Brushed vs Brushless Motors in Treadmills

There’s a lot to consider when choosing the perfect treadmill for your home fitness space. But one important aspect that a lot of users tend to overlook is the motor powering your machine. The type of motor in your treadmill plays an essential role in determining its performance, durability and overall user experience.

If there’s one thing you should understand about treadmill motors, it is the difference between brushed and brushless types. In treadmills, we often use permanent magnet DC motors because they're easier to control compared to AC motors. There are two main types: brushed and brushless motors. While both serve the same fundamental purpose of driving the treadmill belt, each comes with its distinct set of advantages and considerations.

That’s why we’re here to help you make a better decision and give you the confidence to make the right choice for your workout.

Brushed Motors

How they work:

A brushed motor works by using magnets and coils to create motion. Inside the motor, there are fixed magnets that create a magnetic field, and coils of wire that become magnetic when electricity flows through them. The rotor, which is the part that spins, has its own magnets. The magnetic force interacts with the opposing magnets, causing the rotor to turn. The brushes make sure that electricity keeps flowing to the coils as the rotor turns.

Advantages:

The advantages of brushed motors lie in their simplicity, affordability and ease of control. Their straightforward design makes them easier and cheaper to manufacture compared to brushless motors, making them a preferred choice for applications where cost is a significant factor.

Brushed motors are relatively easy to control, particularly in applications where precise speed or direction adjustments are not critical. Due to these factors, brushed motors find widespread use in various low-cost applications such as toys, small appliances, and some automotive systems.

Disadvantages:

The disadvantages of brushed motors stem primarily from their mechanical components, which are prone to wear over time, leading to a limited lifespan and decreased efficiency. This wear results in increased noise and potential vibration during operation. The physical contact between brushes generates friction, causing energy losses and limiting the motor's speed and torque control capabilities, particularly at higher speeds.

While brushed motors offer simplicity and cost-effectiveness, their limitations in lifespan, efficiency and performance make them less suitable for applications requiring high reliability, efficiency and precise control.

Brushless Motors

How they work:

Brushless motors operate using electronic controls to generate motion, eliminating the need for brushes and a commutator found in brushed motors.

Electronic circuits control the timing and strength of the electric current flowing through the coils, using feedback from internal sensors. This information enables the electronic control system to activate the coils in a specific sequence as the rotor rotates, creating a magnetic field that propels the rotor.

Advantages:

Because brushless motors don't rely on physical contact, they tend to be more efficient, produce less noise and have a longer lifespan compared to brushed motors. This makes them ideal for applications where reliability, precision and performance are essential.

Application of Brushless Motors in Treadmills:

Brushless motors provide smoother and quieter operation compared to brushed motors, enhancing the overall treadmill experience by reducing noise levels and vibration during workouts. This improved quietness allows users to exercise without disturbing others nearby.

Brushless motors are known for their durability and longevity, requiring less maintenance and reducing the likelihood of motor failure over time. This means that users can enjoy their treadmill for longer periods without the need for frequent repairs or replacements, resulting in cost savings and increased convenience.

These motors are more energy efficient as well, consuming less power during operation, which can lead to reduced electricity bills.

Overall, the adoption of brushless motors in treadmills enhances user satisfaction by providing smoother, quieter and more reliable performance, ultimately contributing to a more enjoyable and efficient workout experience.

Conclusion:

The choice between brushed and brushless motors in treadmills boils down to several key factors. Brushed motors, while simpler and more affordable, tend to be noisier, less efficient and have a shorter lifespan due to mechanical wear of brushes. On the other hand, brushless motors offer smoother and quieter operation, increased efficiency, longer lifespan and reduced maintenance requirements.

While initially more expensive, the benefits of brushless motors in terms of performance, reliability and energy efficiency often outweigh the higher upfront cost, providing treadmill users with a more enjoyable and reliable workout experience in the long run. Therefore, for customers seeking quieter, more durable and energy-efficient treadmills, brushless motors represent a superior choice, while those prioritising affordability and simplicity may want brushed motors.