Taken directly from wikipedia: ( http://en.wikipedia.org/wiki/Brushless_DC_electric_motor )
Brushless versus Brushed motor
Brushed DC motors have been in commercial use since 1886.[1][2] BLDC motors, however, have only been commercially possible since 1962.[3][4]
Limitations of brushed DC motors overcome by BLDC motors include lower efficiency and susceptibility of the commutator assembly to mechanical wear and consequent need for servicing, at the cost of potentially less rugged and more complex and expensive control electronics. BLDC motors develop maximum torque when stationary[5] and have linearly decreasing torque with increasing speed as shown in the adjacent figure.
Brushless DC Electric Motor Torque-Speed Characteristics
A BLDC motor has permanent magnets which rotate and a fixed armature, eliminating the problems of connecting current to the moving armature. An electronic controller replaces the brush/commutator assembly of the brushed DC motor, which continually switches the phase to the windings to keep the motor turning. The controller performs similar timed power distribution by using a solid-state circuit rather than the brush/commutator system.
The interface circuitry between a digital controller and motor. The waveforms show multiple transitions between high and low voltage levels, approximations to a trapezoid or sinusoid which reduce harmonic losses. The circuit compensates for the induction of the windings, regulates power and monitors temperature.
BLDC motors offer several advantages over brushed DC motors, including more torque per weight, more torque per watt (increased efficiency), increased reliability, reduced noise, longer lifetime (no brush and commutator erosion), elimination of ionizing sparks from the commutator, and overall reduction of electromagnetic interference (EMI). With no windings on the rotor, they are not subjected to centrifugal forces, and because the windings are supported by the housing, they can be cooled by conduction, requiring no airflow inside the motor for cooling. This in turn means that the motor's internals can be entirely enclosed and protected from dirt or other foreign matter.
The maximum power that can be applied to a BLDC motor is exceptionally high, limited almost exclusively by heat, which can weaken the magnets. (Magnets demagnetize at high temperatures, the Curie point, and for neodymium-iron-boron magnets this temperature is lower than for other types.) A BLDC motor's main disadvantage is higher cost, which arises from two issues. First, BLDC motors require complex electronic speed controllers to run. Brushed DC motors can be regulated by a comparatively simple controller, such as a rheostat (variable resistor). However, this reduces efficiency because power is wasted in the rheostat. Second, some practical uses have not been well developed in the commercial sector. For example, in the Radio Control (RC) hobby arena, brushless motors are often hand-wound while brushed motors are usually machine-wound. (Nevertheless, see "Applications", below.)
BLDC motors are often more efficient at converting electricity into mechanical power than brushed DC motors. This improvement is largely due to the absence of electrical and friction losses due to brushes. The enhanced efficiency is greatest in the no-load and low-load region of the motor's performance curve. Under high mechanical loads, BLDC motors and high-quality brushed motors are comparable in efficiency.
AC induction motors require induction of magnetic field in the rotor by the rotating field of the stator; this results in the magnetic and electric fields being out of phase. The phase difference requires greater current and current losses to achieve power. BLDC motors are microprocessor-controlled to keep the stator current in phase with the permanent magnets of the rotor, requiring less current for the same effect and therefore resulting in greater efficiency.
In general, manufacturers use brush-type DC motors when low system cost is a priority but brushless motors to fulfill requirements such as maintenance-free operation, high speeds, and operation in explosive environments where sparking could be hazardous.
