• Skip to primary navigation
  • Skip to main content
  • Skip to primary sidebar
  • Skip to footer
  • Advertise
  • Subscribe

Motion Control Tips

Automation • Motion Control • Power Transmission

  • News
    • Industry News
    • Editor Blogs
  • Controls
    • HMIs
    • PC-Based Controllers
    • PLCs + PACs
    • Stand-Alone Controllers
    • Software
  • Drives
    • Servo Drives
    • Stepper Drives
  • Encoders
    • Absolute Encoders
    • Incremental Encoders
    • Rotary Encoders
  • Mechanical
    • Bearings
    • Brakes + Clutches
    • Belt + chain
    • Couplings
    • Gears + Gearing
    • Lubrication
    • Shock + Vibration Mitigation
    • Springs + Rings + Seals
  • Linear
    • Actuators
    • Linear Motors
    • Linear Encoders
  • Motors
    • AC Motors
    • DC Motors
    • Brushless Motors
    • Gearmotors
    • Piezo Motors
    • Servo Motors
    • Stepper Motors
  • Systems
    • Conveyors + linear transport systems
    • Gantries + Stages
    • Rotary Tables
    • Grippers + End Effectors
    • Robotics
  • Networks
    • Connections + Sliprings
    • Fieldbuses
    • I/O
    • Sensors + Vision
  • Resources
    • FAQs
      • Motion Casebook
      • Motion Selection Guides
    • Suppliers
    • Video
You are here: Home / Motors / DC Motors / FAQ: How to pick between stepper motor, brush dc, and brushless motors?

FAQ: How to pick between stepper motor, brush dc, and brushless motors?

July 22, 2015 By Zak Khan Leave a Comment

When choosing a motor for an application, consider key differences between each motor’s operation.

Stepper motors
A typical stepping motor cross section showing
the stator, rotor, shaft, bearing and lead wires.

Stepper motors: Performance positioning

Stepper motors work for precise positioning and control with torque. Intermittent moves is what steppers output best. Tip: Don’t use stepper motors for continuous operation. When applications need motors to operate nonstop, steppers exhibit dwindling efficiency and torque.

Also read: How to select a dc motor

Stepper motors are also suitable on axes that must hold loads still for extended lengths of time, as the motors can remain in one position indefinitely. With proper design and damping, the motors can also output motion with minimal velocity ripple. Additionally, stepper motors have high repeatability and are reliable. From a cost perspective, they are often far cheaper than servomotors and can often be used in applications where servomotors are used with significant savings.

Brushed motors: Consumer designs, mobile machinery and more

Brushed DC Motors
Brushed dc coreless motors have air core armatures, so they can reach high speeds in a matter of only milliseconds with about 90% efficiency.

Brushed dc motors are a mature technology. Their familiarity makes them easy to use. Despite drawbacks (such as commutator and brush wear) they still have advantages. They cost less than some options, especially when OEMs buy them in bulk. A linear torque-speed relationship makes them easier to control.

Also read: Where do brush DC motors still make sense?

When designers pair them with simple speed controllers, brush motors can be useful in automotive, consumer appliances and home goods and toys.

Brushless dc motors: Efficient and durable

Brushless DC Motors
A brushless DC motor from Johnson Electric.

Brushless DC motors remove the concern of brushes and their associated wear and arcing. They are more efficient than brush motors as they have less internal friction. They usually last longer and expose the surrounding environment to less electromagnetic interference. Brushless dc motors are suitable in low-power applications (such as consumer products) as well as high-power uses (in electric vehicles and industrial machinery, for example). They are slightly more expensive than brushed DC motors.

For all of these types of motors, keep in mind voltage availability, size and torque and speed, as well as lifespan requirements.

You Might Also Like

Filed Under: DC Motors, FAQs + basics, Motors, Servo Motors, Stepper Motors

Reader Interactions

Leave a Reply

You must be logged in to post a comment.

Primary Sidebar

LEARNING CENTER

Design World Learning Center

Motion Control Handbook

“mct
EXPAND YOUR KNOWLEDGE AND STAY CONNECTED
Get the latest info on technologies, tools and strategies for Design Engineering Professionals.

RSS Featured White Papers

  • Robotic Automation is Indispensable for the Logistics Industry’s Continued Growth and Success
  • Reliable Linear Motion For Packaging Machines
  • Polymers Outperform Metals In Precision Gearing

Footer

Motion Control Tips

DESIGN WORLD NETWORK

Design World Online
The Robot Report
Coupling Tips
Linear Motion Tips
Bearing Tips
Fastener Engineering.
Wire and Cable Tips

MOTION CONTROL TIPS

Subscribe to our newsletter
Advertise with us
Contact us
About us

Copyright © 2025 · WTWH Media LLC and its licensors. All rights reserved.
The material on this site may not be reproduced, distributed, transmitted, cached or otherwise used, except with the prior written permission of WTWH Media.

Privacy Policy | RSS