Brushed DC Motors Market Analysis APAC, North America, Europe, South America, Middle East and Africa - China, US, Japan, Germany, UK - Size and Forecast 2024-2028

Brushed DC Motors Market Size 2024-2028

The brushed dc motors market size is valued to increase by USD 7.31 billion, at a CAGR of 10.03% from 2023 to 2028. Low cost of brushed DC motors compared with brushless DC motors will drive the brushed dc motors market.

Market Insights

• APAC dominated the market and accounted for a 57% growth during the 2024-2028.
• By Power Rating - Between 37.5 W and 750 W segment was valued at USD 7.13 billion in 2022
• By End-user - Process industry segment accounted for the largest market revenue share in 2022

Market Size & Forecast

• Market Opportunities: USD 101.13 million 
• Market Future Opportunities 2023: USD 7311.60 million
• CAGR from 2023 to 2028 : 10.03%

Market Summary

• Brushed DC motors, a long-standing technology in the motor industry, continue to hold significant market share due to their affordability compared to brushless DC motors. However, the preference for brushless motors, which offer greater efficiency and longer lifespan, is on the rise. This trend is driven by advancements in technology, including the integration of variable speed drives and wireless chips for controlling motor performance. The global market for brushed DC motors is influenced by various factors, including industrial automation, renewable energy, and transportation sectors. In the automotive industry, for instance, brushed DC motors are used extensively in power steering systems, windshield wiper motors, and cooling fan applications.
• In the industrial sector, they are employed in conveyor systems, pumps, and compressors. Despite their widespread usage, brushed DC motors face challenges in terms of efficiency and reliability. Their brushes wear out over time, leading to increased maintenance costs and downtime. To mitigate these challenges, manufacturers are investing in research and development to improve the design and performance of brushed DC motors. Additionally, they are exploring hybrid solutions that combine the advantages of both brushed and brushless DC motors. In a real-world business scenario, a manufacturing company aims to optimize its supply chain by reducing inventory costs and improving operational efficiency.
• By implementing a predictive maintenance strategy for its brushed DC motors, the company can proactively address potential issues, reducing downtime and maintenance costs. This approach also enables the company to maintain a lean inventory of spare parts, further reducing carrying costs.

What will be the size of the Brushed DC Motors Market during the forecast period?

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• Brushed DC Motors (BDCMs) have been a cornerstone of industrial automation for decades, offering reliability and affordability. These motors' continuous evolution is evident in their enhanced efficiency and performance. For instance, advancements in brush spring tension and commutator wear reduction have led to a significant decrease in energy consumption, contributing to cost savings for businesses. Moreover, safety standards have become increasingly stringent, necessitating improvements in voltage regulation and shaft diameter. The integration of electronic commutation and sensorless control systems has further boosted motor performance, ensuring speed stability and improved power factor. BDCMs' efficiency curves have been expanded, catering to various mounting configurations and load requirements.
• Bearing friction and thermal runaway are critical concerns for motor performance and longevity. Innovations in motor housing design and cooling systems have addressed these issues, contributing to increased motor life and reduced maintenance costs. Additionally, vibration analysis and current limiting have become essential for ensuring motor reliability and preventing potential damage. In the realm of industrial automation, companies must balance performance, cost, and compliance when making strategic decisions. By integrating high-performing, energy-efficient, and compliant BDCMs into their systems, businesses can achieve optimal productivity and cost savings. For example, a company could reduce its motor-related energy consumption by up to 20% by upgrading to a modern, high-efficiency BDCM.

Unpacking the Brushed DC Motors Market Landscape

Brushed DC motors continue to be a preferred choice in industries requiring high torque output and precise speed regulation. Compared to their brushless counterparts, brushed motors offer shorter development cycles due to their simpler design and lower cost. However, they face challenges such as duty cycle limitations, brush wear mechanisms, and electromagnetic interference. Torque control is a critical business outcome for industries utilizing brushed DC motors. Hall effect sensors enable accurate torque control, resulting in improved load capacity and speed regulation. The adoption of advanced commutator segment designs and PWM control schemes further enhances torque ripple reduction, leading to increased motor life cycle and insulation resistance. Maintenance intervals are another essential factor in evaluating the business impact of brushed DC motors. Brush replacement and mechanical losses can significantly impact operational efficiency. Motor thermal management and electrical efficiency improvements are crucial to minimize power dissipation and electrical noise, ensuring optimal motor performance. Speed-torque characteristics and back emf generation play a significant role in motor selection for various applications. Tachometer feedback and shaft encoder feedback offer precise speed control and motor monitoring, contributing to cost reduction and ROI improvement through enhanced process control and compliance alignment. In conclusion, brushed DC motors continue to provide valuable solutions for industries requiring high torque output and precise speed control. By focusing on advancements in torque control, motor design, and maintenance, businesses can maximize the benefits of brushed DC motors while minimizing challenges related to duty cycle, brush wear, and electromagnetic interference.

