What are Brushless and Brushed Servo Motors?

Brushed and brushless servo motors are among the most commonly preferred motor types in the industrial sector. These motor types, which offer advantages in terms of work, are often confused. For this reason, there is confusion about which servo motor should be used for which processes. At this point, we invite you to review our content titled “What Are Brushed and Brushless Servo Motors?” to gain insight into where brushed and brushless servo motors are used, the advantages they offer, and the differences between them. We wish you all an enjoyable reading experience.

What is a Brushless Servo Motor?

A brushed servo motor is a type of electric motor that converts electrical energy into mechanical motion. This type of servo motor typically consists of a rotor and a stator. The rotor represents a rotating shaft or disk-shaped component, while the stator represents the magnetic field surrounding the rotor. For this reason, brushed servo motors are designed to operate at a specific position or speed. As a result, they respond to signals provided by the control system, offering precise control advantages.

The term “brush” in the name refers to the transmission element inside the motor. For this reason, brushes are usually made of carbon or metal. This ensures that electrical energy is transferred smoothly with the rotor, enabling the rotor to rotate. In short, brush-type servo motors typically feature position control, speed control, or torque control capabilities.

Where are brush servo motors used?

Brush servo motors have a wide range of applications. Brush servo motors, which have a very wide range of applications, are used in industrial robotics to enable the movement of robot arms and control the robot, while in CNC machines they are used to control the axis of lathes and milling machines and to assist in the precise machining of parts. Additionally, they are preferred in automation systems to ensure synchronized and precise motion control. They are also used in medical devices and transportation vehicles. These servo motors, which offer numerous advantages, are also preferred in optical and camera systems, printers and scanners, and gaming consoles for precise steering.

What are the advantages of a brushed servo motor?

Brush servo motors offer many advantages in workflows. These advantages ensure that work progresses smoothly. This prevents work from being interrupted. The advantages of these brush servo motors are as follows:

Precision Control

Brush servo motors, which offer considerable convenience, are preferred in applications that require precise control, particularly in terms of position, speed, and torque control, thanks to their ability to provide precise control.

High Performance

Brush servo motors, which offer advantages in terms of performance, are generally considered to be high-performance motors. These motors are characterized by fast response times and high dynamic performance.

High Torque

These brush servo motors with high torque structure can produce high torque values despite their small size. This feature ensures that the motor is powerful and compact.

Linear Response

Brush servo motors, which are capable of responding quickly and linearly to commands from the control system, provide fast and accurate movement, ensuring a safe work process.

Easy Controllability

Brush servo motors can usually be easily integrated with PID (Proportional-Integral-Derivative) control systems. For this reason, users can customize the motor’s behavior as they wish.

Low-Level Noise

Brush servo motors generally produce low levels of vibration and noise. This is particularly important in sensitive applications.

Small Size and Lightweight

Brush servo motors are generally compact and lightweight. This gives them a significant advantage in applications or spaces where space is limited.

Low Inversion

The low internal friction and lightweight construction of brush servo motors enable low versions. This makes rapid starts and stops easier.

What is the Working Principle of a Brushless Servo Motor?

Brush servo motors have a simple operating principle that is not very complicated. Brush servo motors have a fairly simple operating logic and five effective operating principles.

Magnetic Field Generation

Brush servo motors typically contain a fixed stator (stationary part) and a rotating rotor (moving part). This allows electrical energy to be applied to the coils on the stator, creating a magnetic field.

Rotation of the Rotor in a Magnetic Field

Due to its structure, the rotor usually contains a magnet or magnetic material. For this reason, the magnetic field created by the stator rotates the rotor through interaction with the magnet on the rotor.

Directing Electric Current

The rotor, which rotates with electrical energy, rotates by affecting its magnetic field. This rotational movement varies depending on changes in the rotor’s magnetic field. The commutator performs a switching function that changes the direction of the rotor’s magnetic field and causes the rotor to rotate in a specific direction.

Motion Control

A control system is required to control the movement of the motor. For this reason, a feedback mechanism is usually included in the control system. Brushed servo motors typically move to a specific position based on feedback signals provided by a sensor.

