From Leading to Mainstream: Brushless Fans
Category:
Industry Trends
Release time:
2022-04-06
For many years, automotive engine cooling has relied on brushed fans—fans driven by brush motors that rapidly rotate fan blades to dissipate heat from the radiator. Initially, brushless fans were pioneered by companies such as Bosch. Leading-edge technologies in this field are now offered by major international corporations like Bosch and Brose. However, in recent years, brushless fans have begun gaining popularity in China and have become a highly sought-after and widely recognized technological product.
Brushless fan The core component is the brushless motor. Compared to traditional brushed motors, brushless motors offer advantages such as compact size, high efficiency, and long service life.
1
Small in size
Optimized design and copper wire selection enhance slot fill factor, improve heat dissipation, boost motor efficiency, and reduce motor volume. Let’s compare a brushed motor with a 200W fan to a brushless motor. When the outer diameter remains constant, the motor height is reduced from 88.2 mm to 68.5 mm, making it more space-efficient for the overall vehicle layout. Currently, the thinnest 400W brushless motor under development can be as thin as 63 mm.
2
High efficiency
The motor is the component that consumes the most power in an electromechanical system, making it even more critical to improve its efficiency. For a single motor, the brush efficiency is around 65%, whereas our 400W brushless motor achieves an efficiency of up to 85%. This means the motor’s efficiency is 20% higher than that of a conventional motor.
3
Long lifespan
The brushless fan motor eliminates friction between the carbon brushes and the commutator. As a result, only the bearings wear out, significantly extending the motor's service life. Under comprehensive operating conditions, the motor can last up to 30,000 hours—about three times longer than the service life of a brushed motor. Note: The sensor used is not a Hall sensor; instead, the side position is detected using the back electromotive force method.
The advantages of brushless fans.
The motor starts smoothly, with the starting current gradually increasing, without any large inrush current that could blow fuses or cause a drop in supply voltage.
Stepless speed regulation with a wide adjustment range (currently, fan speeds can be controlled between 600 and 3000 RPM) and strong overload capacity; however, brushed motors require resistance-based speed control, resulting in lower efficiency. When using a brushed motor combined with a PWM speed-control module, the overall cost advantage is not as significant as that of brushless motors.
The motor itself has no excitation losses or brush losses, boasts high efficiency, delivers excellent overall energy-saving performance, achieves energy savings of up to 15%, and has a comprehensive operational lifespan of 30,000 hours.
It employs PWM communication and features multiple protection functions, including stall protection, overcurrent protection, overvoltage protection, and undervoltage protection, as well as fault feedback. LIN communication can also be used to meet various customer requirements.
Lightweight design involves selecting more efficient and lightweight raw materials and simplifying the structural design. For example, brushless fans feature a spherical design with a pronounced concave-convex structure; the lightest 400W fan assembly weighs only 3 kg.
Brushless, spark-free, and featuring an integrated motor and controller design, this product boasts superior EMC performance, with conducted and radiated emissions meeting Class 3 standards.
From the patch to the stator and rotor, all components are custom-made, demonstrating complete process capabilities. Our services cover product structural design, electromagnetic design, structural and performance simulation, vibration analysis, strength analysis, product validation, testing, EMC testing, noise testing, airflow testing, and more. We can perform LIN programming for brushless fans and offer rapid, customized development based on customer requirements, providing customers with comprehensive solutions.
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