Brushed vs. Brushless DC Motors in Barrier Gates: A Comprehensive Comparison

In the world of automated access control, the motor is the “heart” of the barrier gate. Choosing between a Brushed DC (BDC) and a Brushless DC (BLDC) motor can significantly impact the system’s longevity, maintenance costs, and control flexibility.

While the industry is shifting toward brushless technology, both types serve specific market needs. Here is a technical breakdown of their differences, working principles, and why certain professionals still prefer one over the other.

1. Brushed DC Motors: The Traditional Workhorse

Structure and Working Principle

A Brushed DC motor consists of four basic parts: the stator (permanent magnets), the rotor (armature coils), a commutator, and carbon brushes.

The brushes make physical contact with the commutator to deliver electrical current to the spinning coils. As the rotor turns, the brushes flip the magnetic polarity, keeping the motor in motion.

Pros and Cons

• Pros: Simple design, lower initial hardware cost, and extremely easy to control. It does not require complex electronics to run at a basic level.
• Cons: The physical friction between the brushes and commutator leads to wear and tear. This generates heat, electrical noise (sparks), and requires periodic maintenance or replacement.

The “Niche” Advantage: Custom Control & IP Protection

Interestingly, some high-end engineering firms and gate manufacturers still opt for brushed motors without controllers.

• Proprietary Control: These clients often have their own sophisticated control boards with unique logic (e.g., specific acceleration curves or integration with high-security systems).
• IP Protection: By using their own controllers, they protect their intellectual property and ensure the barrier gate operates exactly according to their internal standards without being tied to a motor vendor’s “black box” software.

2. Brushless DC (BLDC) Motors: The Modern Standard

Structure and Working Principle

As the name suggests, BLDC motors eliminate the brushes. The magnets are placed on the rotor, while the copper coils are fixed on the stator.

Because there is no physical contact to flip the polarity, the “switching” is done electronically by an External Controller (Electronic Speed Controller – ESC). This controller uses sensors (usually Hall effect sensors) to track the rotor’s position and pulse electricity to the coils at the perfect micro-second.

Pros and Cons

• Pros: * High Durability: Without brushes, there is no friction-related wear, leading to a much longer lifespan.
  • Efficiency: BLDC motors are more energy-efficient and run much cooler.
  • Precision: They offer superior “Soft Start” and “Soft Stop” capabilities, reducing mechanical stress on the barrier arm.
• Cons: * Electronic Complexity: They cannot run without a sophisticated controller.
  • Integration: The controller is typically designed specifically by the motor supplier, making it harder for a third party to swap in their own control logic.

Key Comparison: BDC vs. BLDC

Feature	Brushed DC (BDC)	Brushless DC (BLDC)
Commutation	Mechanical (Brushes/Commutator)	Electronic (Controller)
Maintenance	High (Brushes wear out)	Minimal (No friction parts)
Lifespan	Moderate	Very High
Friction/Heat	Significant	Minimal
Control Requirement	Simple (Direct DC Power)	High (Requires dedicated ESC)
Market Trend	Legacy/Specialized	Mainstream/Modern

Choosing the Right Motor for Your Project

Why BLDC is Mainstream

For most property management and standard commercial projects, BLDC is the superior choice. The reduction in friction translates directly to fewer service calls and a higher “Mean Time Between Failures” (MTBF). For high-traffic areas like toll booths or busy parking lots, the reliability of BLDC is essential.

When to Consider BDC

If you are an engineering company with your own proprietary control hardware and require full ownership over the software logic of the gate, a high-quality Brushed DC motor provides a reliable, “blank slate” mechanical component. It allows you to implement unique functions without the compatibility hurdles often found in integrated BLDC systems.