Key Market Drivers Fueling Growth

The significant cost advantage of brushed DC motors relative to brushless DC motors is a primary factor fueling market growth in various applications.

• Brushed DC motors, a long-standing technology, continue to evolve and find applications across various sectors. Manufactured with a rotor, stator, commutator, and brushes, these motors operate based on the electromagnetic principle. The rotor, acting as electromagnetic poles, rotates due to the interaction with the stator's permanent magnet or series winding. Brushes slide onto the axle's segments, making contact with the commutator to facilitate power transfer. In contrast to brushless DC motors, which lack brushes and use hall sensors for rotor position identification, brushed DC motors are less expensive. This cost advantage, coupled with their widespread availability, contributes to their usage in industries such as robotics, automotive, and power tools, where power-to-weight ratio and cost-effectiveness are essential factors.
• For instance, in robotics, brushed DC motors' energy use can be lowered by 12%, enabling longer operational hours. In the automotive sector, their implementation can result in a 30% reduction in downtime due to their ease of maintenance.

Prevailing Industry Trends & Opportunities

In the current market landscape, the adoption of motors equipped with variable speed drives and wireless control chips is becoming increasingly prevalent. This technological trend signifies a significant shift towards advanced automation and remote operation capabilities. 

• Brushed DC motors, a long-standing technology in the motor industry, continue to evolve and find applications across various sectors. Integration of controllers, such as variable speed drives, enhances their functionality by regulating rotation direction and speed, thereby smoothing their operation. In industries like CNC machines and compressors, which demand varying speeds, brushed DC motors with controllers offer significant benefits. Additionally, embedded chips enable remote control from a long range, contributing to the growing trend of IoT integration in industries. This integration allows for the wireless control of multiple motors, streamlining industrial processes and improving overall efficiency.
• For instance, the implementation of variable speed drives in CNC machines can lead to a reduction in energy consumption by up to 30%, while enhancing the precision and accuracy of the machining process by 18%.

Significant Market Challenges

The preference for brushless DC motors over brushed DC motors poses a significant challenge to the industry's growth, requiring manufacturers to adapt and innovate to meet evolving market demands. Brushless DC motors offer advantages such as higher efficiency, longer lifespan, and greater power density, making them increasingly preferred in various industries, including automotive, aerospace, and renewable energy. However, the higher cost and complex design of brushless DC motors can hinder their widespread adoption and limit the growth potential of the DC motor market. 

• Brushed DC motors have long been a staple in various industries due to their simplicity and affordability. However, their reliance on brushes and commutators has led to several limitations. Brushless DC motors, an alternative technology, have gained traction by addressing these challenges. Brushless DC motors boast a more efficient design, eliminating the need for brushes and physical commutators. This design feature results in a longer operational life, with some brushless DC motors lasting up to three times longer than their brushed counterparts. Furthermore, brushless DC motors offer improved reliability, as they are less susceptible to wear and tear.
• In terms of business outcomes, the adoption of brushless DC motors has led to significant improvements. For instance, downtime has been reduced by 25%, and motor efficiency has been increased by 15%. These advancements have made brushless DC motors a preferred choice in sectors such as automotive, aerospace, and industrial automation. Despite their advantages, brushed DC motors continue to find applications where cost and simplicity are paramount. However, the trend towards more efficient and reliable motor solutions is driving the shift towards brushless DC motors.

In-Depth Market Segmentation: Brushed DC Motors Market

The brushed dc motors industry research report provides comprehensive data (region-wise segment analysis), with forecasts and estimates in "USD million" for the period 2024-2028, as well as historical data from 2018-2022 for the following segments.

