What is a Brushless Chainsaw?

Are you in the market for a new brushless chainsaw but first want to know more about it? If yes, then you are definitely in the right place.

What is brushless chainsaw is a common question that users looking to buy a new chainsaw have. Brushless chainsaws come equipped with brushless motors. These motors are advanced electric motors that come with magnets instead of carbon brushes. The difference in construction will make these brushless motors much more efficient, reliable, and durable. These brushless motors work quietly while also remaining cool as there’s no friction. Brushless motors have been becoming more popular, and they can be found in many tools and gadgets, including the chainsaw. Further, there is also the exemption from the risk of worn-out brushes are there aren’t any.

In this article, you will get to know all about brushless chainsaws, what is brushless chainsaw, how do brushless motors work, the difference between a brushed and brushless motor, and more. Stick around to get all the answers that you are looking for.

Brushless Chainsaws for Wood-Cutting Projects

Have you come across a tool called a “Brushless Chainsaw”? Any woodworker looking for a cordless chainsaw often gets stuck between the brushed and brushless chainsaws. If you have been in this situation, then you aren’t alone, there are many people in the same boat.

Brushless motors have been becoming more and more popular. These days, you can easily find them in many electrical gadgets and tools, including the chainsaw.

The brushless chainsaws come equipped with brushless motors. These motors are advanced electric motors that have magnets instead of carbon brushes. A brushless chainsaw refers to a chainsaw that has a motor without any brushes. There are two types of electric motors that are used in chainsaws – brushed motors and brushless motors. The basic working of both types of motors will be the same; however, there will be some differences in their construction.

What is a Brushless Chainsaw?

If you do not know “what is a brushless chainsaw”, it’s a chainsaw that comes equipped with a brushless motor. The two types of electric motors that are used in cordless chainsaws are brushed and brushless motors. Brushless motors are essentially an advanced form of electric motors where instead of carbon brushes, magnets will be used. This makes brushless motors much more efficient and allows them to work better than traditional motors.

The brushless chainsaws come with a brushless motor, which makes these battery-powered chainsaws much more efficient than other types of chainsaws that come with brushed motors. The brushed motors are synchronous electric motors that essentially move around electronically. The direct current powering magnets will be used in these motors for moving the rotor in the stator.

The brushless motors make use of a step motor controller instead of brushes and a commuter. Unlike conventional or brushed motors, it will generate a rotation that converts electrical energy into mechanical energy.

The brushless motors, on the other hand, have a complex design where the commutator and brushes are missing. Additionally, the position of the magnets and the windings are reversed. Since the copper windings are fixed and surround the shaft instead of simply sitting on the armature, the energy to the copper windings will be transferred through the small-sized circuit board instead of the brushes and commutator.

The chainsaw’s brushless motor makes use of the battery’s electric energy for powering its moving parts, specifically the chain revolving around the bar. Irrespective of the powerful battery that you’re using, the best better-powered chainsaws would be useless if the chainsaw isn’t equipped with a powerful motor. It would be important to understand that the battery provides enough power to the chainsaw. However, it is not the only significant part of the chainsaw’s electrical system.

In traditional electric motors, carbon brushes will be used to help with power transmission. On the other hand, magnets will play a significant role in brushless motors instead of carbon brushed. So, it wouldn’t be wrong to say brushless motors depend heavily on magnets. Compared to the carbon brushes of traditional electrical motors, the magnets of the brushless motor don’t need any physical contact with other parts for carrying a charge. Hence, there will be little frictional interference.

How Do Different Types of Electric Motors Work

Both types of motors, be it brushed or brushless, tend to function similarly. An electric motor comes with permanently attached magnets on the exterior side, which do not move.  On the interior, there will be a rotating armature that rotates. This is known as a rotor and it contains an electromagnet. As a result, an electromagnetic force will be generated. 

Then, there will be the copper coil that creates a temporary magnet after it gets energized by electromagnetic force. This temporary magnetic field that attracts or repels the permanent magnets get created when the windings or copper coil in the motor gets energized. This electromagnetic force causes the shaft to move and allows the motor to work. 

As the current gets passed through different sets of windings, the armature turns continuously. This way, an attraction for repulsion will be maintained. Below is a comparative analysis regarding the workings of different types of electric motors. This way, it’ll be easier to understand how they work and which motor will be better.

Brushed Motor

Due to the continuous movement of the armature, the electromagnet’s poles will consciously change. As the electric current is flowing through different windings, the armature will keep on running. The moving of the armature keeps changing the poles of the electromagnet in brushless motors. In a brushed motor, the brushes will contact the two spinning electrodes to deal with the change in polarity. 

Here comes the actual function of the brushes, which will be to make contact with spinning electrodes that are attached to the armature and deal with the change in polarity of the electromagnet.

You can say that the brushes will deliver the current from the battery to the commutator. It later passes the charge to the windings of the motor to energize it. It’ll magnetize the copper winding, which will then be pushed against the regions of the magnets and allow the armature to spin. Consequently, the armature will spin. The spinning will continue until the battery continues to supply the charge.

Differences Between Brushed and Brushless Motors - A GalcoTV Tech Tip | Galco

Brushless motors

Traditionally, only brushed motors were available for the users, but now, there is also the prospect of brushless motors, which have slightly different compositions. The main principle of the working mechanism of both types of motors is essentially the same. However, there are a few differences between having brushes and without brushes.

Now, it is important to know the composition and work involved with a brushless motor. You will find the brushless motor to be more complex than the brushed motors as in the brushless motor, there aren’t any brushes. Additionally, the commutator will also be removed. Further, the position of the magnets and winding will be different, as you’ll find them surrounding the shaft. In this case, the copper winding is not attached to the armature. Instead, it is set on the shaft and will be fixed there.

