be a shunt wound Brush DC motor (SWDC). Today, because of cost-effectiveness and reliability, the PMDC motor is the motor of choice for applications involving fractional horsepower DC brush motors, as well as most applications up to about 2.0 horsepower. • Opposing the stator field is the armature field, which is generated by a changing electromagnetic flux coming from windings located on the rotor of the 12V DC motor. The magnetic poles of the armature field will attempt to line up with the opposite magnetic poles generated by the stator field. Next, the section of the rotor where the electricity enters the rotor windings is called the commutator. The electricity is carried between the brush motor rotor and the stator by conductive graphite-copper brushes (mounted on the rotor) which contact rings on stator. Important to Note: If a 12V DC motor suffers a loss of field (if for example, the field power connections are broken), the 12V DC Motor will immediately begin to accelerate to the top speed which the loading will allow. This can result in the motor flying apart if the motor is lightly loaded. The possible loss of field must be accounted for, particularly with a shunt wound 12V DC Motor. Imagine power is supplied: A 12V DC Motor rotates toward the pole alignment point. Just as the 12V DC motor would get to this point, the brushes jump across a gap in the stator rings. Momentum carries the brush motor forward over this gap. When the brushes get to the other side of the gap, they contact the stator rings again and - the polarity of the voltage is reversed in this set of rings! The brush motor begins accelerating again, to the opposite set of poles. (The momentum has carried the brush motor past the original pole alignment point.) This continues as the brush motor rotates. In most 12V DC motors, several sets of windings or permanent magnets are present to smooth out the motion. Te Brush DC Motor is simple to control speed • Simple to control speed - Controlling the speed of a 12V DC motor is simple. The higher the armature voltage, the faster the rotation. This relationship is linear to the brush motors maximum speed. • The maximum armature voltage which corresponds to the rated speed of the brush motors (these brush motors are usually given a rated speed and a maximum speed, such as 1750/2000 rpm) are available in certain standard voltages, which roughly increase in conjunction with horsepower. • The smallest industrial-type brush motors are rated 90 VDC and 180 VDC. Larger units are rated at 250 VDC and even higher (dependent upon the individual manufacturer). • Most industrial DC brush motors operate reliably over a speed range of about 20:1 - down to about 5-7% of base speed. This is much better performance than the comparable AC motor. This fact is in part due to the fact of the mere simplicity of control. However, it is also partly due to the fact that most industrial DC brush motors were designed with variable speed operations in mind. The addition of heat dissipation features/ devices provided for lower operating speeds of 12V DC brush motors. • NOTE: The specialty DC motor is used in mobile applications and are typically rated 12, 24, or 48 VDC. Other tiny brush motors can be rated as low as 5 VDC. This DC Motor is very popular among hobbyists. The 12V DC Motor is simple to control torque • In a 12V DC motor, torque control is also easy to accomplish. Output torque is proportional to current. So, if the current is limited, you have just limited the torque which the brush motor can achieve. • This fact makes the 12V DC brush motor ideal for delicate applications such as textile manufacturing. Simple and inexpensive drive/control design The result of this design is that variable speed or variable torque electronics are easy to design and manufacture. Varying the speed of a DC motor requires little more than a large enough potentiometer. In practice, these have been replaced for all but sub-fractional horsepower applications by the SCR and PWM drives (sometimes referred to as controls), which offer relatively precisely control voltage and current. Common drives for a 12V DC brush motor is available at the low-end of the product offering (up to 2 horsepower). The cost will depend on the accuracy requirement, but many brush motors can be accompanied with drives ranging from $29.00 - $199.00 USD. Disadvantages of the 12V DC Motor • A 12V DC motor can be a bit expensive to produce, in that the raw materials have become more costly in recent year • A 12V DC motor is less reliable in control at lowest speeds • A 12V DC motor is physically larger than other motors with the same torque • A 12V DC motor is much more high maintenance than are brushless motors • A 12V DC motor becomes vulnerable to dust which decrease

Although the 24V DC Motor has been overshadowed by the brushless motor, the 24V DC Motor is still used in a wide range of applications. Just because we may not see Brush Motors very often, they really are everywhere ranging from toys to cellular phones to Jacuzzi pumps. Most automatic car windows and automatic seat adjustments are operated by Brush Motors. The 24V DC Motor has been an automotive industry favorite because of their relatively low cost and simple design. Brush Motors come in all different sizes all with different torque and speed specifications; so whatever your application may be there most likely is a 24V DC Motor that will meet your demands.

