What the difference between brushed and brushless DC Motor

The primary difference between brushed and brushless DC motors lies in their commutation methods:   

Brushed DC Motors:

• Commutation: Mechanical. Brushes and a commutator physically switch the current direction in the rotor coils.   
• Construction: Rotor has electromagnets, stator has permanent magnets.
• Pros: Simple and inexpensive to manufacture.
• Cons:
  • Friction and wear from the brushes limit lifespan and efficiency.   
  • Generate electrical noise (electromagnetic interference).   
  • Limited speed due to brush wear.

Brushless DC Motors:

• Commutation: Electronic. An electronic controller switches the current to the stator coils, creating a rotating magnetic field.   
• Construction: Rotor has permanent magnets, stator has electromagnets.   
• Pros:
  • Higher efficiency due to the absence of friction from brushes.   
  • Longer lifespan due to no brush wear.  
  • Quieter operation with less electrical noise.   
  • Higher speeds and greater torque.   
• Cons:
  • More complex and expensive to manufacture.
  • Require an electronic controller.   

In Summary:

Brushless DC motors offer significant advantages in terms of efficiency, lifespan, speed, and noise reduction compared to brushed DC motors.