What is a Brushless Motor?

A brushed motor is a type of DC (Direct Current) electric motor. It has a simple structure consisting of the rotor (armature), the stator, and carbon brushes (also called commutator brushes). These brushes conduct electricity to the commutator, which in turn makes the motor spin and generate power.

Brushed motors are widely used in traditional power tools like drills, hammers, and grinders.

How it works:

The windings of the motor are connected to the commutator, and electricity flows through the carbon brushes. This creates a temporary electromagnet that is attracted or repelled by the permanent magnets in the stator. The polarity changes continuously, making the motor rotate.

Weaknesses of brushed motors:

• Heat buildup due to friction
• Brush wear over time at the contact points
• Need for regular cleaning and brush replacement
• Friction limits rotation speed and reduces efficiency
• Shorter run time due to energy loss from friction

A brushless motor is a more advanced type of electric motor that does not use carbon brushes or a mechanical commutator. Instead, it uses electronic control to manage the current flow and rotation.

Brushless technology offers higher efficiency, longer lifespan, and less maintenance compared to brushed motors. It is widely used in modern cordless tools for smooth, consistent performance.

Advantages of brushless motors:

• Higher power and efficiency for cordless tools
• Longer lifespan with minimal maintenance
• Reduced heat buildup
• More compact and up to 2–3× lighter than brushed motors
• Lower vibration and noise
• Speeds up to 50,000 RPM while maintaining torque
• Up to 25% more efficient with standard batteries, and up to 50% more efficient with Li-Ion batteries (as used in TOTAL tools)
• No sparks due to lack of contact points — safer and more durable