The first generation of electromotors surfaced in the early 19th century. They use mechanical elements to produce unidirectional motion. Advancements in technology have led to the changing of mechanical aspects to more efficient solid-state components. This advancement resulted in the emergence of brushless AC motors and DC engines. What are the features that make the brushless technology preferable?
Brushed vs. Brushless
By examining their structures and operating principles more closely, you will appreciate the difference between these two technologies
An engine using mechanical motors consists of an armature made of winding wires, a static ring, and permanent magnets. Other components include a communicator, a cylinder mounted on the shaft that joins the armature, and graphite-based brushes.
This device energises the armature to create a magnetic field that turns the rotor. The rotation lasts for a half-circle, after which it must be reversed. At the zero-torque point, the brushes act with the communicator to switch the current. This is how the current produces continuous torque without changing direction.
The structural composition of a brushless motor is similar to the configurations above with its movable and stationary components.
Both have a rotor and a stator. However, brushless drives use semiconductor-based transistors instead of brushes.
Since the device lacks mechanical elements to communicate, power is derived directly from the stator coils, creating a magnetic field. When the magnetic field interacts with the rotor magnets, movements occur.
In this case, the transistors reverse their amperage at the half-turn to produce continuous torque in the same direction.
The difference between the two technologies:
The brushed models are bulky because of the many mechanical parts. The brushless motor has a lighter weight and smaller dimensions.
The many rubbing parts in the brushed model lead to a considerable loss of capacity. The brushless types have high power-to-mass and torque-to-mass ratios.
The mechanical-based design limits the maximum RPM in brushed models. However, the minimum rotor inertia allows for maximum velocity in brushless models.
The sliding contacts in brushed motors cause sparks, which is a risky, inflammable atmosphere, but the brushless models do not spark because the transistors handle commutation.
The Graphite element in brushed motors gets worn out quickly, while the brushless types, lacking wearable parts, are more durable.
What are the brushless AC motors benefits?
The following improvements are achieved by replacing the mechanical-based communicators with solid-state electronics.
Smaller size
Increased efficiency
Enhanced safety
Low maintenance and increased durability
High level of flexibility and low operating noise due to fewer -moving parts.
FMI brushless engines
Rozum Robotics's motors in the FMI series have a proprietary design and use brushless communication, which minimizes power loss from friction.
It gives low noise while functioning, does not have the risk of sparking, and has high levels of controllability.
It was designed to be durable and equipped with a hollow shaft for easy integration.
It uses a star winding model for high torque delivery, even a slow rotation.
It has an in-running configuration, and rare-earth magnets give it a compact dimension and ultra-high efficiency.
It has built-in temperature sensing elements that monitor temperature to prevent demagnetization.
The AC synchronization subtype allows smooth rotation without noise, cogging, or electromagnetic interference. It is also highly efficient thanks to its superior power-to-mass ratio and torque density.
If you need an advanced motor designed exclusively for your technical demands, it can quickly be done after a technical consultation with Rozum experts.
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