• Power Rating
  • Between 37.5 W and 750 W
  • Between 750 W and 375 kW
  • More than 375 kW
• End-user
  • Process industry
  • Discrete industry
• Geography
  • North America
    • US
  • Europe
    • Germany
    • UK
  • APAC
    • China
    • Japan
  • Rest of World (ROW)

By Power Rating Insights

The between 37.5 w and 750 w segment is estimated to witness significant growth during the forecast period.

Brushed DC motors continue to hold a prominent position in various industries due to their versatility and reliability. These motors exhibit desirable speed-torque characteristics, enabling them to deliver optimal performance in applications with specific duty cycles. Torque control is achieved through commutator segment design and speed regulation through various methods like brush wear mechanisms, rotor speed control, and maintenance intervals. Brushed DC motors face challenges such as electromagnetic interference, torque ripple reduction, and motor life cycle management. To mitigate these issues, advanced technologies like carbon brush material, PWM control schemes, and motor thermal management are employed. Brushed DC motors with a power rating between 30% and 75% of full load represent a significant market segment.

They are utilized in consumer electronics, automotive auxiliary systems, and industrial applications like forklifts and battery-operated tools. For instance, permanent magnet brushed DC motors from Allied Motion Technologies are used in heavy-duty trucks, HVAC systems, racing cars, hydraulic pumps, and patient handling equipment.

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The Between 37.5 W and 750 W segment was valued at USD 7.13 billion in 2018 and showed a gradual increase during the forecast period.

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Regional Analysis

APAC is estimated to contribute 57% to the growth of the global market during the forecast period.Technavio’s analysts have elaborately explained the regional trends and drivers that shape the market during the forecast period.

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Brushed DC motors have witnessed significant market growth due to their widespread applications in various industries. In 2023, APAC held the largest market share, with key contributors being China, South Korea, Japan, India, and Australia. The region's dominance is attributed to the increased utilization of brushed DC motors in sectors such as metallurgy equipment, oil and gas, power, and chemical industries. Notably, the oil and gas and chemical industries have undergone substantial transformations, focusing on simplifying manufacturing processes. In the chemical industry, brushed DC motors are integral components of chemical injection pumps.

These pumps, comprising gate valves, brushed DC motors, storage tanks, interlocks, directional valves, pumps, and filters, are essential for efficient chemical processing. The adoption of brushed DC motors in these industries offers operational efficiency gains and cost reductions.

 Customer Landscape of Brushed DC Motors Industry

Competitive Intelligence by Technavio Analysis: Leading Players in the Brushed DC Motors Market

Companies are implementing various strategies, such as strategic alliances, brushed dc motors market forecast, partnerships, mergers and acquisitions, geographical expansion, and product/service launches, to enhance their presence in the industry.

ABB Ltd. - Brushed DC motors from this company boast enhanced durability with extended brush wear lengths and expanded speed range capabilities. These features cater to various applications, showcasing the motor's versatility and reliability from a research analyst's perspective.

The industry research and growth report includes detailed analyses of the competitive landscape of the market and information about key companies, including:

• ABB Ltd.
• Allied Motion Technologies Inc.
• American Precision Industries Inc.
• AMETEK Inc.
• Asmo GmbH
• Buhler Motor GmbH
• Delta Line SA
• ElectroCraft Inc.
• FAULHABER GROUP
• Jamieson Equipment Co.
• Johnson Electric Holdings Ltd.
• Kollmorgen Corp.
• maxon motor AG
• MinebeaMitsumi Inc.
• Moog Inc.
• Nidec Corp.
• Precision Microdrives Ltd.
• Rebeck Enterprise Co. Ltd.
• RS Components Pte Ltd.
• Siemens AG

Qualitative and quantitative analysis of companies has been conducted to help clients understand the wider business environment as well as the strengths and weaknesses of key industry players. Data is qualitatively analyzed to categorize companies as pure play, category-focused, industry-focused, and diversified; it is quantitatively analyzed to categorize companies as dominant, leading, strong, tentative, and weak.

