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Technical Manual Series: Types of Brushless Motors
This is part 1 of the Technical Manual Series on brushless motors, where we explore the three main types: inner rotor, outer rotor, and disk rotor. Brushless motors combine permanent magnets, windings, magnetic pole sensors, and a drive circuit to function as an efficient and controllable motor. Unlike traditional induction motors that rely on inverters and firing angle control, brushless motors can operate across a wide range of speeds—from low to high—making them highly versatile.
One of their key advantages is energy efficiency. Since they use permanent magnets in the rotor and don't require induced current like induction motors, they are compact, powerful, and efficient. However, these motors were once expensive due to the need for rare-earth magnets, sensors, and specialized drive circuits. Fortunately, with advancements in electronics and increased integration, the cost and size of drive circuits have significantly decreased.
As global demand for energy-efficient solutions grows, brushless motors are now widely used in appliances like air conditioners, refrigerators, and washing machines, as well as in electric and hybrid vehicles. Their small size and high output make them ideal for applications such as cooling fans in touch-screen computers, disk drives, and drones.
Despite their versatility, there are limitations in design. To address this, several configurations have been developed. In this article, we will focus on the three most common types: inner rotor, outer rotor, and disk rotor. Each has unique characteristics that make it suitable for different applications.
### 1.1 Inner Rotor Type
The inner rotor type is the most common configuration. The rotor is located inside the stator, with segmented permanent magnets installed on its outer surface. This design allows for excellent acceleration and deceleration due to its smaller diameter and lower moment of inertia. Additionally, the proximity of the stator to the motor's surface helps with heat dissipation, enabling a compact and high-output motor.
This type is commonly used in material handling systems, such as conveyor pulleys and automated guided vehicles (AGVs). Its space-saving and high-efficiency design makes it a popular choice in industrial settings.
[Video embedded: Brushless Motor Inner Rotor Overview]
### 1.2 Outer Rotor Type
In the outer rotor type, the rotor is positioned outside the stator, with the permanent magnet installed on the inner surface of the rotor. This configuration results in a larger rotor diameter, allowing more magnets to be used, which increases the number of magnetic poles and enables higher power output in a compact form.
However, the larger moment of inertia leads to slower acceleration and deceleration, and the heat generated by the internal windings can be harder to dissipate. To counter this, many drone motors include ventilation holes to help cool the windings using airflow from the propellers.
Applications for this type include cooling fans and drones, especially when proper thermal management is considered.
[Image: Brushless Motor - Outer Rotor Type]
### 1.3 Disk Rotor Type
The disk rotor type features a thin design, where the stator is mounted on a circuit board with windings and magnetic pole sensors. Permanent magnets are placed on the rotor surface, facing the stator. This configuration is ideal for applications requiring stable speed under light loads, and since there is no shaft, the load is directly attached to the rotor.
This type is commonly found in hard disk drives and optical disc players. While Oriental Motor does not offer disk rotor brushless motors, we provide flat-type stepper motors in 42/60 mm frame sizes for precise positioning and indexing applications.
[Image: Brushless Motor - Disk Rotor Type]
### Conclusion
Brushless motors have become essential in modern technology due to their efficiency, reliability, and versatility. Whether you're looking for high-speed control, compact design, or specific application requirements, there’s a brushless motor solution that fits your needs.
In the next part of this series, we’ll cover brushed DC motors. Make sure to subscribe to stay updated!
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