Brushed DC Motor
Duowei Electric: Your Leading Brushed DC Motor Supplier
Changzhou Duowei Electric Co., Ltd. was founded in 1997 and has more than 200 employees. It has developed hundreds of different product applications and established extensive strategic partnerships around the world.
Why Choose Us?
Wide Range of Applications
Our products can be used in various industries including automotive, industrial automation, robotics, household equipment, medical equipment, HVAC systems, office equipment, defense and aerospace, electrical equipment, and power tools.
Professional Services
We can provide customers with "customized services" to meet their long-term needs through tailor-made products. At the same time, we have more than 20 years of production experience and can provide large-scale electric motor production services.
Quality Assurance
ZWS series brushless DC motors, HC series motors, and YY series induction motors have passed UL certification. HC series motors, YY series induction motors, and YDK series air-conditioning motors have passed 3C certification and obtained "Export Product Quality License"
Mass Production of Various Motors
We have realized mass production of 57ZWS, 83ZWS, 120ZWS brushless DC motors. Besides, the linear motor was also successfully developed and put into mass production.
High Torque Brushed DC Motor uses copper worm gears, high-performance grease, and high-quality bearings. It can operate normally under extreme ambient temperatures and has high output power. It is widely used in construction vehicles, agricultural equipment, etc. We can also customize products for you according to your needs.
400W Brushed DC Motor is a 90mm outer diameter permanent magnet DC motor with an external terminal structure, which can run for a long time under high current and has high reliability. It can also be adjusted according to the customer's installation size requirements.
High Performance PMDC Motor is a permanent magnet DC motor with an outer diameter of 57mm, which increases the precision control of the encoder. It can be used as a control motor for many applications. It has been widely used in measuring instruments and other equipment with high precision requirements. The shell is completely sealed, so nothing can enter the motor and damage it, so the service life can be effectively extended.
200W PMDC Motor is a permanent magnet DC motor with a 76mm outer diameter, small size, high efficiency, high quality, low energy consumption, long life, and competitive price. It can be customized according to customer requirements for new or alternative solutions.
The Worm Gear Motor of High Torque PMDC Motor adopts an external terminal structure, which can be driven by the on-board 12VDC power supply, and can run normally and smoothly under high current conditions. It has been widely used in foreign construction vehicles such as muck trucks.
The 300W Brushed DC Motor is a permanent magnet DC motor with an outer diameter of 82mm. It is equipped with high-quality bearings and can face many extreme environments. High-quality carbon brushes can achieve long-term operation and are maintenance-free. The performance and size can be customized, which can replace many imported motors.
200W Brushed DC Motor is a permanent magnet DC motor with an outer diameter of 80mm. It uses high-performance magnetic steel and an external carbon brush structure to achieve a small size, high performance, and long life. We can adjust the length of the motor to achieve different power and work systems, and we can customize the outer diameter and length of the shaft according to customer requirements to meet different scenarios.
48V PMDC Motor is a 52mm outer diameter permanent magnet DC motor, using standard high-performance ball bearings, capable of bidirectional operation. The shaft diameter (φ8 maximum), shaft length, motor length, double shaft extension, etc. can be customized according to customer requirements to meet different applications. Gearbox structures (worm gearboxes, planetary gearboxes, push rod mechanisms, etc.) are widely used in window drives, automatic doors, industrial controls, etc.
24V PMDC Motor is a permanent magnet DC motor with a 63mm outer diameter. It can be used as a control motor (encoder assembly) and drive motor. It can also be equipped with different gearboxes for different applications, such as worm gearboxes and planetary gearboxes. Widely used in solar energy systems, door operator systems, etc. At the same time, we can customize development and provide solutions to customer requirements.
The 12V PMDC Motor has an IP67 protection level and can run underwater for a long time. The double oil seal design ensures the reliability of the motor working under water. Corrosion-resistant surface, suitable for various application scenarios such as sea water and swimming pools. Custom carbon brushes have high reliability, long life, and low failure rate. 100% factory air tightness inspection. At the same time, we can customize development and provide solutions to customer requirements.
