Comparison of brushed and brushless screwdrivers - advantages and disadvantages

How does a brushless motor work?

There are many types of screwdrivers. To understand the advantages of each, you need to study their data and operating principles. This will allow you to understand which screwdriver is better, brushed or brushless, and in what cases they should be used. After all, all electric tools have different technical parameters.

At the end of the last century, changes occurred in the field of semiconductor electronics. This made it possible not to use the usual brushes. The mechanical method of connecting contacts in a brushless one was replaced by an amplifier.

Studying how a brushless screwdriver motor works, it can be noted that it is much more convenient during operation and provides higher torque. This type of engine wears out less, is quieter, and is protected from dirt getting inside.

Brush detail

In this case, the rotation speed is enhanced by the tension created inside, and not by centrifugal force. In this case, the engine operates in the desired mode without malfunctioning.

Even if current leaks in or the motor becomes magnetized, the speed will remain the same.

For normal operation, a commutator and winding are not required. And the built-in magnet is not as large as in brush equipment.

A brushless motor has a rotor and a stator, just like the elements of any motor. But there is no collector here. Therefore, its brushless version will be more reliable.

Interesting! Such devices are installed in low-power screwdrivers (up to 5 kW). In models with large parameters they are less effective.

Rating of the best brushed and brushless screwdrivers

Design and principle of operation

The brushless tool has taken its place in the set of necessary tools. When purchasing equipment for a home, the owner must become familiar with the principles of its operation.

You can consider the features of how a brushless motor works in a screwdriver:

• The current here is switched in the stator windings. There is no coil on the armature, and the magnetic field is created using magnets installed inside the housing.
• The time when you need to connect electricity is regulated using built-in sensors. The Hall effect is used. Short electrical pulses and speed signals that regulate operation are sent to the built-in processor. This action is usually called a PWM signal.
• Alternately, the generated pulses are sent to amplifiers, which amplify the current. Inverters (amplifiers) are connected to a winding on the stator. These elements accumulate the current generated by the coils and transmit it from the internal processor using pulses.

As a result, a magnetic field arises, which causes the armature to rotate and the tool begins to work.

Brushless tool

Power supply and its characteristics

for the screwdriver motor can be mains or battery powered. Models equipped with a wire for connecting to an alternating current network have limitations in operation and are the least compact. But they have increased power and operational reliability.

Screwdrivers with a constant current source are equipped with 1 or more batteries. Its power can vary from 9 to 36 watts. For solving everyday problems, a good power range is considered to be 12-15 W. The following types of batteries are used:

• lithium-ion (Li-Ion);
• nickel-cadmium (Ni-Cd);
• nickel metal hydride (Ni-MH).

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They differ in voltage and service life. It is recommended to purchase screwdrivers with a 3.6 V Li-Ion battery. They are reliable and durable in operation. In addition, you should take into account the capacity of the power source, which directly affects the service life. It varies from 1.2 to 3.5 Ah.

When choosing a screwdriver, consider the purpose of the job. Professional tools are distinguished by increased motor power and 2-3 phases of gearbox operation. The case should be comfortable for the hand, comfortable for long-term use. It is recommended that the spindle speed be adjusted, small range – 0-1250 rpm. It is imperative to have a reliable and capacious power source; for convenience, it is better to get models with 2 or more lithium-ion batteries.

DeWALT DCD791D2

The screwdriver works without a network connection. The set includes two lithium-ion batteries with a capacity of 2 Ah and a voltage of 18 V. A torque of 70 Nm ensures fast drilling of holes.

Thanks to the quick-release chuck, it takes a minimum of time to replace the equipment.

The battery holds a charge for a long time, and recharging takes only 1 hour. The model is used to create holes up to 40 mm in wood and up to 13 mm in metal.

15 torque positions are provided.

Properties:

• torque - 70 Nm;
• speed - 2000 rpm;
• battery capacity - 2 Ah;
• size - 175×203 mm;
• weight - 1.5 kg.

Pros:

• iron cartridge;
• power;
• rapid change of nozzles;
• high quality assembly;
• long battery life.

Disadvantages:

• the cartridge's lips do not close completely;
• for metal it takes only 13 mm.

BOSCH GSR 18 V-EC TE

A non-impact screwdriver from one of the favorite power tool companies. Designed to work with different fasteners.

The user has access to one high-speed mode and 25 torque control positions with the highest being 25 Nm.

The tool is distinguished by the highest rotation speed of up to 4200 rpm.

For convenience, there is a light bulb on the body to illuminate the work area.

The screwdriver is powered by a lithium-ion battery with a capacity of 4 Ah. The kit includes 2 batteries, a charger, an annotation, a depth stop, a Ma55 attachment and a bit.

