Why is Brushless fuel pump better than a brushed one

Published On August 14, 2019

As we all know, fuel pumps are regarded as the backbone of the fuel system. So it is crucial to know the types of fuel pumps. A typical representative is brushless fuel pumps and brushed fuel pumps.

There are numerous big benefits from technological developments, one of them being the brushless fuel pump. Please note; this article will delve into 3 aspects in which the brushless is better than the brushed.

1.BL(brushless) fuel pumps

Adding a brushless fuel pump is a method to improve both efficiency and performance. BL design offers less friction and allows more flow without using as much current as possible. Since these pumps are friction-free, you can apply more voltage to them, and their response is much better than brushed pumps. BL is compatible with both gasoline and methanol and has a much longer service life than the older-fashioned brushed fuel pumps.

Whether the engine is a carburetor cylinder or fuel injection cylinder, it can benefit from the brushless motor fuel pump. That is to say, brushless pumps will benefit any type of engine, no matter what power adder may be in play.

Whether it's a fuel injection system or a carburetor, the induction system you use can benefit from a brushless fuel pump. Each still needs a high enough fuel flow to support the engine while providing sufficient fuel pressure.

Because the BL pump is more efficient than the carbon brushed pump, and the controller provides closed-loop speed control, the solution provides significant improvements in power consumption and carbon dioxide (CO2) emissions.

Through years of research and development, our brushless fuel pumps are smaller and quieter than their counterparts, and the most important thing is that they boast more flow at higher pressure( It's fortunate for you to know F&S Always BL pumps for we both live in a world where 1000-horsepower applications are common). With a two-year comprehensive warranty, and are rigorously tested in-house before being sent to the customers from all around the world, our fuel pumps can give you 100% quality assurance.

F&S Always will mainly promoting three different styles in the brushless series 265, 340, 425-liter per hour pumps. It is to be observed that the 425 brushless pumps can produce 1000 horsepower at the highest on gasoline.

2.Let’s then explore the texture of the material and operation of DC Motors.

Brushed DC motors usually use ceramic (ferrite) magnets, consisting of strontium carbonate and ferric oxide. While Brushless DC motors usually use neodymium magnets, which consist of neodymium (rare earth metals), iron and boron alloys. Neodymium magnets produce a much stronger magnetic field than ferrite magnet and are the strongest and most economical rare earth magnet. Neodymium magnets have higher magnetic density, allowing smaller motors to provide more power. (Neodymium magnets are relatively more expensive than ceramic magnets)

The conductive efficiency of the brushed DC motor is lower than that of the brushless motor. Voltage drop occurs due to the interface between the carbon brush (conductor less efficient than copper) and the copper commutator. Brushless DC motor "hard wiring" to the power supply. Copper on the copper connection does not cause a significant voltage drop.

Brushless DC motors do not suffer from brush friction on rotating commutators. Although carbon brushes are made of carbon and have lubricity, friction still exists, which reduces the energy efficiency of brushed motors. Because of brushless wear of brushless DC motor, its service life is greatly prolonged compared with brushed DC motor, which prolongs the reliability of motor for a longer period. It should be noted that some brushed motor brushes can be replaced, which can extend the overall life of the motor. However, brushless motor eliminates the possibility of motor failure due to brush wear.

As mentioned earlier, neodymium magnets have higher magnetic density, allowing smaller motors to provide more power. Therefore, the brushless DC motor for specific output needs can be smaller and lighter than its rival. During operation, the brushed DC motor should not be immersed in some fuels, because this may lead to premature wear and failure of the brush. This is especially true in diesel engine applications: ultra-low sulfur content fuels have low lubricity. Brushless pumps are usually designed with a shaft seal to ensure that fuel does not flood the motor. These seals often wear and fail, leading to fuel leakage into motor bearings, which is one of the main reasons for the failure of a brushed diesel pump. Brushless DC motor can be immersed in fuel without any problem during operation. Therefore, the brushless pump does not need a shaft seal, so that it is more durable and reliable.

Diving capacity also allows the motor to be cooled by liquid, which is particularly beneficial for small high-energy motors that generate a lot of heat.

For gasoline applications, the advantage of immersion in water is that gasoline helps prevent corrosion of internal components. In brushing systems, non-submerged motors may be exposed to water, leading to corrosion.

Using oxygenated fuels, copper commutators on brushed motors may start to corrode. Brushed motors also suffer from power loss, while brushless pumps do not.

3.BL controller

The advantage of the BL controller is that besides reducing the noise coupled with the back electromotive force (EMF) sensing phase, it can also realize the speed measurement of the sensorless motor.

The BL pump controller adopts similar technology as the brushed pump voltage controller, which regulates the current flowing through three phases by cutting off the power supply voltage at high frequency. Adjust the shutdown time to achieve the drive current level required to maintain the pump speed at the level of the engine control module (ECM) instruction. This pulse width modulation (PWM) voltage signal can achieve closed-loop speed control to ensure that fuel flow is not affected by environmental factors such as pressure, power supply voltage, fuel characteristics, and temperature.

The BL controller also includes pump diagnosis for monitoring power supply voltage, drive current, controller temperature and motor speed. Changes in these parameters beyond predictable and/or acceptable limits may cause system downtime to prevent damage or simply inform ECM of abnormal conditions. F&S Always is proud to have made unremitting efforts in brushless and speed controllable fuel pumps in the automotive aftermarket. 

The technology that made us use brushless DC motor in our fuel pump as the whole efficiency, long life and reliability provide better performance than brushless motor. Besides, because more power can be obtained from lighter engines, our fuel pumps are lighter, and they provide more flow than fuel pumps with brush engines of the same size.