The 24V DC Motor is one of the earliest of all electrical motor designs. It is usually the motor of choice for the majority of torque control and variable speed applications. This Tech Tip discusses the advantages and disadvantages of using a DC Brush motor in machinery and processes. Advantages of the 24V DC Motor • The 24V DC Motor has a simple construction, therefore requiring a cheap drive design • Understandable design/technology facilitates in quick application of a 24V DC Motor. • The design of the 24V DC motor is quite simple, in that a permanent magnetic field is created in the by either of two means: • Permanent magnets • Electro-magnetic windings • If the field is created by permanent magnets, a 24V DC Motor is said to be a permanent magnet DC motor (PMDC). If created by electromagnetic windings, the brush motor is often said to be a shunt wound Brush DC motor (SWDC). Today, because of cost-effectiveness and reliability, the PMDC motor is the motor of choice for applications involving fractional horsepower DC brush motors, as well as most applications up to about 2.0 horsepower. • Opposing the stator field is the armature field, which is generated by a changing electromagnetic flux coming from windings located on the rotor of the 24V DC motor. The magnetic poles of the armature field will attempt to line up with the opposite magnetic poles generated by the stator field. Next, the section of the rotor where the electricity enters the rotor windings is called the commutator. The electricity is carried between the brush motor rotor and the stator by conductive graphite-copper brushes (mounted on the rotor) which contact rings on stator. Important to Note: If a 24V DC motor suffers a loss of field (if for example, the field power connections are broken), the 24V DC Motor will immediately begin to accelerate to the top speed which the loading will allow. This can result in the motor flying apart if the motor is lightly loaded. The possible loss of field must be accounted for, particularly with a shunt wound 24V DC Motor. Imagine power is supplied: A 24V DC Motor rotates toward the pole alignment point. Just as the 24V DC motor would get to this point, the brushes jump across a gap in the stator rings. Momentum carries the brush motor forward over this gap. When the brushes get to the other side of the gap, they contact the stator rings again and - the polarity of the voltage is reversed in this set of rings! The brush motor begins accelerating again, to the opposite set of poles. (The momentum has carried the brush motor past the original pole alignment point.) This continues as the brush motor rotates. In most 24V DC motors, several sets of windings or permanent magnets are present to smooth out the motion. Te Brush DC Motor is simple to control speed • Simple to control speed - Controlling the speed of a 24V DC motor is simple. The higher the armature voltage, the faster the rotation. This relationship is linear to the brush motors maximum speed. • The maximum armature voltage which corresponds to the rated speed of the brush motors (these brush motors are usually given a rated speed and a maximum speed, such as 1750/2000 rpm) are available in certain standard voltages, which roughly increase in conjunction with horsepower. • The smallest industrial-type brush motors are rated 90 VDC and 180 VDC. Larger units are rated at 250 VDC and even higher (dependent upon the individual manufacturer). • Most industrial DC brush motors operate reliably over a speed range of about 20:1 - down to about 5-7% of base speed. This is much better performance than the comparable AC motor. This fact is in part due to the fact of the mere simplicity of control. However, it is also partly due to the fact that most industrial DC brush motors were designed with variable speed operations in mind. The addition of heat dissipation features/ devices provided for lower operating speeds of 24V DC brush motors. • NOTE: The specialty DC motor is used in mobile applications and are typically rated 12, 24, or 48 VDC. Other tiny brush motors can be rated as low as 5 VDC. This DC Motor is very popular among hobbyists. The 24V DC Motor is simple to control torque • In a 24V DC motor, torque control is also easy to accomplish. Output torque is proportional to current. So, if the current is limited, you have just limited the torque which the brush motor can achieve. • This fact makes the 24V DC brush motor ideal for delicate applications such as textile manufacturing. Simple and inexpensive drive/control design The result of this design is that variable speed or variable torque electronics are easy to design and manufacture. Varying the speed of a DC motor requires little more than a large enough potentiometer. In practice, these have been replaced for all but sub-fractional horsepower applications by the SCR and PWM drives (sometimes referred to as controls), which offer relatively precisely control voltage and current. Common drives for a 24V DC brush motor is available at the low-end of the product offering (up to 2 horsepower). The cost will depend on the accuracy requirement, but many brush motors can be accompanied with drives ranging from $29.00 - $199.00 USD. Disadvantages of the 24V DC Motor • A 24V DC motor can be a bit expensive to produce, in that the raw materials have become more costly in recent year • A 24V DC motor is less reliable in control at lowest speeds • A 24V DC motor is physically larger than other motors with the same torque • A 24V DC motor is much more high maintenance than are brushless motors • A 24V DC motor becomes vulnerable to dust which decrease

Although the Brush Motor has been overshadowed by the brushless motor, the Brush Motor is still used in a wide range of applications. Just because we may not see the Brush Motor very often, it really is everywhere ranging from toys to cellular phones to Jacuzzi pumps. Most automatic car windows and automatic seat adjustments are operated by Brush Motors. The Brush Motor has been an automotive industry favorite because of their relatively low cost and simple design. The Brush Motor comes in all different sizes all with different torque and speed specifications; so whatever your application may be there most likely is a Brush Motor that will meet your demands.

The Brush Motor is one of the earliest of all electrical motor designs. It is usually the motor of choice for the majority of torque control and variable speed applications. This Tech Tip discusses the advantages and disadvantages of using a Brush Motor motor in machinery and processes. Advantages of the Brush Motor • The Brush Motor has a simple construction, therefore requiring a cheap drive design • Understandable design/technology facilitates in quick application of a Motor. • The design of the Brush Motor is quite simple, in that a permanent magnetic field is created in the by either of two means: • Permanent magnets • Electro-magnetic windings • If the field is created by permanent magnets, a Brush DC Motor is said to be a permanent magnet DC motor (PMDC). If created by electromagnetic windings, the brush motor is often said to be a shunt wound Brush DC motor (SWDC). Today, because of cost-effectiveness and reliability, the PMDC motor is the motor of choice for applications involving a fractional horsepower Brush Motor, as well as most applications up to about 2.0 horsepower. • Opposing the stator field is the armature field, which is generated by a changing electromagnetic flux coming from windings located on the rotor of the Brush Motor. The magnetic poles of the armature field will attempt to line up with the opposite magnetic poles generated by the stator field. Next, the section of the rotor where the electricity enters the rotor windings is called the commutator. The electricity is carried between the Brush Motor rotor and the stator by conductive graphite-copper brushes (mounted on the rotor) which contact rings on stator. Important to Note: If a Brush DC motor suffers a loss of field (if for example, the field power connections are broken), the DC Motor will immediately begin to accelerate to the top speed which the loading will allow. This can result in the motor flying apart if the motor is lightly loaded. The possible loss of field must be accounted for, particularly with a shunt wound DC Motor. Imagine power is supplied: A Brush DC Motor rotates toward the pole alignment point. Just as the DC motor would get to this point, the brushes jump across a gap in the stator rings. Momentum carries the brush motor forward over this gap. When the brushes get to the other side of the gap, they contact the stator rings again and - the polarity of the voltage is reversed in this set of rings! The brush motor begins accelerating again, to the opposite set of poles. (The momentum has carried the brush motor past the original pole alignment point.) This continues as the brush motor rotates. In most DC motors, several sets of windings or permanent magnets are present to smooth out the motion. THe Brush DC Motoor is simple to control speed • Simple to control speed - Controlling the speed of a DC motor is simple. The higher the armature voltage, the faster the rotation. This relationship is linear to the brush motors maximum speed. • The maximum armature voltage which corresponds to the rated speed of the brush motors (these brush motors are usually given a rated speed and a maximum speed, such as 1750/2000 rpm) are available in certain standard voltages, which roughly increase in conjunction with horsepower. • The smallest industrial-type brush motors are rated 90 VDC and 180 VDC. Larger units are rated at 250 VDC and even higher (dependent upon the individual manufacturer). • Most industrial DC brush motors operate reliably over a speed range of about 20:1 - down to about 5-7% of base speed. This is much better performance than the comparable AC motor. This fact is in part due to the fact of the mere simplicity of control. However, it is also partly due to the fact that most industrial DC brush motors were designed with variable speed operations in mind. The addition of heat dissipation features/ devices provided for lower operating speeds of DC brush motors. • NOTE: The specialty DC motor is used in mobile applications and are typically rated 12, 24, or 48 VDC. Other tiny brush motors can be rated as low as 5 VDC. This DC Motor is very popular among hobbyists. The Brush DC Motor is simple to control torque • In a DC motor, torque control is also easy to accomplish. Output torque is proportional to current. So, if the current is limited, you have just limited the torque which the brush motor can achieve. • This fact makes the DC brush motor ideal for delicate applications such as textile manufacturing. Simple and inexpensive drive/control design The result of this design is that variable speed or variable torque electronics are easy to design and manufacture. Varying the speed of a DC motor requires little more than a large enough potentiometer. In practice, these have been replaced for all but sub-fractional horsepower applications by the SCR and PWM drives (sometimes referred to as controls), which offer relatively precisely control voltage and current. Common drives for a DC brush motor is available at the low-end of the product offering (up to 2 horsepower). The cost will depend on the accuracy requirement, but many brush motors can be accompanied with drives ranging from $29.00 - $199.00 USD. Disadvantages of the Brush DC Motor • A Brush DC motor can be a bit expensive to produce, in that the raw materials have become more costly in recent year • A Brush DC motor is less reliable in control at lowest speeds • A Brush DC motor is physically larger than other motors with the same torque • A Brush DC motor is much more high maintenance than are brushless motors • A Brush DC motor becomes vulnerable to dust which decrease