Properties:

• torque - 25 Nm;
• speed - 4200 rpm;
• battery capacity - 2 Ah;
• battery voltage - 18 V;
• size - 251x239 mm;
• weight - 1.6 kg.

Pros:

• little weight;
• comfortable handle;
• highest power;
• reverse function;
• quick drilling.

Disadvantages:

• Not all equipment from past tools is suitable;
• complex bit mount.

Makita DF032DWAX1

A universal tool suitable for working with fasteners and drilling holes in materials of different densities.

The design is very thoughtful: the tool is lightweight, and the handle is covered with rubberized material. The model operates in 2 high-speed modes.

Due to the highest power and torque, you can drill a hole up to 28 mm in a wood surface and up to 10 mm in an iron surface in a few seconds.

The highest rotation speed of the equipment is 1500 rpm. The model is distinguished by the highest performance when operating at any of the two speeds.

Reversing allows you to quickly remove a stuck drill. It takes only one hour to charge the battery.

Properties:

• torque - 35 Nm;
• speed - 1500 rpm;
• battery capacity - 2 Ah;
• battery voltage - 10.8 V;
• size - 124x217x66 mm;
• weight - 0.87 kg.

Pros:

• power;
• a light weight;
• battery charge indicator;
• A good hook for attaching to a belt.

Disadvantages:

• complex bit fastening;
• Standard equipment is not suitable, as for other screwdrivers.

DeWALT DCF620D2K

A reliable and safe tool to use, with which you can quickly tighten and unscrew fasteners.

The handle is made of rubberized material, due to which the tool does not slip out of the hand. The weight of the model is 1.88 kg, due to which you can hold it for a long time without rest.

The screwdriver is equipped with 2 speeds for various jobs. The largest drilling diameter for wood is 28 mm, for metal - 10 mm.

The most powerful engine provides a rotation speed of up to 4400 rpm. The set includes a case for storing and transporting the screwdriver.

Properties:

• torque - 30 Nm;
• speed - 4400 rpm;
• battery capacity - 2 Ah;
• battery voltage - 18 V;
• size - 380×233 mm;
• weight - 1.88 kg.

Pros:

• successful;
• reliable;
• safe to use;
• no play.

Disadvantages:

• small battery life;
• From time to time the depth stop does not work when tightening screws.

Brushless screwdrivers differ from standard models in that they are equipped with brushless electric motors.

This provides easy adjustment of the rotation speed and its configuration over a wide range.

In similar models, malfunctions occur less frequently, which simplifies their service.

The tools withstand short-term torque overloads well and at the same time consume less electricity than traditional screwdrivers.

Advantages of brushless motors in theory

We have already figured out the structure of a brushless motor and now it is worth considering the positive and negative aspects of such tools.

There are several advantages of such engines:

• They do not have the problems that brushed models have. They are more resistant to wear, since the brushes do not produce internal friction. The fire rate is also lower. The absence of sparking allows you to work in the most difficult conditions.
• Easier torque control system. The number of levels (15) allows you to immediately select the desired mode and simply press a button. They have a higher level of efficiency.
• Economical in terms of energy use. This is especially true. If the engine is battery-powered. The tool can be used on any material.

Important! In addition, brushless motors can produce maximum rotation almost immediately.

How does a screwdriver or device design work?

The type of instrument under consideration works on the principle of converting electronic energy into mechanical energy, thereby performing useful work. Based on this, screwdrivers are classified into corded and cordless. Rechargeable models are popular due to their portability, but networked ones also have the advantage of higher power compared to rechargeable ones. Corded screwdrivers are also called drills, because they can not only screw fasteners, but also drill wood and metal.

The external device of network and battery models is actually similar, except for minor differences. This difference lies in the presence of a battery on portable instruments, as well as the presence of a wire for connecting to an outlet on network-type devices. The internal structure has more differences, but the operating mechanism of corded and cordless screwdrivers is the same. The main structural elements of the devices under consideration are:

• Impact-resistant plastic housing
• Chuck (usually quick-release type)
• Button, switch or trigger for starting the tool
• Switch for direction of movement of the executive body - reverse
• Speed ​​controller in the form of a switch
• Torque control - better known as a ratchet

To understand the device, below is a photo with a description of each element. The operation of the device is based on the following parts that are located inside the case:

• Electric motor of commutator or brushless type
• Gear mechanism in the form of a planetary gearbox
• Safety clutch with force regulator - eliminates jamming and overheating of the motor, thereby preventing its failure

Depending on the model of the tool, they can also be additionally equipped with backlighting, battery charge indication or an LED display. The housing design may have grooves to accommodate replaceable bits, which simplifies the operation of the device.

