Brushed motors are commonly used in household appliances (e.g., vacuum cleaners, power tools), toys, and automotive systems (e.g., windshield wipers, seat adjusters) . They typically operate at 12V-24V and require regular brush replacement every 1,000-3,000 hours.
Hair Dryer Motors
More than 400 million hair dryers are made globally every year, and most of them – about 75% – rely on brushed motors. These typically range in power from 500 watts to 2000 watts, with the efficiency being as high as 80% and as low as 90%. The cost to make one brush motor is somewhere between $1.5 and $4; the retail value of a completed hair dryer typically ranges from $15 to $50.
A consumer survey revealed that 68% of users prefer hair dryers priced below $30. Brushed motors in hair dryers have a lifespan of 800 to 1200 hours, sufficient for 3 to 5 years of regular use in an average household.
An entry-level hair dryer from a well-known brand features a brushed motor with a rotational speed of 22,000 RPM, capable of drying wet hair in 10 minutes. Brushed motors typically generate noise levels between 60 and 75 decibels, whereas high-end brushless motors can reduce noise to below 50 decibels.
Brushless motors generally last over 2000 hours, doubling the lifespan of brushed motors. Manufacturing costs for a brushless hair dryer range from $15 to $25. In 2022, the sales growth rate for budget hair dryers in Southeast Asia reached 8.7%, with 90% of these products featuring brushed motors.
Low-friction carbon brush materials developed by a research team reduce motor friction losses by 30%, which extends motor life. The technology has been implemented in some premium brushed hair dryers with a 10% increase in retail price to 1500 hours of motor life.
Data from 2023 indicates that around 20% of discarded hair dryers were successfully recycled, with brushed motors accounting for the majority. China remains the largest producer of brushed hair dryers, manufacturing over 200 million units in 2022, representing more than 50% of global output. By 2030, the global hair dryer market is projected to reach $30 billion, with brushed motor models maintaining a market share of approximately 60%.
Vacuum Cleaner Motors
Over 250 million vacuum cleaners are manufactured worldwide annually, with more than 70% equipped with brushed motors. an average power range of 400 watts to 1400 watts, generating suction pressures up to 18 kPa, sufficient for routine cleaning needs.
Among household vacuum cleaners, approximately 65% are low-cost models, priced between $50 and $200. brushed motor costs account for only 10% to 15% of the total manufacturing cost. A $100 vacuum cleaner typically contains a brushed motor costing $8 to $12.
The lifespan of brushed motors in vacuum cleaners is generally 500 to 1500 hours. Typical households use vacuum cleaners 2 to 3 times per week, with an average runtime of 15 to 20 minutes per session, allowing brushed motors to last 3 to 5 years under these conditions.
A widely used handheld vacuum model comes with a standard brushed motor, which can reach a maximum speed of 18,000 RPM and has a suction power of 16 kPa. Brushed motors have an efficiency range of 70% to 85%, while brushless motors achieve efficiencies of more than 90%. The noise levels for brushed motors are between 75 and 85 decibels when in operation, while high-end brushless motors have noise levels below 60 decibels.
In 2022, the market share of high-end vacuum cleaners increased by 12%, with over 90% of these models equipped with brushless motors. In India, brushed motor vacuum cleaners dominate the market with an 88% share due to cost-sensitive consumer preferences.
Electric Drill Motors
In 2023, 420 million electric drills were sold worldwide, with about 65% using brushed motors. The power range for brushed motors in electric drills is usually between 300 watts and 800 watts.
For entry-level household drills, the retail prices are between $30 and $80, and the cost of the brushed motor is 10% to 15% of the total manufacturing cost. These drills usually provide maximum torque outputs between 15 Nm and 40 Nm.
The lifespan of the brushed motor drills is between 300 and 800 hours, which depends on usage intensity and operating conditions. In a typical usage, with 1 to 2 sessions per week, with 10 to 15 minutes average per session, a drill would last about 5 years.
The cost of replacing carbon brushes in a brushed motor drill is $5 to $10, with replacement intervals every 200 to 300 hours of operation. Brushed motors operate at efficiencies of 75% to 85%, compared to brushless motors that achieve efficiencies above 90%. Noise levels for brushed motor drills range from 75 to 85 decibels, while brushless motor drills operate below 60 decibels.
Brushed motor drills of 800-1200 watts are mainly utilized by construction workers for drilling purposes on concrete. It is able to deliver maximum torque output up to 60 Nm and helps to drill big-diameter holes faster. During the year 2022, such industrial-grade drill sales rose by 8.5%.
Sewing Machine Motors
Every year, over 70 million sewing machines are manufactured worldwide. More than 60 percent of these units use brushed motors as the sole source of power. these motors operate in the power range between 50 watts and 200 watts, capable of driving speeds of 3,000 to 8,000 stitches per minute.
A standard household sewing machine costs between $100 and $300. Brushed motor costs make up approximately 10% of the manufacturing cost. A $150 sewing machine, for instance, might contain a $10 to $15 brushed motor.
Lifespans for brushed motors of sewing machines vary from 1,000 to 2,000 hours depending on the usage and workload. For instance, a household sewing machine, used 2 to 3 hours a week, will serve over 10 years in that usage pattern. For an industrial sewing machine used over 8 hours daily, it needs to be replaced after every 2 to 3 years.
The cost of replacing carbon brushes in a household sewing machine is approximately $5 to $10, with replacement intervals every 500 to 800 hours. Compared to brushless motors, brushed motors generate higher noise levels, typically between 60 and 75 decibels.
