If we look at the motor industry graph, you can see a huge spike rising for brushless impact drivers. What could be the possible reason for it when you can drive the screws with a brushed impact driver too? Well, there are significant differences and benefits of brushless impact drivers that give a certain edge to it over brushed impact drivers.
A Brushless impact driver works without any sort of friction leading it to be more efficient. As no friction means it can generate more power, more control, precision, more battery run time, requires less maintenance, and the best part is, as there is less heat-generating while in use, it gives the battery a longer life.
If we put it to an example; The brushed impact driver has a lot of friction, it is like riding a bike with breaks slightly applied while on the other hand, the brushless impact driver works without any friction. Now if we use the same amount of energy for both of the bikes, the bike with the friction will be much slower. It will require more energy onto your legs if you want to maintain the speed. If there is friction, it certainly is going to heat up the rims too while on the other hand, the brushless motor runs cooler giving you extra efficiency.
If we talk about maintenance, brushless impact driver doesn’t require any sort of maintenance while in comparison to brushed motors. Their carbon brushes wear down over some time and you need to replace them in order to keep the tool running. It is one of the reasons that causes the spark inside some of the tools too. So, even in maintenance, the brushless impact drivers take an edge.
First, we need to understand how brushless motors work. The answer is very simple; “ All about the magnets “. Having two oppositely charged magnets that are always attracted towards each other. One of them is the rotating piece (the rotator) while the other one is permanent (the stator). So, there’s always a constant attraction pulling forward.
Now, as the brushless motor requires electromagnetics, the combination of stator and rotator gives the opportunity of compact size and lighter weight. While on the other hand, brushed impact drivers use carbon brushes taking a lot of space and heavier in weight.
Brushless impact drivers use electromagnets, that require electronic communicators. This costs a lot of money because basically, you’re building a computer inside the cordless impact driver. While on the other hand, the brushed impact driver doesn’t have any expensive parts inside it except for the copper tho.
The brushless impact driver is certainly better in terms of efficiency, power, design, control, precision, battery run time, longer battery life, maintenance, and whatnot except for the fact that they are slightly expensive than the brushed ones. Having all these benefits is worth a bit of extra money though.