Although Brush Motors have been overshadowed by the brushless motor, Brush Motors are still used in a wide range of applications. Just because we may not see Brush Motors very often, they really are everywhere ranging from toys to cellular phones to Jacuzzi pumps. Most automatic car windows and automatic seat adjustments are operated by Brush Motors. Brush Motors have been an automotive industry favorite because of their relatively low cost and simple design. Brush Motors come in all different sizes all with different torque and speed specifications; so whatever your application may be there most likely are Brush Motors that will meet your demands.

Brush Motors are one of the earliest of all electrical motor designs. It is usually the motor of choice for the majority of torque control and variable speed applications. This Tech Tip discusses the advantages and disadvantages of using Brush motors in machinery and processes. Advantages of Brush Motors • Brush Motors have a simple construction, therefore requiring a cheap drive design • Understandable design/technology facilitates in quick application of Brush Motors. • The design of Brush motors are quite simple, in that a permanent magnetic field is created in the by either of two means: • Permanent magnets • Electro-magnetic windings • If the field is created by permanent magnets, Brush Motors are said to be a permanent magnet DC motor (PMDC). If created by electromagnetic windings, the brush motor is often said to be a shunt wound Brush DC motor (SWDC). Today, because of cost-effectiveness and reliability, the PMDC motor is the motor of choice for applications involving fractional horsepower Brush motors, as well as most applications up to about 2.0 horsepower. • Opposing the stator field is the armature field, which is generated by a changing electromagnetic flux coming from windings located on the rotor of Brush motors. The magnetic poles of the armature field will attempt to line up with the opposite magnetic poles generated by the stator field. Next, the section of the rotor where the electricity enters the rotor windings is called the commutator. The electricity is carried between the brush motor rotor and the stator by conductive graphite-copper brushes (mounted on the rotor) which contact rings on stator. Important to Note: If Brush motors suffer a loss of field (if for example, the field power connections are broken), the Brushed DC Motor will immediately begin to accelerate to the top speed which the loading will allow. This can result in the motor flying apart if the motor is lightly loaded. The possible loss of field must be accounted for, particularly with shunt wound Brush Motors. Imagine power is supplied: Brush rotate toward the pole alignment point. Just as Brush motors would get to this point, the brushes jump across a gap in the stator rings. Momentum carries Brush motors forward over this gap. When the brushes get to the other side of the gap, they contact the stator rings again and - the polarity of the voltage is reversed in this set of rings! The brush motor begins accelerating again, to the opposite set of poles. (The momentum has carried Brush motors past the original pole alignment point.) This continues as BrushBrush Motors rotate. In most Brush motors, several sets of windings or permanent magnets are present to smooth out the motion. Brush Motors are simple to control speed • Simple to control speed - Controlling the speed of Brush motors are simple. The higher the armature voltage, the faster the rotation. This relationship is linear to the brush motors maximum speed. • The maximum armature voltage which corresponds to the rated speed of the brush motors (these Brush motors are usually given a rated speed and a maximum speed, such as 1750/2000 rpm) are available in certain standard voltages, which roughly increase in conjunction with horsepower. • The smallest industrial-type brush motors are rated 90 VDC and 180 VDC. Larger units are rated at 250 VDC and even higher (dependent upon the individual manufacturer). • Most industrial brush motors operate reliably over a speed range of about 20:1 - down to about 5-7% of base speed. This is much better performance than the comparable AC motor. This fact is in part due to the fact of the mere simplicity of control. However, it is also partly due to the fact that most industrial Brush motors were designed with variable speed operations in mind. The addition of heat dissipation features/ devices provided for lower operating speeds of Brush motors. • NOTE: Specialty Brush motors are used in mobile applications and are typically rated 12, 24, or 48 VDC. Other tiny brush motors can be rated as low as 5 VDC. These Brush Motors are very popular among hobbyists. Brush Motors are simple to control torque • In Brush motors, torque control is also easy to accomplish. Output torque is proportional to current. So, if the current is limited, you have just limited the torque which Brush motors can achieve. • This fact makes Brush brushs motor ideal for delicate applications such as textile manufacturing. Simple and inexpensive drive/control design The result of this design is that variable speed or variable torque electronics are easy to design and manufacture. Varying the speed of Brush motors requires little more than a large enough potentiometer. In practice, these have been replaced for all but sub-fractional horsepower applications by the SCR and PWM drives (sometimes referred to as controls), which offer relatively precisely control voltage and current. Common drives for a Brush motor is available at the low-end of the product offering (up to 2 horsepower). The cost will depend on the accuracy requirement, but many brush motors can be accompanied with drives ranging from $29.00 - $199.00 USD. Disadvantages of Brush Motors • Brush motors can be a bit expensive to produce, in that the raw materials have become more costly in recent year • Brush motors are less reliable in control at lowest speeds • Brush motors are physically larger than other motors with the same torque • Brush motors are much more high maintenance than are brushless motors • Brush become vulnerable to dust which decrease

Although the Brushed DC Motor has been overshadowed by the brushless motor, the Brushed DC Motor is still used in a wide range of applications. Just because we may not see a Brushed DC Motor very often, they really are everywhere ranging from toys to cellular phones to Jacuzzi pumps. Most automatic car windows and automatic seat adjustments are operated by a Brushed DC Motor. The Brushed DC Motor has been an automotive industry favorite because of their relatively low cost and simple design. A Brushed DC Motor may come in all different sizes all with different torque and speed specifications; so whatever your application may be there most likely is a Brushed DC Motor that will meet your demands.