In 2022, demand for sewing machines in Southeast Asia grew by 7.5%, with over 80% of these machines equipped with brushed motors.
Water Pump Motors
In 2023, global water pump sales exceeded 150 million units, with approximately 58% driven by brushed motors. power ratings between 100 watts and 750 watts, delivering water flow rates of 30 liters to 150 liters per minute.
A portable water pump for household use is usually priced between $50 and $150, with brushed motor costs accounting for about 15% of the total manufacturing cost. Compared to brushless motor-driven pumps, brushed motor pumps are typically 20% to 30% cheaper.
The operational lifespan of brushed motor pumps ranges from 800 to 1500 hours, depending on usage frequency and water quality. In typical household settings, pumps are used 2 to 3 times a week for 20 to 30 minutes per session, allowing the equipment to last over 5 years. For industrial users, the replacement cycle for brushed motors is generally 2 to 3 years.
Standard carbon brushes require replacement every 400 to 600 hours, with each replacement costing approximately $5 to $8. Brushed motors have slightly lower efficiency compared to brushless motors, operating at 70% to 85%, while brushless motors achieve efficiencies above 90%.
Brushed motor pumps normally have a sound level between 65 and 80 decibels, whereas brushless motors are usually less than 60 decibels. As of 2022, demand for water pumps increased by 8.3% in Southeast Asia and 7.9% in Africa. About 70 percent of water pumps have brushed motors. A 500-watt water pump will lift water up to a height of 40 meters ideal for high altitude and its price is around $120.
Electric Vehicle Starters
The brushed motor starters of electric vehicles typically have a power rating between 250 watts and 750 watts. Acceleration from a standstill in 3 to 5 seconds is possible with these starters. The standard electric bicycle costs between $500 and $1500, while the cost of the brushed motor starter accounts for 10% to 12% of the overall cost.
For an $800 electric bicycle, the brushed motor starter costs approximately $50 to $80. Brushed motor versions are approximately 30% cheaper than brushless motor starters.
Brushed motor starters typically have lifespans of 1000 to 1500 hours, supporting 2 to 3 years of regular use. The average daily riding time for electric bike users is 40 to 60 minutes, with replacement cycles for brushed starters occurring about every year.
The replacement of carbon brushes in the brushed motor starters would cost between $5 and $10 and should be done after 500 to 800 hours. Brushed motors have 75% to 85% efficiencies, while brushless motors work with 90% or more. Noise levels are also different with the brushed motor starters ranging between 65 and 80 decibels, whereas brushless motors produce noise that is less than 60 decibels.
In 2022, electric bicycle demand increased by 10% in China, 12% in India, and 15% in Southeast Asia, with about 70% of vehicles in these regions using brushed motor starters. In 2023, the number of shared electric bicycles around the world reached over 80 million, with about 60% of them having brushed motor starters.
Kitchen Blenders
Each year, over 200 million kitchen blenders are manufactured worldwide, with approximately 75% utilizing brushed motors. typically operate within a power range of 200 watts to 1000 watts. A standard household blender is priced between $30 and $120, with brushed motor costs accounting for about 15% of the total manufacturing cost.
For a $50 blender, the motor cost ranges from $8 to $12. The lifespan of brushed motor blenders typically ranges from 800 to 1200 hours, depending on usage frequency and the hardness of the ingredients being blended.
For a typical household using the blender 3 to 5 times a week, with each session lasting 10 to 15 minutes, the appliance can last over 5 years. Commercial blenders, due to higher usage intensity, generally require replacement every 1 to 2 years.
Carbon brushes in brushed motor blenders must be replaced every 500 to 800 hours, costing between $5 and $10 to replace. Brushed motors run at an efficiency of 70% to 85%, whereas brushless motors operate with efficiencies above 90%.
The brushed motors in blenders are mostly in the range of 60 to 75 decibels, while the brushless motor blenders go as low as below 50 decibels. In 2022, the mid- to low-end blender market was growing at 7.8%, and 85% of this market was from brushed motor blenders. A 600-watt multifunctional blender that crushes ice into fine texture within 20 seconds costs about $70.
Electric Vehicle Starters
About 65% of low-speed electric vehicles and electric bicycles use brushed motor starters. usually in the power range of 250 watts to 1500 watts, which enables vehicles to accelerate from standstill within 3 to 5 seconds, adapting to various terrains and load demands.
A regular electric bicycle ranges between $500 and $1500, while a brushed motor starter costs $50 to $100, representing 10% to 15% of the total price. Brushed motor starters are also 20% to 30% cheaper than brushless ones.
The design lifespan of brushed motor starters is 1000 to 2000 hours, depending on vehicle usage frequency and operating conditions. For average electric bicycle users riding 30 to 60 minutes daily, brushed motor starters can last 3 to 5 years. In high-intensity applications like food delivery and logistics, replacement cycles are typically 1 to 2 years.
Carbon brushes in brushed motor starters need replacement after every 500 to 800 hours of running time, and the cost of every replacement is $5 to $10. Brushed motors have efficiencies ranging from 70% to 85%. Brushless motors have efficiencies ranging above 90%.
Noise levels for brushed motor starters are typically 65 to 80 decibels, whereas brushless motors reduce noise to below 60 decibels. In 2022, electric vehicle demand grew by 12% in China, 10% in India, and 15% in Southeast Asia, with brushed motor starters being used in 70% of vehicles.
Technological improvements have extended the lifespan of brushed motor starters by 20% to 30% while reducing operational noise and energy consumption. In 2023, the global fleet of shared electric vehicles reached 90 million, with approximately 60% equipped with brushed motor starters.
