Brushed vs Brushless in Automated Packaging

Brushed vs Brushless in Automated Packaging

Packaging automation can be a total gamechanger for any distribution center, as it not only streamlines the process, but can save money, improve throughput, reduce waste and be more time and energy efficient. However, when it comes to packaging automation machinery, motors are the driving force behind performance, reliability, and efficiency and therefore choosing the right model is a pivotal point of the process. This starts with the choice of whether to use brushed or brushless motors. As each has its own advantages, limitations, and ideal applications the right choice is dependent on the project and its requirements.

Brushed Motors

Brushed DC motors (PMDC) are the most widely used motor technologies and have wide reaching applications. They operate by passing electrical current through carbon brushes, which then make physical contact with a commutator to power the rotor. There are several pros and cons to a brushed motor. Starting with the benefits which include:

• Being Cost-Effective – Brushed (PMDC) motors typically are more cost effective than brushless motors to set up.
• Providing Simple Control – This motor type is easy to integrate and control without the need for complex electronic drivers, which is ideal for straightforward packaging automation systems.
• Offering a High Starting Torque – Brushed DC motors deliver strong torque at low speeds, which is invaluable in intermittent packaging operations like sealing, capping, or indexing.

Despite the benefits there are the challenges to consider when planning your automated packaging process.

• Higher Maintenance Needs – The existence of carbon brushes within the motors means there are more moving parts which wear down over time, requiring replacement to maintain performance. This means there is a higher ongoing maintenance cost.
• Shorter Lifespan – Due to the continuous contact between brushes and commutator there is an element of friction leading to wear, which can limit the service life in high-duty-cycle environments.
• Higher Noise Levels – The mechanical contact can lead to audible noise and electrical interference. In some environments this is not a concern, but there are others where quiet operation is necessary.

Brushless Motors

As an alternative you can choose brushless motors which present different benefits and challenges than brushed (PMDC) motors. Brushless DC (BLDC) motors eliminate the need for brushes by using electronic commutation. Instead of mechanical contact, magnetic fields controlled by electronics drive the rotor. This provides numerous benefits including:

• High Efficiency – Reduced friction means there is lower energy consumption and less heat generation, which is ideal for continuous high-speed packaging lines.
• Longer Service Life – With no brushes, BLDC motors are more durable and have lower maintenance costs over their life span.
• Low Noise and Vibration – Brushless motors operate quietly, which can make them more suited to some environments.
• Better Speed and Torque Control – Advanced electronics within the BLDC allows precise performance tuning for fast-changing, high-accuracy tasks.

Of course, the higher technical specification of the BLDC motor means there are different challenges including:

• Higher Initial Cost – The electronic commutation systems and advanced components make BLDC motors more expensive to purchase upfront.
• Complex Control Requirements – BLDC motors require controllers or drivers to operate which can add to system complexity and increased integration time.

How to Avoid Overspecification

For many, opting for the more powerful motor may seem like an easy decision but in some applications, the performance advantages of the BLDC may not be worth the extra cost compared to a brushed motor. Brushed motors are more suited to applications where:

• Duty cycles are low-to-medium.
• Cost is a major consideration.
• Simplicity is more important than high precision.

Whereas brushless (BLDC) motors are needed where:

• Continuous operation is required.
• Noise and vibration must be minimized.
• High precision and speed control are critical.

Partnering with Parvalux

When making the decision on which motor you require as the driving force behind your automated packaging system you are not alone. Here at Parvalux we have decades of experience with brushed and brushless motors and can work with you to ensure the best solution for your specific requirements. We can help you choose the right motor for the job, whether that is off-the-shelf, modular, semi- or fully customized. Get in contact today!