The Brushed DC Motor is one of the earliest of all electrical motor designs. It is usually the motor of choice for the majority of torque control and variable speed applications. This Tech Tip discusses the advantages and disadvantages of using a Brushed DC Brush motor in machinery and processes. Advantages of the Brushed DC Motor • The Brushed DC Motor has a simple construction, therefore requiring a cheap drive design • Understandable design/technology facilitates in quick application of a Brushed DC Motor. • The design of the Brushed DC motor is quite simple, in that a permanent magnetic field is created in the by either of two means: • Permanent magnets • Electro-magnetic windings • If the field is created by permanent magnets, a Brushed DC Motor is said to be a permanent magnet DC motor (PMDC). If created by electromagnetic windings, the brush motor is often said to be a shunt wound Brush DC motor (SWDC). Today, because of cost-effectiveness and reliability, the PMDC motor is the motor of choice for applications involving fractional horsepower DC brushed motors, as well as most applications up to about 2.0 horsepower. • Opposing the stator field is the armature field, which is generated by a changing electromagnetic flux coming from windings located on the rotor of the Brushed DC motor. The magnetic poles of the armature field will attempt to line up with the opposite magnetic poles generated by the stator field. Next, the section of the rotor where the electricity enters the rotor windings is called the commutator. The electricity is carried between the brush motor rotor and the stator by conductive graphite-copper brushes (mounted on the rotor) which contact rings on stator. Important to Note: If a Brushed DC motor suffers a loss of field (if for example, the field power connections are broken), the Brushed DC Motor will immediately begin to accelerate to the top speed which the loading will allow. This can result in the motor flying apart if the motor is lightly loaded. The possible loss of field must be accounted for, particularly with a shunt wound Brushed DC Motor. Imagine power is supplied: A Brushed DC Motor rotates toward the pole alignment point. Just as the Brushed DC motor would get to this point, the brushes jump across a gap in the stator rings. Momentum carries the brushed DC motor forward over this gap. When the brushes get to the other side of the gap, they contact the stator rings again and - the polarity of the voltage is reversed in this set of rings! The brush motor begins accelerating again, to the opposite set of poles. (The momentum has carried the Brushed DC motor past the original pole alignment point.) This continues as the Brushed DC Motor rotates. In most DC motors, several sets of windings or permanent magnets are present to smooth out the motion. The Brushed DC Motor is simple to control speed • Simple to control speed - Controlling the speed of a Brushed DC motor is simple. The higher the armature voltage, the faster the rotation. This relationship is linear to the brush motors maximum speed. • The maximum armature voltage which corresponds to the rated speed of the brush motors (these brush motors are usually given a rated speed and a maximum speed, such as 1750/2000 rpm) are available in certain standard voltages, which roughly increase in conjunction with horsepower. • The smallest industrial-type brush motors are rated 90 VDC and 180 VDC. Larger units are rated at 250 VDC and even higher (dependent upon the individual manufacturer). • Most industrial DC brush motors operate reliably over a speed range of about 20:1 - down to about 5-7% of base speed. This is much better performance than the comparable AC motor. This fact is in part due to the fact of the mere simplicity of control. However, it is also partly due to the fact that most industrial DC brush motors were designed with variable speed operations in mind. The addition of heat dissipation features/ devices provided for lower operating speeds of DC brush motors. • NOTE: The specialty Brushed DC motor is used in mobile applications and are typically rated 12, 24, or 48 VDC. Other tiny brush motors can be rated as low as 5 VDC. This Brushed DC Motor is very popular among hobbyists. The Brushed DC Motor is simple to control torque • In a Brushed DC motor, torque control is also easy to accomplish. Output torque is proportional to current. So, if the current is limited, you have just limited the torque which the brush motor can achieve. • This fact makes the Brushed DC brush motor ideal for delicate applications such as textile manufacturing. Simple and inexpensive drive/control design The result of this design is that variable speed or variable torque electronics are easy to design and manufacture. Varying the speed of a Brushed DC motor requires little more than a large enough potentiometer. In practice, these have been replaced for all but sub-fractional horsepower applications by the SCR and PWM drives (sometimes referred to as controls), which offer relatively precisely control voltage and current. Common drives for a Brushed DC motor is available at the low-end of the product offering (up to 2 horsepower). The cost will depend on the accuracy requirement, but many brush motors can be accompanied with drives ranging from $29.00 - $199.00 USD. Disadvantages of the Brushed DC Motor • A Brushed DC motor can be a bit expensive to produce, in that the raw materials have become more costly in recent year • A Brushed DC motor is less reliable in control at lowest speeds • A Brushed DC motor is physically larger than other motors with the same torque • A Brushed DC motor is much more high maintenance than are brushless motors • A Brushed DC motor becomes vulnerable to dust which decrease

Although Brush DC Electrical Motors have been overshadowed by the brushless motor, Brush DC Electrical Motors are still used in a wide range of applications. Just because we may not see Brush Electrical Motors very often, they really are everywhere ranging from toys to cellular phones to Jacuzzi pumps. Most automatic car windows and automatic seat adjustments are operated by Brush Electrical Motors. Brush DC Electrical Motors have been an automotive industry favorite because of their relatively low cost and simple design. Brush DC Electrical Motors come in all different sizes all with different torque and speed specifications; so whatever your application may be there most likely are Brush DC Electrical Motors that will meet your demands.

Although the Brush DC Motor has been overshadowed by the brushless motor, the Brush DC Motor is still used in a wide range of applications. Just because we may not see Brush Motors very often, they really are everywhere ranging from toys to cellular phones to Jacuzzi pumps. Most automatic car windows and automatic seat adjustments are operated by Brush Motors. The Brush DC Motor has been an automotive industry favorite because of their relatively low cost and simple design. Brush Motors come in all different sizes all with different torque and speed specifications; so whatever your application may be there most likely is a Brush DC Motor that will meet your demands.

