Structural Aspect

Brushless DC Motor: consists of a motor body and a driver, including a rotor, a stator, a sensor and an electronic controller. There is no brush and commutator, relying on the electronic controller to control the direction and size of the current in the stator winding according to the rotor position information detected by the sensor to realize the rotation of the rotor.

Brush DC Motor: mainly composed of a stator (usually a permanent magnet), a rotor (composed of winding), a brush and a commutator. The brush and commutator change the direction of the current through mechanical contact, so that the rotor continues to rotate.

Performance Aspect

Brushless DC Motor: higher efficiency, generally 85%-90%, more stable operation, low noise, almost no electrical spark, electromagnetic interference is small, due to the reduction of mechanical wear parts, long service life.

Brush DC Motor: the starting speed is fast, the torque is large, but the mechanical friction between the brush and the commutator will lead to greater noise and heat during high-speed operation, and will also produce electrical sparks, which may cause electromagnetic interference to other equipment, and the efficiency is generally 75%-80%.

Control Aspect

Brushless DC Motor: requires a complex electronic control unit to achieve accurate commutation control, usually using digital control technology, according to the rotor position sensor feedback information, precisely control the current in the stator winding on and off and order.

Brush DC Motor: The control is relatively simple, by adjusting the size and direction of the DC voltage applied to both ends of the brush, you can control the speed and steering of the motor, which can be controlled by traditional analog circuits such as thyristor.

Application Aspect

Brushless DC Motor: suitable for applications requiring high efficiency, noise, life and control accuracy, such as drones, electric vehicles, industrial automation equipment, high-end home appliances, etc. 

Brush DC Motor: Often used in cost-sensitive, precision requirements are not high, the need for large starting torque occasions, such as electric toys, some traditional power tools, small appliances, etc. 

Cost Aspect

Brushless DC Motor: Due to the need for components such as electronic controllers and position sensors, and high manufacturing process and material requirements, manufacturing costs are high.

Brush DC Motor: simple structure, mature production process, low manufacturing cost.