48V Brushed DC Motor is a permanent magnet DC motor with a 90mm outer diameter, which is a self-developed product. It adopts the structure of a plane commutator and external terminal, which can withstand greater current while ensuring the life of the motor. It can be widely used in machinery, metallurgy, transportation, textile, printing, and other industries.
The 24V Brushed DC Motor is a permanent magnet DC motor with an outer diameter of 40mm. It has a small appearance and a special structure. The use of high-performance magnetic steel and high-temperature enameled wire, coupled with customized high-performance bearings, enables the motor to be used in many special environments. Widely used in dentist equipment, medical equipment, etc.
We call this type of motor a brushed DC (BDC) motor as it uses brushes for its commutator. Brushed DC motors are used widely and frequently in home appliances and in automobiles ranging from toys to push-button for adjusting seats in cars. They are inexpensive, easy to use, and have different shapes and sizes. A BDC motor provides exact control of speed, driven by a direct current. This type of motor can supply three to four times more torque than its rated torque and If needed, it even has the potential to supply up to five times more, without stalling. BDC Motors uses rings to power a magnetic drive that conducts the motor's armature, and provides stable and continuous current.
A BDC Motor is made up of two magnets facing the same direction, surrounding two coils of wire that lie in the middle of the Motor and around a rotor. The coils are set to face the magnets which causes electricity to flow to them. This builds a magnetic field, ultimately pushing the coils away from the magnets they are encountering which finally makes the rotor turn. The current cut-off at the rotor makes a turn of 180 degrees. This makes each rotor face the opposite magnet. once the current starts over again, the electricity flows oppositely and sends another pulse having the rotor turned once again. By transferring the electricity from the rotor, brushes that exist within the motor turn it off and on.
Benefits of Brushed DC Motor
Replaceable Brushes
Many brushed motors – especially large ones – have replaceable brushes, typically made of carbon, which are designed to maintain good contact as the wear. Thus, they can often be rebuilt to extend life.
Smooth Operation
Compared to some other motor types, brushed DC motors provide relatively smooth operation and low vibration levels. Also, they are capable of producing high torque at low speeds suitable for a wide range of applications.
Robustness
Brushed DC motors are known for their durability and ability to withstand rugged use, making them suitable for many environments. They can be used in a variety of applications, including automotive systems, power tools, and medical equipment.
Efficiency
Brushed DC motors are very efficient, with high power output relative to their size. They are also easy to control and can be precisely adjusted for the desired output.
Permanent Magnet DC Motor
Permanent magnet DC motor (PMDC motor) is the most common among the brushed DC motor. The inductor of this motor includes permanent magnets that create a magnetic field of the stator. Permanent magnet DC motors are usually used in tasks that do not require high power. PMDC motors are cheaper in production than wound field DC motors. At the same time, the torque of the PMDC motor is limited by the field of permanent magnets of the stator. The PMDC motor reacts very quickly to voltage changes. Thanks to the constant field of the stator, it is easy to control the speed of the motor. The disadvantage of a PM DC motor is that over time the magnets lose their magnetic properties, as a result of which the stator field decreases and the motor performance decreases.
Separately Excited and Shunt Wound Motors
In separately excited electric motors, the field winding is not electrically connected to the armature winding (figure above). Usually, the excitation voltage UFW differs from the voltage in the armature circuit U. If the voltages are equal, then the field winding is connected in parallel with the armature winding. The use in the electric drive separately excited or shunt wound motor is determined by the electric drive scheme. Properties (characteristics) of these motors are the same. In shunt wound brushed DC motors, the currents of the field winding (inductor) and the armature are independent of each other, and the total motor current is equal to the sum of the field winding current and the armature current. During normal operation, increasing the supply voltage increases the total current of the motor, which leads to an increase in the stator and rotor fields. With an increase in the total motor current, the speed also increases, and the torque decreases. When the motor load increased, the armature current increases, with the result that the armature field increases. As the armature current increases, the inductor (field winding) current decreases, resulting in a decrease in the inductor field, which leads to a decrease in motor speed and an increase in torque.
