What is a Brushless Screwdriver?

The manufacturing industry has made many advancements forward and the production has been made easier and faster. The electric screwdriver is one of those tool to make a significant impact. Whether in high-volume production assembly-lines or performing delicate electronic work, the right electric screwdriver can impact assembly-line productivity and product quality. Specifically, brushless screwdrivers have been making waves in the industry. But what exactly is a brushless screwdriver? And how does it compare to its brushed motor counterpart? What is the difference between brushed vs brushless tools?

What is a Brushed Motor Screwdriver?

Standard electric torque screwdrivers are simply screwdrivers that use a motor inside of them to create the torque necessary to tighten a fastener. They have been a staple of the manufacturing industry for many years. The secret to their long running success is the brushed motors inside of them, a traditional design that relies on carbon brushes for the tool to work. These carbon brushes and motors work well, but they come with significant downsides that wear out the tool over time. The main components, which include brushes and switches, need to be replaced regularly, to keep the tool running and long-lasting. In addition to regular maintenance, brushed motors generate heat, which eventually wears the tool down and reduces the tool’s lifespan. As these parts deteriorate, performance plummets and soon the tool may even cease to function properly. It’s these things that make the brushed tool less reliable for heavy, long-term use, especially industrial assembly.

What is a Brushless Screwdriver?

More recent electric torque screwdrivers utilize a design that forgoes the need for any carbon brushes. Instead of creating power through physical contact, the brushless motor screwdriver uses electronics to create torque via electromagnetism. This reduces any friction and heat previously created by brushed motor parts and as a result the tool runs cooler and more efficiently for much longer. Because there are fewer parts to wear out in these torque tools, they don’t need as much maintenance as their brushed counterparts. Brushless motor screwdrivers also provide more consistent power, which make them a perfect tool for high-precision or heavy-duty tasks. These reasons make brushless screwdrivers a powerful choice over standard brushed screwdrivers.

Benefits of Brushless Screwdrivers

1. Lower Maintenance Requirements: With no brushes to replace, the maintenance needs are minimal, reducing both time and expenses.
2. Longer Lifespan: The absence of brush and commutator erosion extends the tool’s operational life.
3. Reduced Noise: Brushless motors operate much quieter, which contributes to a more comfortable work environment for the operator.

Why Are Brushless Tools Better?

The advantages of brushed vs brushless tools go beyond longer life and reduced maintenance. They offer several operational improvements, such as:

• No Carbon Dust: Because of the lack of physical parts in the tool, brushless screwdrivers no longer generate carbon dust, which make them a great choice for clean rooms, and electronic work. 
• No Sparking or EMI Disturbances: without the physical brushes, there is no sparking and therefore reduces all chances of electromagnetic interference (EMI). At the same time it reduces heat which allows the screwdriver to used safely for longer periods of time. 
• Less Fatigue: eliminating the brushes from the tool, allows the screwdriver to run quieter and cooler. As result the screwdrivers can be used for an extended period of time.
• Better Battery Life: For our cordless torque screwdriver models, brushless tools run more efficiently therefore consuming less power, resulting in longer battery life. This increases the longevity of the tool in general.

Conclusion

Brushless screwdrivers represent a significant advancement over traditional brushed electric torque screwdrivers. Their longer lifespan, lower maintenance, and improved performance make them a superior choice for industries that demand precision, reliability, and efficiency. With fewer moving parts and a more efficient design, brushless screwdrivers not only enhance production output but also reduce overall operational costs.

For manufacturers seeking to optimize their assembly processes, investing in brushless electric screwdrivers is a smart choice that delivers both cost savings and better product quality. These tools are the future of electric screwdrivers, offering power, precision, and longevity unmatched by their brushed counterparts.

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