(Part III in the brushless motor DIY tools series)
It is practice that completes technology
In the previous instalments, we discussed the operation, construction, and advantages of brushed and brushless motors. Now we move on to what matters most for the DIY enthusiast: how these tools perform in practice, what faults may occur, how to maintain them, and what to consider when buying.
1. Practical advantages in the DIY workshop
Using brushless machines offers immediately noticeable benefits:
- Quieter operation: no sparking commutator, reduced vibration → longer work becomes less tiring.
- Longer battery life: more efficient power usage can extend continuous operation by 20–40%.
- Greater durability: no brush or commutator wear, less maintenance required.
- Safe operation: the electronics shut down the motor in the event of a jam. – It doesn’t burn out or spark.
- Compact machine: more power in a smaller motor; a lighter, more ergonomic tool.
2. Typical faults and common problems
Although the brushless motor is more reliable, it is not entirely faultless:
- Electronics failure (ESC)
- Most often caused by overheating or moisture.
- Signs: the motor does not start, unusual vibration, or irregular speed.
- Solution: ensure cooling, professional servicing, and indoor storage.
- Loss or weakening of magnetism
- Rare, but can be caused by a heavy blow, heat, or poor quality.
- Symptom: reduced performance, increased current consumption.
- Bearing wear
- The rotor rotates, and the bearings are physical components.
- Symptom: noise, vibration, heat generation.
- Solution: regular lubrication, bearing replacement.
- Sensor issues
- Fault in the Hall sensor or in the feedback circuit; – the motor does not detect the rotor’s position.
- Symptom: irregular rotation, shutdown.
- Solution: professional repair, sensor replacement.
Summary: The brushless motor is far more reliable than its carbon-brush counterpart, but maintenance of the electronics and bearings remains important.
3. Maintenance tips
With brushless motors, maintenance is simpler, but not entirely negligible:
- Cleaning – keep the machine free of dust and dirt.
- Bearing inspection – regular lubrication or replacement if required.
- Battery maintenance – fully charge and store properly to ensure a long lifespan.
- Keep ventilation openings clean – to optimise heat dissipation.
4. How to choose a brushless machine?
A few practical points to bear in mind when making a purchase:
- Performance and torque – check the maximum torque and speed.
- Battery type and capacity – lithium-ion is recommended; a higher amp-hour rating provides longer operating time.
- Machine ergonomics – lightweight design, comfortable grip, and well-balanced weight distribution.
- Brand and service support – a high-quality motor, reliable electronics, and readily available spare parts.
- Additional features – electronic torque control, soft-start, and overload protection.
5. What you need to know in practice
- With a brushless motor, there’s no need to worry about brush wear.
- If the tool jams, it switches off immediately, making it safer than a brushed motor.
- Greater performance is achieved in a compact, lighter tool. More ergonomic, extended work becomes less tiring.
- Speed and torque are electronically optimised, enabling the tool to work “smarter” than conventional tools.
6. The complete picture for the DIY enthusiast
Brushless motors are revolutionising DIY:
- More durable and quieter – extended use with less maintenance.
- Greater efficiency and performance – more accomplished in less time.
- Safe operation – electronics protect the motor from overload and jamming.
- Lighter machine – more ergonomic and easier to use.
Summary table: Brushed vs Brushless (practical considerations)
| Characteristic | Brushed motor | Brushless motor |
|---|---|---|
| Wear / maintenance | Wearing of brushes and commutator | Minimal, mainly bearings |
| Stalling | Short circuit → sparking, motor damage | Electronics switch off; safe |
| Operating time | Shorter | Longer (more efficient) |
| Weight | Heavier | Lighter, compact |
| Noise | Medium to high | Low |
| Speed / torque | Limited | Wide range, electronic optimisation |
| Durability | 500–1000 hours | 5,000–10,000+ hours |