The benefits of brushless tools in practice

Theoretical advantages are fully realized in practice. This must be taken into account when choosing a brushed or brushless screwdriver; you can find out which motor is better after working with it.

Experts note that such a tool:

• Much lighter and smaller in size. Compactness makes it possible to work in difficult places and carry even in a regular bag.
• More powerful and efficient in energy consumption. The modern operating principle of the motor, based on the use of electronics, improves user performance.
• Brushless cordless models work on a single charge for quite a long time. Compared to classic engines, this is 30% more.
• Due to the low heat generation, no additional cooling or interruptions during operation are required.
• When working, it does not make too loud sounds or give sudden jerks.
• No sparks. This allows you to work in difficult conditions near fuel tanks and gas appliances.
• Easy to maintain. No need to buy or select brushes.
• It breaks less often, since the absence of a brush allows you to work even under high loads without fear of clogging the engine.

Brushed vs Brushless: Summary Table

Now - a comparative description of the two types of tools in the form of a table with key parameters.

Noticeable difference in body size

Why are brushless tools so expensive?

The main disadvantage of such a tool is its high price. It is due to the presence of an expensive power board and electronic control. Thanks to this, the electric motor becomes more reliable.

But the high cost of such a tool sometimes becomes a decisive factor when purchasing a tool. Which screwdriver is better, brushed or brushless, each user decides for himself. And many are inclined to favor a cheaper product.

Important! Replacing parts with brushless tools is always expensive.

How to choose?

To work effectively with a brushless screwdriver, you should be very responsible when choosing a model when purchasing. The store inspects the main characteristics of the instrument and other nuances:

Important! In any price range, you should choose a model from a manufacturer that has been on the market for a long time and has proven the quality of its products over time. These include Bosch, DeWALT, Makita, Hitachi, Casals. Some people prefer to buy Chinese models, but they rarely differ in service life.

Brushless screwdrivers differ significantly from their counterparts with CSA technology. They are more productive and durable, but less noisy and heavy. The main disadvantage of screwdrivers with brushless motors is the high price, but when buying a professional tool that will last for many years, you have to sacrifice something. The store pays attention to engine power, ease of use, additional functionality and the purpose of using the screwdriver.

Source

Is it worth buying a tool with a brushless motor?

If you need a tool several times or just for home use, then it is better to choose a cheaper option. But professionals need a reliable and powerful screwdriver that will pay for itself very quickly. This can be understood by seeing how a brushless screwdriver works and how many processes can be done with it without interruption.

You can wait until the technology becomes more accessible. After all, it was introduced not so long ago and the new engines with which they are equipped are too expensive, unlike conventional ones. When analyzing the price, the difference will be 30-50%. Such overpayments are too significant to buy a tool just to have a home.

Operation of a brushless screwdriver

Operating principle of the cartridge

There are two types of chucks on screwdrivers: quick-release and main. Quick-clamping ones are more popular, and they come in single and double coupling types. The main ones are more reliable because they eliminate the possibility of turning the nozzle. The main executive bodies are usually used on drills, which prevent the rotation of drills with cylindrical shanks. On screwdrivers, quick-release screwdrivers are usually used, because they quite firmly fix attachments in the form of bits with a hexagonal shank design.

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The main and quick-release chucks on screwdrivers have a similar design and operating mechanism, which is based on the movement of the clamping jaws. The design has three lips, which secure the shanks of the working attachments - drills, bits, polishing attachments, etc.

In order for the cartridge to serve for a long time, it is necessary to periodically add lubricants inside and also clean the working parts from blockages. If the sponges fail, they cannot be replaced. When choosing a cartridge, you need to take into account that they differ in such a parameter as the diameter of the shanks of the nozzles that can be fixed in it. You also need to take into account the diameter of the hole for mounting on a screwdriver.

The chuck is attached to the screwdriver with 2 threaded clamps. The first clamp is located on the inside, and is presented in the form of a tetrahedral (less often single-sided) screw, which has a left-hand thread. To turn it out, you need to twist it to the right. After unscrewing the screw, you need to unscrew the element itself, which is fixed to the shaft.

Screwdriver operating mechanism

ordinary and simple, but it should be understood by everyone who plans to repair, remodel, modernize, etc. Knowing the mechanism of operation of screwdrivers and impact wrenches, you can remove any damage to these devices and return the tool to working condition.

Advantages and disadvantages

The advantages include:

Flaws:

It is very important to pay attention to what type of battery is included in the design of the tool. If you choose the right screwdriver with a brushless motor, it will work for a long time and will delight you with its performance.