Shunt-wound DC motor has the torque/speed characteristic with decreasing torque at high speeds and high, but more constant torque at low speeds. The current in the inductor winding and the armature does not depend on each other, thus, the total current of the electric motor is equal to the sum of the currents of the inductor and the armature. As a result, this type of motor has excellent speed control characteristics. Shunt-wound brushed DC motor is commonly used in applications that require a power of more than 3 kW, in particular in automotive applications and industry. In comparison with PMDC motor, the shunt wound DC motor does not lose its magnetic properties with time and is more reliable. The disadvantages of the shunt wound brushed DC motor is higher cost and the possibility of the motor runaway if the inductor current decreases to zero, which in turn can lead to motor failure.
Series Wound DC Motor
In series wound brushed DC motors, the field winding is connected in series with the armature winding, and the excitation current is equal to the armature current (Ie = Ia), which gives the motors special properties. Under small loads, when the armature current is less than the rated current (Ia < Irat) and the magnetic system of the motor is not saturated (Ф ~ Iа), the electromagnetic torque is proportional to the square of the current in the armature winding.
M = cm∙Ф∙Ia = c'm∙Ia^2, where M is the motor torque, N∙m, сМ is a constant coefficient determined by the design parameters of the motor, Ф is main magnetic flux, Wb, Ia is armature current, A.
With load increasing, the magnetic system of the motor is saturated and the proportionality between the current Ia and the magnetic flux Ф is disturbed. With significant saturation, the magnetic flux Ф with increasing Ia practically does not increase. The graph of the dependence M=f(Ia) in the initial part (when the magnetic system is not saturated) has the shape of a parabola, then, when saturated, deviates from the parabola and in the region of large loads turns into a straight line.
Series wound brushed DC motor has a high torque at low speed and develops high speed with no load. This electric motor is ideal for devices that need to develop a high torque (cranes and winches), as the current of the stator and the rotor increases under load. Unlike PMDC motors and shunt wound brushed DC motors, the series wound DC motors does not have the exact characteristics of speed control, and in case of a short circuit of the field winding it can become uncontrollable.
Compound Wound DC Motor
Compound wound brushed DC motor has two field windings, one of them is connected in parallel with the armature winding, and the second is connected in series. The ratio between the magnetizing forces of the windings can be different, but usually one of the windings creates a large magnetizing force and this winding is called main, the second winding is called auxiliary. If the windings are connected such that the series field aids the shunt field, then the motor is called Cumulative compound brushed DC motor. On the other hand, if the windings are connected such that the two fields oppose each other, then the motor is called the Differential compoud brushed DC motor. The speed characteristics of cumulative compound brushed DC motor are located between the speed characteristics of shunt wound and series wound DC motors. Opposite connection of the windings (differential compounding) is used when it is necessary to obtain a constant rotational speed or an increase in the rotational speed with increasing load. Thus, the performance characteristics of a compound wound DC motor is close to those of a shunt or series wound brushed DC motor, depending on which field winding plays the main role.
Compound brushed DC motors has the performance characteristics of shunt and series wound brushed DC motors. It has a high torque at low speed, as well as a series wound brushed DC motor and good speed control, like, a shunt wound brushed DC motor. Compound wound brushed DC motor runaway is less likely, because the shunt current should decrease to zero, and the serial field winding should be short-circuited.
Applications of Brushed DC Motor
Automotive Industry
The BDC Motor is simple to run and is easily affordable, it is particularly a favorite in the automotive industry. To power windows, seats, and more, automotive manufacturers make use of them. Thus, brush DC Motors can be found in nearly every industry ranging from computers to manufacturing.
Home Appliances
They are found in home appliances like vacuum cleaners, blenders, mixers, food processors, fans, and electric shavers.
Power Tools
Brushed DC motors are widely used in power tools such as drills, saws, sanders, and polishers.
Industrial Equipment
Brushed DC motors find application in industrial machinery such as conveyor belts, pumps, blowers, and mixing equipment. Also, brushed motors continue to be used for electrical propulsion, cranes, paper machines and steel rolling mills.
Components of Brushed DC Motor
Stator and Rotor
Stator and RotorA brushed DC motor has two important parts, such as stator and rotor. Stator is the stationary portion of the motor and the rotor is the rotating portion of the motor. The rotor usually highlights coils around an iron core and enclosed by magnets located in the stator.
