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The performance of an electric screwdriver fundamentally depends on the type of motor technology it uses. The key difference between brushed and brushless electric screwdrivers lies in how electric current is conducted and how the motor is driven.

Brushed electric screwdrivers use traditional brushed motors. These rely on physical contact between carbon brushes and a commutator on the rotor to conduct electricity. The electromagnetic field generated drives the rotor to spin. While this mechanical contact design is simple, the constant friction between the brushes and commutator causes energy loss and accelerates wear. Over time, this leads to noticeable performance degradation.

Brushless electric screwdrivers represent a technological breakthrough. They eliminate the wear-prone carbon brushes and instead use electronic commutation. In this design, the roles of the stator and rotor are reversed. Sensors detect the rotor’s position in real time, and an electronic controller precisely manages the energizing sequence of the windings to create a rotating magnetic field that drives the motor. This contactless design addresses the inherent flaws of brushed motors and has become the mainstream direction in modern power tools.

Performance Comparison

1. Efficiency and Energy Consumption
   In brushed motors, friction between the brushes and commutator converts a significant amount of energy into heat, resulting in low efficiency. Over time, heat buildup further reduces performance. Brushless motors, free from friction losses, offer much higher energy conversion efficiency. Under the same power supply, they can complete more work—especially beneficial in battery-powered applications, where extended runtime is a clear advantage.

2. Power and Precision
   Brushed electric screwdrivers typically have a fixed torque output with limited adjustment range. At low speeds, they struggle to maintain high torque, which can lead to inconsistent results when handling screws of different sizes. Brushless motors, controlled electronically, can adjust both speed and torque. They automatically adapt the output force based on screw size and material hardness, preventing screw stripping or damage to the workpiece—especially valuable in precision assembly tasks.

3. Noise and Vibration
   Brushed motors generate noticeable noise and vibration due to brush-commutator friction, which can cause operator fatigue over time. Brushless motors, with their optimized structure, run more smoothly and quietly, significantly reducing vibration. This not only improves user comfort but also lowers the risk of work-related health issues.

Lifespan and Maintenance

Carbon brushes in brushed electric screwdrivers are consumable parts that wear down over time and require regular replacement. Failure to do so can result in poor contact, reduced power, or even motor failure. Replacing brushes adds maintenance costs and often requires professional handling, which can be inconvenient for non-professional users.

Brushless electric screwdrivers eliminate this issue. With no brushes or other high-wear components, they only need basic maintenance to stay in good working condition. Their lifespan far exceeds that of brushed models. In harsh environments—such as dusty or humid conditions—the sealed structure of brushless motors offers better protection and reliability.

Application Scenarios

Although brushed electric screwdrivers are cheaper, their performance limitations make them suitable only for occasional DIY use or light-duty tasks where precision and efficiency are not critical. Brushless electric screwdrivers, with their high efficiency, precision, and durability, are ideal for demanding applications such as industrial automation, precision manufacturing, and automotive assembly.

Take, for example, Danikor’s brushless electric screwdrivers. Built on mature brushless motor technology, they deliver efficient energy conversion and stable power output. With precise torque control, they meet the strict requirements of precision assembly. Their low-maintenance design reduces operational costs, while their quiet and smooth operation enhances user comfort. Whether for daily professional use or continuous production line operation, they perform reliably—fully demonstrating the practical value of brushless technology.