Which is better, brushless or brushed impact wrench

A brushless impact wrench is an electric tool that uses a brushless motor as its power core. The most fundamental difference from a traditional brushed impact wrench lies in its motor structure: the brushless motor has no carbon brushes that are prone to wear, while the brushed motor relies on friction between the carbon brushes and the rotor's commutator to transfer current. This core difference gives brushless impact wrenches significant advantages in performance, efficiency, and durability.

The working principle of a brushless motor can be understood as a precise electronic control system. It is mainly composed of three parts:

1. Stator: Composed of coils, located on the outside of the motor.

2. Rotor: Composed of permanent magnets, located on the inside of the motor.

3. Electronic Controller: This is the "brain" of the brushless motor, responsible for sensing the rotor's position and precisely controlling the current to the different coils on the stator.

When the electronic controller energizes the stator coils, it generates an electromagnetic field that pushes the rotor, which is made of permanent magnets, to rotate. Because the controller can continuously and precisely switch the direction of the current, the magnetic field generated by the stator constantly changes, thereby pushing the rotor to rotate continuously and efficiently. This entire process has no physical friction, so the energy loss is extremely low.

Brushless Motor vs. Brushed Motor: Parameter Comparison

• Efficiency: A brushless motor does not produce carbon brush friction loss, so its energy conversion efficiency can usually reach over 85% to 90%, while a brushed motor is around 75%. Higher efficiency means longer battery life.

• Service Life and Maintenance: A brushless motor has no carbon brush wear issue, requires almost no daily maintenance, and has a longer service life. A brushed motor, however, requires regular replacement of carbon brushes, which is its main maintenance cost and wear point.

• Performance: A brushless motor can provide a more stable and powerful torque output, and due to its electronic control characteristics, it can achieve more precise speed and torque control, adapting to more complex tasks.

• Noise: Due to the lack of carbon brush friction, a brushless motor runs more quietly.

• Size and Weight: For the same power, a brushless motor is usually more compact and lighter, making a brushless impact wrench easier to handle.

• Cost: A brushless impact wrench is generally more expensive than a brushed one due to its advanced electronic control technology and permanent magnet materials.

Brushless vs. Brushed Impact Wrench: Which Is Better?

Choosing between a brushless and a brushed impact wrench is an important decision for many users. While they are both used for tightening and loosening bolts and nuts, they have significant differences in performance, durability, and cost.

Performance Comparison

• Efficiency: The brushless impact wrench has no physical friction between the carbon brushes and the rotor, so the energy loss is minimal, and the conversion efficiency from electrical to kinetic energy is higher. This means that with the same battery capacity, a brushless tool usually has a longer run time. A brushed tool, on the other hand, generates heat and sparks from carbon brush friction, leading to some energy loss.

• Torque and Speed: The brushless motor is precisely controlled by an electronic controller, which can provide a more stable and powerful torque output and can achieve more precise speed regulation according to the task. This makes a brushless impact wrench perform better in high-intensity jobs or situations requiring precise control.

• Maintenance: The motor of a brushless impact wrench has no wear parts like carbon brushes, so it requires almost no daily maintenance, which greatly reduces maintenance costs and time. The carbon brushes of a brushed tool will wear out with long-term use and need to be checked and replaced regularly.

• Service Life: Because a brushless motor has no carbon brush wear, its overall service life is usually much longer than that of a brushed tool.

Cost and Application

• Initial Cost: A brushless impact wrench is usually more expensive than a brushed one due to the more complex motor and electronic control technology.

• Use Cases:

  • Brushless Impact Wrench: Suitable for professionals who need to use the tool frequently or for heavy-duty tasks. It provides longer run time, higher performance, and a longer service life, thereby increasing work efficiency.

  • Brushed Impact Wrench: Generally more affordable, suitable for home users or hobbyists with a limited budget who use the tool occasionally for light-duty tasks.

Buying Guide for a Brushless Impact Wrench

Choosing a suitable brushless impact wrench requires a comprehensive consideration of multiple factors to ensure it meets your specific work needs. Here are a few key considerations that can help you make a wise decision.

Key Performance Parameters

• Torque: This is the most important parameter of an impact wrench, representing its power to tighten and loosen bolts. The higher the torque, the larger the bolt size and fastening difficulty it can handle. For high-intensity applications such as automotive repair, construction, or heavy machinery, you should choose a model with higher torque.

• Rotational Speed (RPM) and Impacts per Minute (IPM): The RPM (revolutions per minute) affects how fast the bolt is tightened or loosened, while the IPM (impacts per minute) determines the tool's efficiency during fastening. High RPM and IPM can significantly increase work efficiency.

• Battery Voltage and Capacity: Battery voltage (V) determines the tool's power, while battery capacity (Ah) affects the run time. For long work sessions or tasks requiring significant power, choosing a combination of higher voltage and larger capacity is a wise choice.

Ergonomic Design

• Weight and Balance: Using a heavy tool for an extended period can increase fatigue. Choosing a brushless impact wrench with a moderate weight and good balance can significantly improve operating comfort.

• Handle Design: The handle's material and shape should conform to ergonomics, providing a comfortable and non-slip grip to reduce hand fatigue.

Additional Features

• LED Light: In poorly lit working environments, an integrated LED light can provide illumination, making it easier to aim the wrench at the bolt.

• Variable Speed Trigger: You can adjust the tool's speed by controlling the pressure on the trigger, which is crucial for tasks that require precise torque control.

• Impact Mode Selection: Some advanced models offer multiple torque or impact mode selections, allowing you to quickly switch settings to match different bolt sizes and materials.

How to Properly Use and Maintain a Brushless Impact Wrench

To ensure your brushless impact wrench maintains optimal performance and safety over the long term, proper use and daily maintenance are crucial.

Correct Operation Steps

• Choose the right socket: Use an impact-rated socket that matches the bolt size; a regular socket may break under high torque. Ensure the socket is firmly installed on the wrench's anvil.

• Adjust torque settings: Many brushless impact wrenches have multiple torque or speed settings. Choose the appropriate setting based on the bolt's size and material. For removal, you can generally use maximum torque; but for fastening, especially on sensitive materials, you should use a lower torque to avoid over-tightening or damage.

• Maintain stability: When using the tool, hold it with both hands and maintain balance. Place the socket firmly on the bolt head and then smoothly press the trigger.

Safety Precautions

• Wear Personal Protective Equipment (PPE): Always wear safety glasses to prevent bolt fragments or dust from getting into your eyes. If the working environment is noisy, you should also wear earplugs or earmuffs.

• Inspect the tool and battery: Before each use, check that the tool body and battery are in good condition. Ensure the battery is fully charged to avoid work interruptions.

• Work environment: Keep your work area clean and tidy, and avoid damp environments. Do not use power tools near flammable or explosive gases or liquids.

Daily Maintenance Tips

• Battery care: The performance of a brushless impact wrench largely depends on the battery. Avoid letting the battery fully drain before recharging, and do not overcharge it. When not in use, remove the battery from the tool and store it in a dry, cool place.

• Tool cleaning: Regularly wipe the tool body with a clean cloth to remove dust, oil, and debris. Do not use strong solvents for cleaning, as this may damage the plastic casing.

• Storage: Store the tool in a dry, safe place, away from children and unauthorized personnel. It is best to use a toolbox or storage bag to protect the tool from moisture or impact.