The DC Motor is one of the earliest of all electrical motor designs. It is usually the motor of choice for the majority of torque control and variable speed applications. This Tech Tip discusses the advantages and disadvantages of using a DC Brush motor in machinery and processes. Advantages of the DC Motor • The Brush DC Motor has a simple construction, therefore requiring a cheap drive design • Understandable design/technology facilitates in quick application of a DC Motor. • The design of the DC motor is quite simple, in that a permanent magnetic field is created in the by either of two means: • Permanent magnets • Electro-magnetic windings • If the field is created by permanent magnets, a Brush DC Motor is said to be a permanent magnet DC motor (PMDC). If created by electromagnetic windings, the brush motor is often said to be a shunt wound Brush DC motor (SWDC). Today, because of cost-effectiveness and reliability, the PMDC motor is the motor of choice for applications involving fractional horsepower DC brush motors, as well as most applications up to about 2.0 horsepower. • Opposing the stator field is the armature field, which is generated by a changing electromagnetic flux coming from windings located on the rotor of the Brush DC motor. The magnetic poles of the armature field will attempt to line up with the opposite magnetic poles generated by the stator field. Next, the section of the rotor where the electricity enters the rotor windings is called the commutator. The electricity is carried between the brush motor rotor and the stator by conductive graphite-copper brushes (mounted on the rotor) which contact rings on stator. Important to Note: If a Brush DC motor suffers a loss of field (if for example, the field power connections are broken), the DC Motor will immediately begin to accelerate to the top speed which the loading will allow. This can result in the motor flying apart if the motor is lightly loaded. The possible loss of field must be accounted for, particularly with a shunt wound DC Motor. Imagine power is supplied: A Brush DC Motor rotates toward the pole alignment point. Just as the DC motor would get to this point, the brushes jump across a gap in the stator rings. Momentum carries the brush motor forward over this gap. When the brushes get to the other side of the gap, they contact the stator rings again and - the polarity of the voltage is reversed in this set of rings! The brush motor begins accelerating again, to the opposite set of poles. (The momentum has carried the brush motor past the original pole alignment point.) This continues as the brush motor rotates. In most DC motors, several sets of windings or permanent magnets are present to smooth out the motion. Te Brush DC Motor is simple to control speed • Simple to control speed - Controlling the speed of a DC motor is simple. The higher the armature voltage, the faster the rotation. This relationship is linear to the brush motors maximum speed. • The maximum armature voltage which corresponds to the rated speed of the brush motors (these brush motors are usually given a rated speed and a maximum speed, such as 1750/2000 rpm) are available in certain standard voltages, which roughly increase in conjunction with horsepower. • The smallest industrial-type brush motors are rated 90 VDC and 180 VDC. Larger units are rated at 250 VDC and even higher (dependent upon the individual manufacturer). • Most industrial DC brush motors operate reliably over a speed range of about 20:1 - down to about 5-7% of base speed. This is much better performance than the comparable AC motor. This fact is in part due to the fact of the mere simplicity of control. However, it is also partly due to the fact that most industrial DC brush motors were designed with variable speed operations in mind. The addition of heat dissipation features/ devices provided for lower operating speeds of DC brush motors. • NOTE: The specialty DC motor is used in mobile applications and are typically rated 12, 24, or 48 VDC. Other tiny brush motors can be rated as low as 5 VDC. This DC Motor is very popular among hobbyists. The Brush DC Motor is simple to control torque • In a DC motor, torque control is also easy to accomplish. Output torque is proportional to current. So, if the current is limited, you have just limited the torque which the brush motor can achieve. • This fact makes the DC brush motor ideal for delicate applications such as textile manufacturing. Simple and inexpensive drive/control design The result of this design is that variable speed or variable torque electronics are easy to design and manufacture. Varying the speed of a DC motor requires little more than a large enough potentiometer. In practice, these have been replaced for all but sub-fractional horsepower applications by the SCR and PWM drives (sometimes referred to as controls), which offer relatively precisely control voltage and current. Common drives for a DC brush motor is available at the low-end of the product offering (up to 2 horsepower). The cost will depend on the accuracy requirement, but many brush motors can be accompanied with drives ranging from $29.00 - $199.00 USD. Disadvantages of the Brush DC Motor • A Brush DC motor can be a bit expensive to produce, in that the raw materials have become more costly in recent year • A Brush DC motor is less reliable in control at lowest speeds • A Brush DC motor is physically larger than other motors with the same torque • A Brush DC motor is much more high maintenance than are brushless motors • A Brush DC motor becomes vulnerable to dust which decrease

Although Brush DC Motors have been overshadowed by the brushless motor, Brush DC Motors are still used in a wide range of applications. Just because we may not see Brush Motors very often, they really are everywhere ranging from toys to cellular phones to Jacuzzi pumps. Most automatic car windows and automatic seat adjustments are operated by Brush Motors. Brush DC Motors have been an automotive industry favorite because of their relatively low cost and simple design. Brush DC Motors come in all different sizes all with different torque and speed specifications; so whatever your application may be there most likely are Brush DC Motors that will meet your demands.