Dynamic Control

They can respond quickly and dynamically using incoming signals. This allows the motor to move quickly and accurately to the desired position or speed.

What is a Brushless Servo Motor?

Brushless servo motors do not contain wearable parts such as brushes and commutators, so energy transfers are usually achieved through the magnetic interaction of the magnets on the rotor and the coils on the stator. For this reason, the motor can be controlled more precisely and can operate at a specific position, speed, or torque.

Brush motors have a very advantageous structure and require little maintenance, so there is no risk of wear on the brushes and commutator. This ensures that brushless servo motors have a longer service life. In addition, brushless servo motors operate with less friction and energy loss, thus providing higher efficiency.

Where are brushless servo motors used?

Brushless servo motors are a type of motor that we encounter in many areas. This type of motor is generally used in the industrial automation sector for position, speed, and torque control, while in the robotics industry, it is preferred for precise and dynamic motion control. Additionally, they are frequently used in medical devices, transportation vehicles for motion control and energy efficiency, the aerospace industry, and electronic devices for disk drive movement, paper feeding, and focusing.

What are the advantages of brushless servo motors?

Brushless servo motors offer many advantages. These advantages ensure that work progresses more accurately and quickly. This ensures that the workflow is not interrupted. The advantages of these brushless servo motors are as follows:

Low Noise Levels

Brushless servo motors have lower vibration and noise levels because they do not involve mechanical contact. This makes them an ideal choice for applications that are sensitive to noise.

High Performance and Precision

Brushless servo motors can be easily used in many industrial and robotic applications thanks to their precise control, fast response times, and high dynamic performance.

Lighter and More Compact Design

Brushless servo motors are generally lighter and more compact in design. This makes them easier to use in confined spaces or portable devices.

Dynamic Control Capability:

Brushless motors can be effectively applied in dynamic control applications such as rapid start and stop thanks to their precise control and high dynamic response capabilities.

Energy Saving

Brushless servo motors save energy due to their higher efficiency and reduced energy loss, which can lower operating costs in the long term.

What is the working principle of a brushless servo motor?

Brushless servo motors have a simple operating principle. This operating principle makes the motor easy to use in every respect. There are seven basic operating principles for this brushless servo motor. These are:

Magnetic Field Generation

Brushless servo motors contain a fixed outer stator and a rotating inner rotor. A magnetic field is created by applying energy to the coils on the stator in a specific sequence.

Magnetic Field of a Rotating Rotor

The magnetic field created by the stator and coil acts on the rotor’s magnets and helps the rotor to turn.

Sensors and Control Electronics

Brushless servo motors contain sensors to measure the position and speed of the rotor. These sensors are used to determine the correct position of the rotor and provide feedback to the control electronics.

Electronic Control and Commutation

Brushless servo motors do not contain commutators and brush mechanisms. Instead, an integrated control electronics unit manages the rotation of the rotor and power transmission. Electronic control applies energy to the correct coils to ensure that the rotor remains in the correct position and at the correct speed.

Sine or Trapezoidal Control

Brushless servo motors typically use sinusoidal or trapezoidal control techniques. These control strategies are designed to control the rotor’s movement more precisely and provide smoother rotation.

Precise Control and Feedback

Thanks to sensors that measure the position and speed of the rotor, the control system receives continuous feedback and applies energy when necessary. This ensures that the motor operates at the desired position or speed.

7. Quick Response Ability

Brushless servo motors can respond quickly and accurately to commands from the control system. This feature is important in dynamic applications such as rapid start and stop.

The Difference Between Brush and Brushless Motors

There are many differences between brushed and brushless servo motors. These differences also determine the areas of application for the motors. The most significant of these differences is the difference in current. Brushed servo motors carry current to the windings, while brushless motors supply energy to the windings using an electronic commutator instead of a physical commutator. Additionally, brushless servo motors operate on a more logical and simple principle, whereas brushed servo motors operate on the opposite principle. Furthermore, brushed motors have brushes and commutators. These brushes and commutators cause the motor to wear out more quickly, resulting in a shorter service life. However, this is not the case with brushless motors.