Commutators
In a brushed motor, commutators are located around the shaft and connected with each other at every 120°. Commutators do not make mutual contact with each other. Commutators revolve together with the spin of the shaft. Every commutator is joined to a part of one coil and another part of another coil.
Brushes
In it, two brushes are stable at 0° and 180° positions so that those can make connection with the commutators. The brushes are joined to a DC power supply and current flows through the direction like brush to commutator, then commutator to coil and then coil to brush.
Maintenance Tips for Brushed DC Motor
Appropriate inspections are at the heart of successful DC unit upkeep. Inspections give operators visibility into motor unit condition, encourage timely repair and preventative maintenance work, and provide a regular source of information for reference throughout service life. The recommended frequency is based on motor unit usage, the individual unit's criticality, or other conditions that may affect motor service life. Though this timeframe can vary from application to application, the frequency of inspection should adhere to regular inspection periods to monitor performance. Whether your application calls for monthly, quarterly, annual, or otherwise timed inspections, setting and following an inspection schedule is critical to reaping the benefits of inspection. Two types of inspections can be very valuable, an operational inspection and a static inspection. Operation inspection reviews commutation (sparking levels), air temperature, and any unusual vibrations. Static inspection focuses on cleanliness, brush wear, brush wearing signals, signs of overheating, commutator film evaluation, and spring condition.
Maintaining the condition of the commutator is the most important aspect of DC motor unit upkeep because it is the most expensive component to replace. Creation and maintenance of an acceptable brush film, and avoidance of metal transfer, burning, and other destructive conditions are key to ensuring the commutator's condition. Brush films are formed by the gradual, expected degradation of carbon brushes and the mixing of the resulting carbon dust with humidity and small amounts of copper from the commutator. An ideal brush film allows the commutator to spin smoothly without being damaged by the brushes, while still effectively transferring power to the motor. Though it is commonly believed that normal commutators' brush film must be chocolate brown in color with a medium polish, a number of acceptable commutator conditions are concerning but not critical. The most common type of commutator film type is not a uniform film but rather a blotchy, non-uniform finish. Accumulated tolerances in the motor unit such as commutator roundness, brush contact pressure, unequal magnetic fields, and chemical vapors are all possible factors in the development of the film appearance. This type of film is a completely acceptable filming pattern.
Keeping motors clean and clear of brush-wear carbon dust minimizes grounding, arcing, and destructive sparking. Some of this dust goes into the formation of the film on the commutator; but additional dust may become loose and settle within the motor. This, combined with other particulates from the air, can cause grounding. When this happens and the insulation of the motor fails, motors can experience catastrophic failure. Particulates can also make it difficult for motor parts to move freely as they need to. Finally, particulate buildup can inhibit normal dissipation of heat through the outside surfaces of the motor unit frame and make the motor operate at a higher temperature than is ideal. Black commutators are common in DC motor units. Nondestructive sparking is tolerable and pinpoint sparking that does not cause brush or commutator deterioration is also acceptable. Arcing and destructive sparking, however, can electrically erode both the brush and commutator surfaces. If not corrected, this can eventually lead to equipment failure. Arcing and destructive sparking can be identified by the previously mentioned unsatisfactory commutator conditions in which burning occurs, such as slot bar or pitch bar burning.
Carbon brushes are the least expensive component of a DC motor unit, but the most frequently replaced. Depending on the motor unit and service conditions, carbon brushes are likely to last from 3 months to 3 years. Brush life is understandably less important than commutator life, and brush grades are chosen with this in mind – carefully selected to suit the motors' specific application. Monitoring environmental conditions such as humidity and temperature as well as consulting with an expert can help DC motor unit operators to identify the ideal brush grade for each installation, leading to extended brush life and service life for commutators and brush holders. With proper inspection and maintenance practices, commutator life expectancy ranges from 10 years to 20+ years. These upkeep practices help motor operators get the best value, performance, and reliability from commutators, carbon brushes, and motor units in general, providing cost savings and lengthened service life.