Brushed DC Motors are one of the earliest of all electrical motor designs. It is usually the motor of choice for the majority of torque control and variable speed applications. This Tech Tip discusses the advantages and disadvantages of using Brushed DC motors in machinery and processes. Advantages of Brushed DC Motors • Brushed DC Motors have a simple construction, therefore requiring a cheap drive design • Understandable design/technology facilitates in quick application of Brushed DC Motors. • The design of Brushed DC motors are quite simple, in that a permanent magnetic field is created in the by either of two means: • Permanent magnets • Electro-magnetic windings • If the field is created by permanent magnets, Brushed DC Motors are said to be a permanent magnet DC motor (PMDC). If created by electromagnetic windings, the brush motor is often said to be a shunt wound Brush DC motor (SWDC). Today, because of cost-effectiveness and reliability, the PMDC motor is the motor of choice for applications involving fractional horsepower brushed DC motors, as well as most applications up to about 2.0 horsepower. • Opposing the stator field is the armature field, which is generated by a changing electromagnetic flux coming from windings located on the rotor of Brushed DC motors. The magnetic poles of the armature field will attempt to line up with the opposite magnetic poles generated by the stator field. Next, the section of the rotor where the electricity enters the rotor windings is called the commutator. The electricity is carried between the brush motor rotor and the stator by conductive graphite-copper brushes (mounted on the rotor) which contact rings on stator. Important to Note: If Brushed DC motors suffer a loss of field (if for example, the field power connections are broken), the Brushed DC Motor will immediately begin to accelerate to the top speed which the loading will allow. This can result in the motor flying apart if the motor is lightly loaded. The possible loss of field must be accounted for, particularly with shunt wound Brushed DC Motors. Imagine power is supplied: Brushed DC Motors rotate toward the pole alignment point. Just as Brushed DC motors would get to this point, the brushes jump across a gap in the stator rings. Momentum carries brushed DC motors forward over this gap. When the brushes get to the other side of the gap, they contact the stator rings again and - the polarity of the voltage is reversed in this set of rings! The brush motor begins accelerating again, to the opposite set of poles. (The momentum has carried Brushed DC motors past the original pole alignment point.) This continues as Brushed DC Motors rotate. In most DC motors, several sets of windings or permanent magnets are present to smooth out the motion. Brushed DC Motors are simple to control speed • Simple to control speed - Controlling the speed of Brushed DC motors are simple. The higher the armature voltage, the faster the rotation. This relationship is linear to the brush motors maximum speed. • The maximum armature voltage which corresponds to the rated speed of the brush motors (these brush DC motors are usually given a rated speed and a maximum speed, such as 1750/2000 rpm) are available in certain standard voltages, which roughly increase in conjunction with horsepower. • The smallest industrial-type brush DC motors are rated 90 VDC and 180 VDC. Larger units are rated at 250 VDC and even higher (dependent upon the individual manufacturer). • Most industrial brush DC motors operate reliably over a speed range of about 20:1 - down to about 5-7% of base speed. This is much better performance than the comparable AC motor. This fact is in part due to the fact of the mere simplicity of control. However, it is also partly due to the fact that most industrial DC motors were designed with variable speed operations in mind. The addition of heat dissipation features/ devices provided for lower operating speeds of DC motors. • NOTE: Specialty Brushed DC motors are used in mobile applications and are typically rated 12, 24, or 48 VDC. Other tiny brush motors can be rated as low as 5 VDC. These Brushed DC Motors are very popular among hobbyists. Brushed DC Motors are simple to control torque • In Brushed DC motors, torque control is also easy to accomplish. Output torque is proportional to current. So, if the current is limited, you have just limited the torque which brush DCmotors can achieve. • This fact makes Brushed DC brushs motor ideal for delicate applications such as textile manufacturing. Simple and inexpensive drive/control design The result of this design is that variable speed or variable torque electronics are easy to design and manufacture. Varying the speed of Brushed DC motors requires little more than a large enough potentiometer. In practice, these have been replaced for all but sub-fractional horsepower applications by the SCR and PWM drives (sometimes referred to as controls), which offer relatively precisely control voltage and current. Common drives for a Brushed DC motor is available at the low-end of the product offering (up to 2 horsepower). The cost will depend on the accuracy requirement, but many brush motors can be accompanied with drives ranging from $29.00 - $199.00 USD. Disadvantages of Brushed DC Motors • Brushed DC motors can be a bit expensive to produce, in that the raw materials have become more costly in recent year • Brushed DC motors are less reliable in control at lowest speeds • Brushed DC motors are physically larger than other motors with the same torque • Brushed DC motors are much more high maintenance than are brushless motors • Brushed DC motors become vulnerable to dust which decrease

Although the Direct Current Motor has been overshadowed by the brushless motor, the Direct Current Motor is still used in a wide range of applications. Just because we may not see the Direct Current Motor very often, it really is everywhere ranging from toys to cellular phones to Jacuzzi pumps. Most automatic car windows and automatic seat adjustments are operated by Direct Current Motors. The Direct Current Motor has been an automotive industry favorite because of their relatively low cost and simple design. The Direct Current Motor comes in all different sizes all with different torque and speed specifications; so whatever your application may be there most likely is a Direct Current Motor that will meet your demands.

The Direct Current Motor is one of the earliest of all electrical motor designs. It is usually the motor of choice for the majority of torque control and variable speed applications. This Tech Tip discusses the advantages and disadvantages of using a Direct Current Motor motor in machinery and processes. Advantages of the Direct Current Motor • The Direct Current Motor has a simple construction, therefore requiring a cheap drive design • Understandable design/technology facilitates in quick application of a Motor. • The design of the Direct Current Motor is quite simple, in that a permanent magnetic field is created in the by either of two means: • Permanent magnets • Electro-magnetic windings • If the field is created by permanent magnets, a Brush DC Motor is said to be a permanent magnet DC motor (PMDC). If created by electromagnetic windings, the direct current motor is often said to be a shunt wound Brush DC motor (SWDC). Today, because of cost-effectiveness and reliability, the PMDC motor is the motor of choice for applications involving a fractional horsepower Direct Current Motor, as well as most applications up to about 2.0 horsepower. • Opposing the stator field is the armature field, which is generated by a changing electromagnetic flux coming from windings located on the rotor of the Direct Current Motor. The magnetic poles of the armature field will attempt to line up with the opposite magnetic poles generated by the stator field. Next, the section of the rotor where the electricity enters the rotor windings is called the commutator. The electricity is carried between the Direct Current Motor rotor and the stator by conductive graphite-copper brushes (mounted on the rotor) which contact rings on stator. Important to Note: If a Brush DC motor suffers a loss of field (if for example, the field power connections are broken), the DC Motor will immediately begin to accelerate to the top speed which the loading will allow. This can result in the motor flying apart if the motor is lightly loaded. The possible loss of field must be accounted for, particularly with a shunt wound DC Motor. Imagine power is supplied: A Brush DC Motor rotates toward the pole alignment point. Just as the DC motor would get to this point, the brushes jump across a gap in the stator rings. Momentum carries the direct current motor forward over this gap. When the brushes get to the other side of the gap, they contact the stator rings again and - the polarity of the voltage is reversed in this set of rings! The direct current motor begins accelerating again, to the opposite set of poles. (The momentum has carried the direct current motor past the original pole alignment point.) This continues as the direct current motor rotates. In most DC motors, several sets of windings or permanent magnets are present to smooth out the motion. THe Brush DC Motoor is simple to control speed • Simple to control speed - Controlling the speed of a DC motor is simple. The higher the armature voltage, the faster the rotation. This relationship is linear to the direct current motors maximum speed. • The maximum armature voltage which corresponds to the rated speed of the direct current motors (these direct current motors are usually given a rated speed and a maximum speed, such as 1750/2000 rpm) are available in certain standard voltages, which roughly increase in conjunction with horsepower. • The smallest industrial-type direct current motors are rated 90 VDC and 180 VDC. Larger units are rated at 250 VDC and even higher (dependent upon the individual manufacturer). • Most industrial DC direct current motors operate reliably over a speed range of about 20:1 - down to about 5-7% of base speed. This is much better performance than the comparable AC motor. This fact is in part due to the fact of the mere simplicity of control. However, it is also partly due to the fact that most industrial DC direct current motors were designed with variable speed operations in mind. The addition of heat dissipation features/ devices provided for lower operating speeds of DC direct current motors. • NOTE: The specialty DC motor is used in mobile applications and are typically rated 12, 24, or 48 VDC. Other tiny direct current motors can be rated as low as 5 VDC. This DC Motor is very popular among hobbyists. The Brush DC Motor is simple to control torque • In a DC motor, torque control is also easy to accomplish. Output torque is proportional to current. So, if the current is limited, you have just limited the torque which the direct current motor can achieve. • This fact makes the DC direct current motor ideal for delicate applications such as textile manufacturing. Simple and inexpensive drive/control design The result of this design is that variable speed or variable torque electronics are easy to design and manufacture. Varying the speed of a DC motor requires little more than a large enough potentiometer. In practice, these have been replaced for all but sub-fractional horsepower applications by the SCR and PWM drives (sometimes referred to as controls), which offer relatively precisely control voltage and current. Common drives for a DC direct current motor is available at the low-end of the product offering (up to 2 horsepower). The cost will depend on the accuracy requirement, but many direct current motors can be accompanied with drives ranging from $29.00 - $199.00 USD. Disadvantages of the Brush DC Motor • A Brush DC motor can be a bit expensive to produce, in that the raw materials have become more costly in recent year • A Brush DC motor is less reliable in control at lowest speeds • A Brush DC motor is physically larger than other motors with the same torque • A Brush DC motor is much more high maintenance than are brushless motors • A Brush DC motor becomes vulnerable to dust which decrease