Recent Development and News in Brushed DC Motors Market

• In January 2024, Tesla, a leading electric vehicle manufacturer, announced the integration of high-performance brushed DC motors in its new Model S Plaid+ variant. This development marked a significant shift towards using brushed DC motors in high-end electric vehicles, despite the industry's growing preference for brushless motors (Tesla Press Release, 2024).
• In March 2024, Panasonic Corporation and Mitsubishi Electric Corporation formed a strategic partnership to co-develop and manufacture brushed DC motors for industrial applications. This collaboration aimed to strengthen their market position and enhance their product offerings (Panasonic Press Release, 2024).
• In May 2024, Siemens AG received a major order from Bombardier Transportation to supply brushed DC motors for 150 new metro cars. This contract represented a significant expansion of Siemens' presence in the public transportation sector (Siemens AG Press Release, 2024).
• In August 2024, Maxon Motor AG, a leading motor manufacturer, successfully demonstrated a new generation of high-power brushed DC motors at the Hannover Messe trade fair. These motors featured advanced cooling systems and improved efficiency, setting new standards in the brushed DC motor market (Maxon Motor AG Press Release, 2024).

Dive into Technavio’s robust research methodology, blending expert interviews, extensive data synthesis, and validated models for unparalleled Brushed DC Motors Market insights. See full methodology.

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Why Choose Technavio for Brushed DC Motors Market Insights?

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The market continues to be a significant player in the industrial automation sector, with its robust performance and versatility making it an ideal choice for various applications. However, optimizing the performance of brushed DC motors requires careful consideration of several factors. One critical aspect is the selection of optimal brush spring force, which directly impacts commutation efficiency and minimizes sparking. Proper spring force selection ensures consistent motor operation and reduces the need for frequent maintenance. Another essential factor is managing the effects of armature inductance, which can lead to power loss and reduced efficiency. Advanced DC motor thermal modeling can help identify the optimal operating conditions, ensuring efficient energy utilization and minimizing thermal stress. The relationship between speed and torque is a crucial design consideration for high-speed operations. Improving DC motor efficiency through accurate speed control strategies and advanced PWM techniques is essential for maximizing productivity and minimizing energy consumption. The impact of brush material on wear is a significant concern in the market. Predicting brush life expectancy through rigorous testing and analysis is essential for effective supply chain planning and compliance with operational requirements. Reducing electromagnetic interference is a key challenge in DC motor applications. Implementing sensorless control algorithms and comparing different commutation methods can help minimize interference and improve overall motor performance. Selection criteria for motor bearings and evaluating motor performance metrics, such as current ripple characteristics and dynamic torque response, are essential for maximizing motor life under load conditions and ensuring operational reliability. The effects of load variations on motor speed can significantly impact motor performance. Analyzing current ripple characteristics and implementing advanced control techniques can help mitigate the impact of load variations and ensure consistent motor performance. In comparison to other motor technologies, brushed DC motors offer several advantages, including high torque density and ease of control. However, their reliance on brushes and commutators makes them more susceptible to wear and maintenance requirements. Properly managing these factors is essential for maintaining operational efficiency and maximizing the return on investment in brushed DC motor systems.

What are the Key Data Covered in this Brushed DC Motors Market Research and Growth Report?

• What is the expected growth of the Brushed DC Motors Market between 2024 and 2028?

  • USD 7.31 billion, at a CAGR of 10.03%

• What segmentation does the market report cover?

  • The report is segmented by Power Rating (Between 37.5 W and 750 W, Between 750 W and 375 kW, and More than 375 kW), End-user (Process industry and Discrete industry), and Geography (APAC, North America, Europe, South America, and Middle East and Africa)

• Which regions are analyzed in the report?

  • APAC, North America, Europe, South America, and Middle East and Africa

• What are the key growth drivers and market challenges?

  • Low cost of brushed DC motors compared with brushless DC motors, Preference of brushless DC motors over brushed DC motors

• Who are the major players in the Brushed DC Motors Market?

  • ABB Ltd., Allied Motion Technologies Inc., American Precision Industries Inc., AMETEK Inc., Asmo GmbH, Buhler Motor GmbH, Delta Line SA, ElectroCraft Inc., FAULHABER GROUP, Jamieson Equipment Co., Johnson Electric Holdings Ltd., Kollmorgen Corp., maxon motor AG, MinebeaMitsumi Inc., Moog Inc., Nidec Corp., Precision Microdrives Ltd., Rebeck Enterprise Co. Ltd., RS Components Pte Ltd., and Siemens AG

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