Difference Between Brushed and Brushless Alternator

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The difference of brush alternator and brushless alternator

2022-04-01

1. The difference in governor types
In practice, alternator control relies primarily on voltage regulation. Because a brushless DC alternator uses electronic commutation, it requires digital control methods. In contrast, a brushed DC unit commutates using carbon brushes, allowing for straightforward analog control with traditional thyristor circuits.
a) For a brushed alternator, the speed regulation process works by adjusting the motor power supply voltage. As voltage and current are altered through the commutator and carbon brushes, the strength of the magnetic field generated by the electrode changes, thereby modulating the operating speed. This technique is known as variable speed regulation.

b) In a brushless alternator, speed regulation is achieved while motor supply voltage remains constant by adjusting the ESC control signal. The microprocessor modulates the switching frequency of the high-power MOS tube to regulate rotational speed. This mechanism is called variable frequency speed regulation.

2. Performance differences
a) A brushed DC generator offers rapid response and high starting torque. It delivers quick starting performance, substantial torque, and smooth acceleration with virtually imperceptible vibration from zero to maximum speed, allowing it to start under heavy loads. Conversely, a brushless alternator exhibits higher starting resistance, resulting in a lower power factor, reduced starting torque, audible humming, and significant vibration during startup, which restricts its starting load capacity.
b) By eliminating brushes, a brushless alternator prevents the formation of electric sparks during operation. This lack of arcing substantially minimizes electromagnetic interference with remote-controlled radio equipment.
c) With no brushes to wear down, brushless alternators deliver a long service life and minimal maintenance expenses, as mechanical wear is largely confined to the bearings. Mechanically, a brushless generator functions as a virtually maintenance-free unit, generally requiring only occasional dust removal when needed.

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