What is a BLDC motor? What is its function? With the advancement of global industrial automation, intelligentization, and rising living standards, motors will see increasingly widespread applications across automotive, home appliances, electronics and audio-visual equipment, information processing devices, and industrial automation sectors. Statistics indicate that households in developed countries own an average of 80 to 130 motors, while households in China's major cities average only 20 to 40 motors-still far below the developed-country average. This highlights significant growth potential for China's motor industry.
Compared to the over 200-year history of electric motors, BLDC motors are relatively young, with a development history of just over 50 years. However, advancements in semiconductor technology and the widespread adoption of MCUs and drive components have significantly reduced the overall cost of BLDC motors. Consequently, BLDC motors have experienced substantial growth in recent years, with their overall growth rate exceeding that of conventional motors.
The compound annual growth rate (CAGR) for BLDC motors is projected to be around 6.5% in the coming years. Statistics indicate that the BLDC market size was approximately $16.3 billion in 2019, with projections reaching around $22.44 billion by 2024.
Given this market scale, what are the specific applications? Recently, at the Third 2020 Brushless DC Motor Control Technology Seminar hosted by Electronic Enthusiast Network, industry analyst Cheng Wenzhi shared a report titled "Analysis of the Top Ten Potential Application Markets for BLDC Motors." In his view, the primary application markets with significant future BLDC motor usage include automotive, 5G, drones/underwater robots, e-bikes/electric vehicles, industrial robots, fans, compressors, power tools, pumps, and personal healthcare.
I. Automotive Application Market
With the rise of new energy vehicles, the penetration of intelligent driving, and the pilot implementation of vehicle-to-everything (V2X) connectivity, the trend toward automotive electrification is becoming increasingly pronounced.
In future vehicles, beyond drive motors, electric power steering systems, electronic suspension systems, vehicle stability control systems, cruise control systems, ABS, and body systems (windows, door locks, seats, mirrors, wipers, sunroofs, etc.) will all extensively utilize motors.
Typically, economy-class gasoline vehicles incorporate around 10 motors, standard vehicles feature 20 to 30 motors, while luxury vehicles may include 60 to 70 motors or even over 100 motors. New energy vehicles generally require 130 to 200 motors.
As people increasingly prioritize vehicle performance, particularly in terms of comfort, safety, fuel efficiency, and environmental protection, the number of electronic control units and electrical devices in automobiles has correspondingly grown. The adoption of various electric systems has led to a rise in the number of automotive electric motors installed.
New energy vehicles represent a key development trend in recent years, with global policies now simultaneously advancing their growth. Developed nations like Europe and the United States are actively positioning themselves in the new energy vehicle market. Through various subsidies, preferential policies, and legislation, they are driving the development of new energy vehicles and facilitating the transition from traditional fuel-powered vehicles to electric vehicles.
Domestically, growth slowed after July 2019 due to significant subsidy reductions. However, with major automakers continuously launching new energy models in 2020-notably the Tesla Model 3 and Volkswagen ID.3-the industry is poised to shift from subsidy-driven to demand-driven growth, entering a second phase of rapid expansion.
II. 5G
2020 marks a pivotal year for China's 5G development. Although the first quarter saw delays in 5G construction due to the pandemic, China Mobile stated its commitment to achieving the target of 300,000 5G base stations by the end of 2020. China Telecom and China Unicom also aim to jointly complete the construction of 250,000 new 5G base stations in the third quarter to make up for pandemic-related delays. Combined with China Broadcasting Network's planned 50,000 base stations, China will construct a total of 600,000 base stations this year.
In 5G base stations, motors are required in numerous locations, primarily for base station antennas. Currently, control motors with gearbox assemblies used in 5G base station antennas include two solutions: stepper motors and brushless motors. Each antenna equipped with an electronic antenna controller (EAC) requires one control motor with a gearbox.
Typically, a standard communication base station requires approximately three antennas. 4G base stations necessitate four to six antennas, while 5G base stations will feature even more antennas.
Beyond base station antennas, motors are also essential for cooling systems within the base station, such as cooling fans and air conditioning compressors.
III. Drones / Underwater Drones
Drones gained significant popularity several years ago, though not all models utilize brushless motors. Many drones are now transitioning to brushless motors to achieve lighter, more compact designs and extended flight durations.
According to a Droneii report, the global drone market reached $14.1 billion in 2018 and is projected to grow to $43.1 billion by 2024, with Asia and North America experiencing the fastest growth. The compound annual growth rate (CAGR) stands at 20.5%.
Statistics from the Civil Aviation Administration of China's "Civil Drone Mission Registration Information System" show that by the end of 2018, China had 285,000 registered drones. By the end of 2019, the number of registered drones exceeded 392,000, with commercial drone flights totaling 1.25 million hours.
Especially during the pandemic early this year, drones played a significant role. They shuttled between hospitals and disease control centers, automating the transport of emergency medical supplies and specimens for epidemic prevention and control; hovered over highways, replacing manual aerial traffic control; transformed into disinfection tools, completing epidemic prevention and disinfection tasks across vast rural areas and even urban districts nationwide; and became publicity experts, broadcasting messages to persuade people to stay home.
The pandemic has also propelled contactless delivery back into the spotlight. Domestically, China's Civil Aviation Administration launched pilot programs for drone logistics delivery last year. The pandemic is likely to accelerate this domestic rollout. Internationally, logistics giant UPS partnered with German drone manufacturer Wingcopter to introduce new vertical takeoff and landing drones into the freight industry for package delivery.
