How a Low-Cost Brushed Motor Pump Achieves Brushless Motor Lifespan?
How a Low-Cost Brushed Motor Pump Achieves Brushless Motor Lifespan? I. Industry Background and Technical Challenges 1.1 Lifespan Difference Between Brushed and Brushless Motors In applications such as micro pumps, medical devices, small appliances, and industrial fluid control, motors serve as the core driving component. Their lifespan and performance stability directly determine the operational lifecycle and maintenance costs of the system. Conventionally, brushed motors typically last between 500 to 2,000 hours, while brushless motors can easily achieve 5,000 hours or more. This disparity has led to the widespread adoption of brushless motors in high-load, high-frequency applications. 1.2 The Cost Paradox: Performance vs. Affordability Despite the reliability and efficiency advantages of brushless motors, their high manufacturing cost (30-50% higher than brushed solutions) limits their deployment in cost-sensitive scenarios. The industry faces a persistent dilemma: higher performance demands higher costs. 1.3 Hilin’s Technological Vision Hilin Technology is committed to breaking this deadlock through engineering innovation. We propose a high-performance, long-life brushed motor pump solution that significantly extends the lifespan of traditional brushed motors without substantially increasing costs, redefining their value in high-intensity applications. II. Core Technical Approaches 2.1 Power-Lifetime Coupling Modeling Objective: Establish a mathematical model to predict the lifespan trends of brushed motors under different operating conditions, enabling quantitative design. Methods & Achievements: 1)Developed a multi-physics simulation model integrating thermal, electrical, mechanical, and wear processes. 2)Implemented neural network-based regression prediction to fit lifespan trends under multi-load and multi-voltage conditions. 3)Validated model accuracy (<8% error between experiments and simulations) for practical engineering applications. 2.2 High-Precision Dynamic Balancing Rotor System Objective: Reduce vibration-induced wear between brushes and commutators, improving operational stability. Key Measures: 1）Laser balancing + symmetrical structural design, achieving G1-grade dynamic balance (ISO 1940). 2）Vibration testing confirmed a 33% reduction in rotor oscillation amplitude. 3)Extended brush contact lifespan by mitigating brush bounce, arcing, and ablation failures.…