Brushless motors: what do they get you?
More and more cordless tools have a brushless motor. Here’s how it works, what it gets you and how to recognise it.
How a brushed motor works
In a classic DC motor, the coils sit on the rotor and turn with it. Two carbon brushes rub against a commutator and keep switching the current, so the rotor keeps turning.
That rubbing causes friction, heat and sparks. The brushes wear down and have to be replaced after a while. Many tools let you do that, but it is still maintenance.
How a brushless motor works
In a brushless motor, also called a BLDC or EC motor, the magnets sit on the rotor and the coils are fixed in the housing. There is no commutator and there are no brushes.
Electronics determine the rotor’s position and send current through the right coils at the right moment. This is called electronic commutation. The motor and its control form a single unit.
What it gets you
There is no rubbing contact, so less friction and less heat loss. More of the battery’s energy goes into the work. Manufacturers use that for longer runtime per charge, more power at the same size, or a mix of both.
Without brushes, there’s no part that wears in that way. Brushless motors are also often more compact, so the tool can be shorter or lighter.
Because the electronics already control the motor, extra features are easier to build in. Think of speed control under load, or kickback control that stops the motor if the tool suddenly binds. Such features are only found on some models.
How to recognise it
Manufacturers usually put it in the name or the specifications: “brushless”, “sans balais”, “sans charbons” or the abbreviation “BL”. Festool uses the marking “EC”.
At Milwaukee, FUEL is the line with brushless motors. DeWalt marks brushless tools as “XR brushless”. If the specifications say nothing about the motor, don’t assume it’s brushless.
When it’s worth it
A brushless tool usually costs more than a comparable brushed one. The benefit counts most for tools you use often and for tools that draw a lot of current, such as grinders, circular saws and rotary hammers.
If you only do the odd job, a brushed tool will do the work too. Within one battery platform, brushless and brushed tools usually run on the same batteries.
Many corded tools still use a brushed universal motor. That’s not a problem: on mains power, runtime doesn’t matter, and such a motor delivers a lot of power for its size.
Comparing on ToolRango
Brands often have a brushless and a brushed variant of the same type of tool, each as a bare tool or as a kit. Each version has its own EAN or order number. ToolRango compares per version, so you can see which motor and which kit you’re looking at.
Frequently asked questions
Does a brushless motor last longer?
There are no carbon brushes to wear out, so that maintenance disappears. How long the whole tool lasts also depends on bearings, gears, switch and electronics, and on how you use it.
Is a brushless drill more powerful?
Not automatically. Brushless makes more power possible in the same size, but the manufacturer decides how to use it: for power, runtime or a smaller tool. So compare torque in Nm, or impact energy in joules for rotary hammers.
Can you replace carbon brushes yourself?
On many brushed tools, yes: sometimes they sit behind a small cover, sometimes the housing has to be opened. The manufacturer’s manual explains how and which brushes fit. A brushless motor has no carbon brushes.
Keep browsing
ToolRango does not test tools. This guide sets out what manufacturers and standards say. Always follow the manual of your own tool.