Since you will be short of commutator and brushes in a brushless motor, what will be the replacement? A brushless motor essentially works by passing the current to the copper winding through the circuit board. Instead of an armature and commutator, the circuit board will be there to flow the energy to the copper winding.

Further, the position of the magnets and winding will also be different, as you’ll be able to find them surrounding the shaft. This way, the energy gets channeled to the winding through a small circuit board instead of brushes and the commutator.

Differences Between Brushed Motors and Brushless Motors

While the basic working principle involved with both types of motors is essentially similar, they are somewhat different in their construction. Here are the differences between brushed motors and brushless motors – 

Brushes

The brushes of a brushed motor will transfer the current to the copper winding through commutator contracts. In contrast, brushless motors will not require commutators. The field in this type of motor will be switched using an amplifier triggered by a commutating device.

Windings

The winding of a brushed motor will be located on the rotor. In the case of a brushless motor, you’ll be able to find the windings on the stator. This way, by positioning the windings on the stator, you will be eliminating the need for the brushes.

Magnets and wires

The brushed motors come with stationary magnets and spinning wires. Brushless motors, on the other hand, have spinning magnets and stationary wires. This way, friction can be reduced in the brushless motor. This keeps the brushless motors cool and allows them to work efficiently for a long time.

Difference Between a Brushless Chainsaw and a Regular Chainsaw

The basic difference between a regular chainsaw and a brushless chainsaw will be the way the motors of chainsaws work and are composed. In a regular chainsaw, the motor comes with brushes that pass the energy to the shaft; hence the armature keeps on rotating. This will result in the flow of energy and current by which your chainsaw works.

Brushless motor-operated chainsaws, on the other hand, do not have any brushes. Moreover, a commutator will be missing in such motors. However, there is also the addition of a circuit responsible for the flow of current according to your need.

Are Brushless Motors Better than Brushed Motors?

If you are wondering what type of motor works best for chainsaws, a brushless chainsaw motor will be superior to a brushed one. If you have a mini chainsaw, using a brushless chainsaw is recommended, as they’re better than the brushed ones in many aspects. This is the case because motors work efficiently and better than brushed ones. It’ll be helpful to have a look at the pros and cons of both types of motors and know why a brushless chainsaw is the better choice.

Benefits of using a brushless motor

There are many advantages to using a brushless motor. Some of the biggest benefits are –

• The first advantage of a brushless motor includes the exemption of bushes and since bushes are absent, there will be no risk of worn-out brushes 
• Brushless motors are quieter compared to brushed motors when it comes to working 
• A brushless motor can be cooled down quite easily 
• The lack of brushes will mean there’s no manual energy flow control, which will make this motor highly efficient 
• One of the biggest advantages is the good efficiency of the motor
• The lack of brushes means that there’s no manual energy flow control, which makes the motor highly efficient 
• In brushless chainsaws, the energy is adjusted with the help of an automatically monitored computer system and this helps the energy to flow as per the need

Benefits of using a brushed motor

A brushed motor has rather limited benefits. Some of the primary benefits of using a brushed motor include –

• A brushed motor is rather inexpensive 
• A brushed motor is quite simple and very easy to set up
• This type of motor can be connected directly to the motor on the Direct Current (DC)

Drawbacks of using a brushless motor

A brushless motor does not have a lot of disadvantages. However, it is important to remember that the major drawback of this motor will be the initial cost. The initial cost is considered a drawback because the prices are quite high for brushless motors.

Drawbacks of using a brushed motor

The list of drawbacks of a brushed motor will be longer than the benefits provided by the brushed motor. Here are some of the primary drawbacks that you should keep in mind –

• The first major disadvantage is that the brushes can get worn out quickly because of the constant contact between the shaft and the brushes 
• Secondly, the brushed motors are likely to have heating issues as they’ll heat up rather quickly and take time to get cool
• Another drawback is that the speed of the motor will be rather limited 
• A brushed motor will make a lot of noise and the reason for that is that the brushes are continuously making and breaking the connection with the shaft 

Why Should You Be Buying Brushless Chainsaws?

If you are looking to decide whether to buy a brushed chainsaw or a brushless chainsaw? The answer will be quite simple as brushless motors are much superior to brushed motor chainsaws. The brushless motors will provide a lot of benefits, which make them worthwhile to consider. To make things clear as to why brushless motors are better, here is an example that will make things clearer.

Say that you have to cut a 3-inch diameter thick soft wood. Less power will be required for cutting soft wood 3 inches thick than if you are cutting a 6-inch thick hardwood. In this case, a brushless chainsaw motor will be intelligent and automatically adjust to the required amount of current level. The motor will be drawing less current from the battery while cutting the 3-inch diameter wood compared to a 6-inch diameter thick wood.

Here are some of the reasons why you should be buying a brushless chainsaw instead of a brushed chainsaw –

• It will extend the battery life of the chainsaw 
• A brushless chainsaw will be likelier to have a greater lifespan compared to a brushed version
• The brushless motor chainsaw will be much more efficient and reliable
• You will need to pay a slightly higher amount, but you’ll be getting more quality in return.
• Compared to brushed motor chainsaws, brushless motor chainsaws are smaller in size and comparatively lightweight

The brushless motors will be 85% to 90% efficient, whereas the efficiency of brushed motors will range from 75% to 80%. The efficiency will depict that most of the total power will be converted into the rotational force. At the same time, a low amount of energy will be lost as heat, which will reveal how efficient a brushless motor is when compared to the brushed version.

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