The difference between brushed fans and brushless fans

In industrial, household appliances, and automotive air conditioning systems, fans are indispensable components. According to the different types of motors, fans are mainly divided into two types: brushed fans and brushless fans. They have significant differences in structure, performance, lifespan, and application scenarios. This article will provide a detailed comparison of the characteristics of these two types of fans to help users choose the appropriate product based on their needs.

1. Structure and working principle

(1) Brushed fan

Structural features:

Adopting a carbon brush+commutator structure, current commutation is achieved through mechanical contact.

It is usually composed of a stator (permanent magnet or electromagnet), rotor (winding), carbon brush, and commutator.

working principle:

Current is input into the rotor winding through carbon brushes and commutators, generating a rotating magnetic field that drives the motor to rotate.

The continuous friction between the carbon brush and the commutator will cause wear and tear after long-term use.

(2) Brushless fan

Structural features:

Adopting electronic commutation (Hall sensor+controller), no carbon brush is required.

It is mainly composed of stator (winding), rotor (permanent magnet), and electronic control circuit.

working principle:

The controller precisely controls the direction of the current based on the signal from the Hall sensor, ensuring continuous rotation of the motor.

No mechanical contact, reduce wear and improve efficiency.

2. Performance comparison

3. Analysis of advantages and disadvantages

(1) Advantages and disadvantages of brush fans

advantage:

Simple structure, low cost, suitable for low-cost applications.

High starting torque, suitable for scenarios that require high initial loads (such as certain industrial equipment).

Disadvantages:

Carbon brush wear leads to short lifespan and requires frequent maintenance.

Low efficiency, high energy consumption, and easy to generate electric sparks (not suitable for flammable environments).

(2) Advantages and disadvantages of brushless fans

advantage:

Long lifespan, maintenance free, suitable for long-term operation.

Efficient and energy-saving, low noise, suitable for precision equipment such as medical instruments and server cooling.

Disadvantages:

High cost, dependence on electronic controllers, and complex maintenance.

The starting torque is relatively small, requiring additional design optimization for high load starting.

4. Typical application scenarios

Brushed fan:

Household appliances (such as low-end fans, vacuum cleaners)

Automotive HVAC system (some older models)

Industrial ventilation equipment (low-cost demand scenario)

Brushless fan:

High end household appliances (variable frequency air conditioners, air purifiers)

Electric vehicle battery cooling system

Cooling of data center servers

Medical equipment (such as ventilators, centrifuges)

5. How to choose?

Limited budget, short-term use → brushed fan

Long term operation, high energy efficiency requirements → Brushless fan

Precise control, low-noise environment → Brushless fan

Conclusion

Both brushed and brushless fans have their own advantages and disadvantages, and when choosing, it is necessary to consider cost, efficiency, lifespan, and application scenarios comprehensively. With the advancement of technology, brushless fans are gradually replacing traditional brushed fans and becoming the ideal choice for efficient and long-lasting applications.