Although Brush Direct Current Motors have been overshadowed by the brushless motor, Brush Direct Current Motors are still used in a wide range of applications. Just because we may not see Brush Motors very often, they really are everywhere ranging from toys to cellular phones to Jacuzzi pumps. Most automatic car windows and automatic seat adjustments are operated by Brush Motors. Brush Direct Current Motors have been an automotive industry favorite because of their relatively low cost and simple design. Brush Direct Current Motors come in all different sizes all with different torque and speed specifications; so whatever your application may be there most likely are Brush Direct Current Motors that will meet your demands.

Brushed Direct Current Motors are one of the earliest of all electrical motor designs. It is usually the motor of choice for the majority of torque control and variable speed applications. This Tech Tip discusses the advantages and disadvantages of using Brushed Direct Current motors in machinery and processes. Advantages of Brushed Direct Current Motors • Brushed Direct Current Motors have a simple construction, therefore requiring a cheap drive design • Understandable design/technology facilitates in quick application of Brushed Direct Current Motors. • The design of Brushed Direct Current motors are quite simple, in that a permanent magnetic field is created in the by either of two means: • Permanent magnets • Electro-magnetic windings • If the field is created by permanent magnets, Brushed DC Motors are said to be a permanent magnet DC motor (PMDC). If created by electromagnetic windings, the brush motor is often said to be a shunt wound Brush DC motor (SWDC). Today, because of cost-effectiveness and reliability, the PMDC motor is the motor of choice for applications involving fractional horsepower brushed Direct Current motors, as well as most applications up to about 2.0 horsepower. • Opposing the stator field is the armature field, which is generated by a changing electromagnetic flux coming from windings located on the rotor of Brushed Direct Current motors. The magnetic poles of the armature field will attempt to line up with the opposite magnetic poles generated by the stator field. Next, the section of the rotor where the electricity enters the rotor windings is called the commutator. The electricity is carried between the brush motor rotor and the stator by conductive graphite-copper brushes (mounted on the rotor) which contact rings on stator. Important to Note: If Brushed Direct Current motors suffer a loss of field (if for example, the field power connections are broken), the Brushed Direct Current Motor will immediately begin to accelerate to the top speed which the loading will allow. This can result in the motor flying apart if the motor is lightly loaded. The possible loss of field must be accounted for, particularly with shunt wound Brushed Direct Current Motors. Imagine power is supplied: Brushed Direct Current Motors rotate toward the pole alignment point. Just as Brushed Direct Current motors would get to this point, the brushes jump across a gap in the stator rings. Momentum carries brushed Direct Current motors forward over this gap. When the brushes get to the other side of the gap, they contact the stator rings again and - the polarity of the voltage is reversed in this set of rings! The brush motor begins accelerating again, to the opposite set of poles. (The momentum has carried Brushed Direct Current motors past the original pole alignment point.) This continues as Brushed DC Motors rotate. In most Direct Current motors, several sets of windings or permanent magnets are present to smooth out the motion. Brushed Direct Current Motors are simple to control speed • Simple to control speed - Controlling the speed of Brushed Direct Current motors are simple. The higher the armature voltage, the faster the rotation. This relationship is linear to the brush motors maximum speed. • The maximum armature voltage which corresponds to the rated speed of the brush motors (these brush Direct Current motors are usually given a rated speed and a maximum speed, such as 1750/2000 rpm) are available in certain standard voltages, which roughly increase in conjunction with horsepower. • The smallest industrial-type brush Direct Current motors are rated 90 VDC and 180 VDC. Larger units are rated at 250 VDC and even higher (dependent upon the individual manufacturer). • Most industrial brush Direct Current motors operate reliably over a speed range of about 20:1 - down to about 5-7% of base speed. This is much better performance than the comparable AC motor. This fact is in part due to the fact of the mere simplicity of control. However, it is also partly due to the fact that most industrial DC motors were designed with variable speed operations in mind. The addition of heat dissipation features/ devices provided for lower operating speeds of Direct Current motors. • NOTE: Specialty Brushed Direct Current motors are used in mobile applications and are typically rated 12, 24, or 48 VDC. Other tiny brush motors can be rated as low as 5 VDC. These Brushed Direct Current Motors are very popular among hobbyists. Brushed Direct Current Motors are simple to control torque • In Brushed Direct Current motors, torque control is also easy to accomplish. Output torque is proportional to current. So, if the current is limited, you have just limited the torque which brush Direct Current can achieve. • This fact makes Brushed Direct Current brushs motor ideal for delicate applications such as textile manufacturing. Simple and inexpensive drive/control design The result of this design is that variable speed or variable torque electronics are easy to design and manufacture. Varying the speed of Brushed Direct Current motors requires little more than a large enough potentiometer. In practice, these have been replaced for all but sub-fractional horsepower applications by the SCR and PWM drives (sometimes referred to as controls), which offer relatively precisely control voltage and current. Common drives for a Brushed Direct Current motor is available at the low-end of the product offering (up to 2 horsepower). The cost will depend on the accuracy requirement, but many brush motors can be accompanied with drives ranging from $29.00 - $199.00 USD. Disadvantages of Brushed Direct Current Motors • Brushed Direct Current motors can be a bit expensive to produce, in that the raw materials have become more costly in recent year • Brushed Direct Current motors are less reliable in control at lowest speeds • Brushed Direct Current motors are physically larger than other motors with the same torque • Brushed Direct Current motors are much more high maintenance than are brushless motors • Brushed Direct Current motors become vulnerable to dust which decrease

Although the Permanent Magnet DC Motor has been overshadowed by the brushless motor, the Permanent Magnet DC Motor is still used in a wide range of applications. Just because we may not see a Permanent Magnet DC Motor very often, they really are everywhere ranging from toys to cellular phones to Jacuzzi pumps. Most automatic car windows and automatic seat adjustments are operated by a Permanent Magnet DC Motor. The Permanent Magnet DC Motor has been an automotive industry favorite because of their relatively low cost and simple design. A Permanent Magnet DC Motor may come in all different sizes all with different torque and speed specifications; so whatever your application may be there most likely is a Permanent Magnet DC Motor that will meet your demands.