The environment in which a Brush DC Motor will be used plays a major role in the life cycle of a Brush DC Motor and other electrical and electronic devices in the system. Dry, warm environments may increase the wear of the brushes, and quicken the breakdown of the commutator and bearings, ultimately shortening the lifetime of the motor. Running the Brush DC Motor in a cooler environment, with external cooling by forced air, may cause the Brush DC Motor to perform better. However, extreme drops in temperature can potentially increase the viscosity of the Brush DC Motor lubricants, causing it to run at a higher current.
The following environmental and safety considerations must be observed during all phases of operation, service and repair of a Brush DC Motor system. Failure to comply with these precautions violates safety standards of design, manufacture and intended use of the Brush DC Motor and controller (if also used). Please note that even with a well-built Brush DC Motor, products operated and installed improperly can be hazardous. Precaution must be observed by the user with respect to the load and operating environment. The customer is ultimately responsible for the proper selection, installation, and operation of the Brush DC Motor system.
The atmosphere in which a Brush DC Motor is used must be conducive to good general practices of electrical/electronic equipment. Do not operate the Brush DC Motor in the presence of flammable gases, dust, oil, vapor or moisture. For outdoor use, the Brush DC Motor and controller must be protected from the elements by an adequate cover, while still providing adequate air flow and cooling. Moisture may cause an electrical shock hazard and/or induce system breakdown. Due consideration should be given to the avoidance of liquids and vapors of any kind. Contact the factory should your application require specific IP ratings. It is wise to install the Brush DC Motor and controller in an environment which is free from condensation, dust, electrical noise, vibration and shock.
Additionally, it is preferable to work with the Brush DC Motor system in a non-static, protective environment. Exposed circuitry should always be properly guarded and/or enclosed to prevent unauthorized human contact with live circuitry. No work should be performed while power is applied. Don't plug in or unplug the connectors when power is ON. Wait for at least 5 minutes before doing inspection work on the Brush DC Motor and controller system after turning power OFF, because even after the power is turned off, there will still be some electrical energy remaining in the capacitors of the internal circuit of the controller.
Certifications
Our Factory
Changzhou Duowei Electric Co.,Ltd. was founded in 1997 and has more than 200 employees. It has developed hundreds of different product applications and established extensive strategic partnerships around the world with these products. Duowei Electric, the manufacturer of Wit Motors, our company does not use "conflict minerals", and the broad service industries include: automotive, industrial automation, robotics, household equipment, medical equipment, HVAC systems, office equipment, defense and aerospace, Electrical equipment and power tools.
Ultimate FAQ Guide to Brushed DC Motor
Q: What is the difference between a brushed DC motor and a brushless DC motor?
Q: What is the construction of a brushed DC motor?
Q: What are the types of brushes used in a brushed DC motor?
Q: Can the brushes be replaced in a brushed DC motor?
Q: What is the commutator in a brushed DC motor?
Q: How important is the commutator in a brushed DC motor?
Q: What is the role of armature in a brushed DC motor?
Q: What is the role of a stator in a brushed DC motor?
Q: How many poles are there in a brushed DC motor?
Q: What is the function of the brushes in a brushed DC motor?
Q: How is the torque produced in brushed DC motor?
Q: How is the speed of a brushed DC motor controlled?
Q: What is the relationship between voltage and speed in a brushed DC motor?
Q: What is the relationship between current and torque in a brushed DC motor?
Q: Can a brushed DC motor be used for continuous operation?
Q: Can a brushed DC motor be reversed?
Q: How long can a brushed DC motor last?
Q: What are the factors that affect the lifespan of a brushed DC motor?
● Overloading: Operating a motor at or above its maximum rated load can cause damage to the windings and reduce its lifespan.
● Contamination: Dust, dirt, and other contaminants can cause damage to the motor's commutator and brushes, reducing its lifespan.
● Vibration: Excessive vibration can cause damage to the motor's windings and bearings, reducing its lifespan.
Q: How is the size of a brushed DC motor determined?
Q: What is the speed range of a brushed DC motor?
Q: What are the types of brushed DC motors?
Q: What is the construction of brushed DC motors?
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