DC motors, including both brushed and brushless types, find wide applications in linear actuators used across industries like robotics, automation, aerospace, and more. Linear actuators convert rotational motion into linear motion, enabling precise movements in a variety of systems, including drones, landing gear systems, recreational vehicles, and industrial automation. Hence, choosing the right type of motor, brushed or brushless, is essential to ensure the efficiency, reliability, and lifespan of linear actuators.
Brushed DC Motor in Linear Actuators: Overview and Working
A brushed DC motor is a simple, small motor used in linear actuators. It utilizes mechanical brushes to commutate the motor, enabling rotational motion, which is then converted to linear motion by the actuator. A brushed DC motor comprises four key components – stator, rotor, commutator, and brushes.
Once DC voltage is applied across the brushes, current begins to flow through the rotor windings, creating a magnetic field around the rotor. The stator also has its magnetic field which interacts with that of the rotor, prompting it to spin. The commutator also rotates, changing the current flow direction. This process is called commutation, which ensures continuous changes in the magnetic field and maintains rotational motion by alternating the rotor and stator magnets. In a linear actuator, the motor’s rotational movement is then converted into linear motion via a lead screw or similar mechanism, driving the actuator’s mechanical parts to produce the desired movement.
Brushless DC Motor (BLDC) in Linear Actuators: Overview and Working
A brushless DC motor (BLDC) is an advanced motor used in linear actuators for precise, efficient motion. The motor consists of a rotor, stator, and electronic speed controller (ESC). In a linear actuator, the ESC sequentially energizes the stator windings, creating a rotating magnetic field. Its interaction with the rotor’s permanent magnets causes it to spin, converting rotational motion into linear movement via a lead screw or ball screw. The ESC ensures smooth, controlled operation, minimizing power loss and heat generation for efficient actuator performance.
Difference Between Brushed and Brushless Motors in Linear Actuators
Here are some key differences between brushed and brushless DC motors when used in linear actuators
- Working: While the basic principle of both motor types is the same, brushed motors use mechanical brushes for electrical contact, whereas brushless motors rely on electronic controllers for the same purpose. Brushless motors have a more advanced design, making them better suited for precision and efficiency in linear actuators.
- Efficiency: Efficiency of brushed motors may reduce over the time due to the friction between the brushes and the commutator. The brushes need to be replaced regularly to avoid such issues. In contrast, brushless motors are more efficient since they eliminate friction from brushes, resulting in lower wear and heat generation, and providing better overall performance. This makes them ideal for applications that require long-lasting performance in linear actuators.
- Noise: Brushless motors are much quieter than brushed motors, making them a better choice for applications with strict noise requirements, such as medical devices, robotics, or assistive technology that uses linear actuators.
- Complexity: Brushed motors are simple and easy to operate, which makes them ideal for cost-sensitive linear actuator applications. However, brushless motors require more complex control systems and algorithms to manage the electronic commutation, offering more precise and reliable performance in linear actuators that need fine control and smooth motion.
- Cost: While brushless motors are generally more expensive than brushed motors, their lower maintenance requirements, longer lifespan, and improved efficiency can make them more cost-effective in the long run, especially in linear actuators where continuous, high-performance operation is critical.
Learn more on this topic in our related blog: Understanding DC Gear Motors: Working Principles, Selection, and Applications
Are you looking for standard or custom DC motors for your linear actuators? If yes, ensure you partner with a reliable manufacturer that can meet your specific needs. The motor must align with the required speed, range, precision, and repeatability of your application, offering the right level of control. Many DC Motor manufacturers across the US offer custom options to cater to your exact requirements. Making the right motor choice is crucial, as it drives your actuator’s efficiency and enables smooth, precise movements, enhancing the overall performance and reliability of your system.