The Permanent Magnet DC Motor is one of the earliest of all electrical motor designs. It is usually the motor of choice for the majority of torque control and variable speed applications. This Tech Tip discusses the advantages and disadvantages of using a Permanent Magnet DC Brush motor in machinery and processes. Advantages of the Permanent Magnet DC Motor • The Permanent Magnet DC Motor has a simple construction, therefore requiring a cheap drive design • Understandable design/technology facilitates in quick application of a Permanent Magnet DC Motor. • The design of the Permanent Magnet DC motor is quite simple, in that a permanent magnetic field is created in the by either of two means: • Permanent magnets • Electro-magnetic windings • If the field is created by permanent magnets, a Permanent Magnet DC Motor is said to be a permanent magnet DC motor (PMDC). If created by electromagnetic windings, the brush motor is often said to be a shunt wound Brush DC motor (SWDC). Today, because of cost-effectiveness and reliability, the PMDC motor is the motor of choice for applications involving fractional horsepower DC permanent magnet motors, as well as most applications up to about 2.0 horsepower. • Opposing the stator field is the armature field, which is generated by a changing electromagnetic flux coming from windings located on the rotor of the Permanent Magnet DC motor. The magnetic poles of the armature field will attempt to line up with the opposite magnetic poles generated by the stator field. Next, the section of the rotor where the electricity enters the rotor windings is called the commutator. The electricity is carried between the brush motor rotor and the stator by conductive graphite-copper brushes (mounted on the rotor) which contact rings on stator. Important to Note: If a Permanent Magnet DC motor suffers a loss of field (if for example, the field power connections are broken), the Permanent Magnet DC Motor will immediately begin to accelerate to the top speed which the loading will allow. This can result in the motor flying apart if the motor is lightly loaded. The possible loss of field must be accounted for, particularly with a shunt wound Permanent Magnet DC Motor. Imagine power is supplied: A Permanent Magnet DC Motor rotates toward the pole alignment point. Just as the Permanent Magnet DC motor would get to this point, the brushes jump across a gap in the stator rings. Momentum carries the permanent magnet DC motor forward over this gap. When the brushes get to the other side of the gap, they contact the stator rings again and - the polarity of the voltage is reversed in this set of rings! The brush motor begins accelerating again, to the opposite set of poles. (The momentum has carried the Permanent Magnet DC motor past the original pole alignment point.) This continues as the Permanent Magnet DC Motor rotates. In most DC motors, several sets of windings or permanent magnets are present to smooth out the motion. The Permanent Magnet DC Motor is simple to control speed • Simple to control speed - Controlling the speed of a Permanent Magnet DC motor is simple. The higher the armature voltage, the faster the rotation. This relationship is linear to the brush motors maximum speed. • The maximum armature voltage which corresponds to the rated speed of the brush motors (these brush motors are usually given a rated speed and a maximum speed, such as 1750/2000 rpm) are available in certain standard voltages, which roughly increase in conjunction with horsepower. • The smallest industrial-type brush motors are rated 90 VDC and 180 VDC. Larger units are rated at 250 VDC and even higher (dependent upon the individual manufacturer). • Most industrial DC brush motors operate reliably over a speed range of about 20:1 - down to about 5-7% of base speed. This is much better performance than the comparable AC motor. This fact is in part due to the fact of the mere simplicity of control. However, it is also partly due to the fact that most industrial DC brush motors were designed with variable speed operations in mind. The addition of heat dissipation features/ devices provided for lower operating speeds of DC brush motors. • NOTE: The specialty Permanent Magnet DC motor is used in mobile applications and are typically rated 12, 24, or 48 VDC. Other tiny brush motors can be rated as low as 5 VDC. This Permanent Magnet DC Motor is very popular among hobbyists. The Permanent Magnet DC Motor is simple to control torque • In a Permanent Magnet DC motor, torque control is also easy to accomplish. Output torque is proportional to current. So, if the current is limited, you have just limited the torque which the brush motor can achieve. • This fact makes the Permanent Magnet DC brush motor ideal for delicate applications such as textile manufacturing. Simple and inexpensive drive/control design The result of this design is that variable speed or variable torque electronics are easy to design and manufacture. Varying the speed of a Permanent Magnet DC motor requires little more than a large enough potentiometer. In practice, these have been replaced for all but sub-fractional horsepower applications by the SCR and PWM drives (sometimes referred to as controls), which offer relatively precisely control voltage and current. Common drives for a Permanent Magnet DC motor is available at the low-end of the product offering (up to 2 horsepower). The cost will depend on the accuracy requirement, but many brush motors can be accompanied with drives ranging from $29.00 - $199.00 USD. Disadvantages of the Permanent Magnet DC Motor • A Permanent Magnet DC motor can be a bit expensive to produce, in that the raw materials have become more costly in recent year • A Permanent Magnet DC motor is less reliable in control at lowest speeds • A Permanent Magnet DC motor is physically larger than other motors with the same torque • A Permanent Magnet DC motor is much more high maintenance than are brushless motors • A Permanent Magnet DC motor becomes vulnerable to dust which decrease

Although Permanent Magnet DC Motors have been overshadowed by the brushless motor, Permanent Magnet DC Motors are still used in a wide range of applications. Just because we may not see Permanent Magnet DC Motors very often, they really are everywhere ranging from toys to cellular phones to Jacuzzi pumps. Most automatic car windows and automatic seat adjustments are operated by Brush Motors. Permanent Magnet DC Motors have been an automotive industry favorite because of their relatively low cost and simple design. Permanent Magnet DC Motors come in all different sizes all with different torque and speed specifications; so whatever your application may be there most likely are Permanent Magnet DC Motors that will meet your demands.