Underwater drones, a less familiar category, are also gradually scaling up. I recall interviewing an underwater drone company in 2017 when they had just begun mass production, shipping only a few hundred units via crowdfunding. Now, their annual shipments have reached tens of thousands.
IV. E-Bikes / Electric Bicycles
E-bikes preserve the authentic cycling experience while offering intelligent power assistance. Positioned between traditional bicycles and full e-bikes, they primarily use sensors to detect riding signals and provide corresponding power support, reducing rider effort for a more effortless ride. Compared to regular bikes, e-bikes incorporate motors, batteries, sensors, controllers, and instrument panels, enriching the riding experience. Unlike traditional electric bikes, e-bikes do not rely on manual throttle control for speed regulation. Instead, they utilize sensors to detect riding signals, interpret the rider's intent, and deliver corresponding power assistance, making the riding experience more intelligent.
Domestic e-bikes are priced between 2,000 and 10,000 yuan. In Europe, hub-motor e-bikes range from 500 to 1,700 euros, while mid-drive motor e-bikes cost between 2,300 and 3,300 euros. E-bikes command significantly higher prices than traditional bicycles and electric bikes.
The motor is the core component of an e-bike's electrical system. Since the motor's miniaturization, lightweight design, operational efficiency, and aesthetic reliability directly determine the e-bike's performance, motor manufacturers typically develop customized motors tailored to specific e-bike requirements. Motors account for 10% to 30% of an e-bike's total cost.
Demand for e-bikes remains robust in Europe. According to European Bicycle Industry Association statistics, European e-bike sales surged from 98,000 units in 2006 to 2.5 million units by 2018, achieving a compound annual growth rate (CAGR) of 31%.
The Japanese market is also experiencing steady growth. Japan pioneered the research, development, production, and sales of e-bikes, successfully launching the first generation in the 1980s. Given Japan's predominantly hilly terrain, uneven roads, and aging population, e-bikes have become a necessary choice.
The domestic market is in its infancy, offering substantial future growth potential. Companies like Mobike, Xiaomi, Hello Bike, Bisu Travel, and Jinyoung are now beginning to promote electric bicycles domestically.
V. Industrial Robots
The domestic market for industrial robots primarily focuses on replacement applications, offering substantial growth potential. Although China is the world's largest industrial robot application market, globally renowned manufacturers in this sector are predominantly concentrated in developed nations such as the United States, Japan, and Germany. These include the "Big Four" manufacturers: Sweden's ABB, Japan's Fanuc and Yaskawa Electric, and Germany's KUKA.
According to data from the International Federation of Robotics, global industrial robot sales reached 422,000 units in 2018, with China accounting for 154,000 units, representing 36.5% of the total. Additionally, data from the National Bureau of Statistics shows that China's industrial robot production has been steadily increasing, rising from approximately 33,000 units in 2015 to 187,000 units in 2018-a remarkable growth rate.
Moreover, with continuous government support for the industry in recent years and domestic enterprises making steady breakthroughs, the localization rate of domestic industrial robots has been steadily improving. In the first half of 2018, the domestic share of robot body sales rose from 19.42% in 2015 to 28.48%. Concurrently, China's overall industrial robot sales volume has maintained steady growth.
VI. Fans
Fans encompass: electric fans, range hoods, hair dryers, air curtain machines, HVAC fans, etc. Major downstream manufacturers include Midea, Airmate, Gree, Pioneer, Vatti, Robam, and others.
The household fan segment represents a massive market. China's household fan production volume is enormous. According to National Bureau of Statistics data, China's household fan output reached 180 million units in 2018. December 2017 data is unavailable, but the 11-month total was 160 million units. Production in 2016 was 160 million units, with an estimated 190 million units for 2019.
Currently, mainstream domestic small appliance manufacturers such as Midea, Pioneer, Risa, and Airmate have all launched products featuring brushless motors. Among them, Airmate offers the largest volume, while Xiaomi boasts the lowest production costs.
With the entry of cross-industry players like Xiaomi, the adoption rate of brushless motors in the household fan sector has accelerated. Domestic brushless motor manufacturers have now secured a foothold in this market.
Beyond household fans, industrial cooling fans have been transitioning to brushless motors for years. A benchmark company in this sector is EBM-Papst, whose fans and motors are widely used across ventilation, air conditioning, refrigeration, home appliances, heating, and automotive industries.
Currently, numerous domestic companies are producing brushless cooling fans similar to EBM's, and they have already captured a significant portion of EBM's market share.
Particularly with the rise of domestic charging stations, opportunities for domestic manufacturers should be substantial. The government has now included charging stations in its "New Infrastructure" projects, which should lead to even greater development this year.
Refrigerator cooling fans are also transitioning to BLDC motors due to industry standards and national energy efficiency regulations. This shift is occurring relatively quickly with substantial product volumes. By 2022, an estimated 60% of refrigerator cooling fans will be replaced with variable-speed motors. Domestic suppliers for refrigerator cooling fans are primarily concentrated in the Yangtze River Delta and Pearl River Delta regions.
In the fan sector, range hoods-a key component of kitchen appliances-are also transitioning. However, cost constraints have limited the adoption of brushless motors in range hoods. Variable-speed solutions currently cost around 150 yuan, while non-brushless motor options can be implemented for under 100 yuan, with low-cost alternatives available for approximately 30 yuan.
Many ventilation units and air purifiers also adopt brushless motor solutions. Currently, smaller models on the market typically use Nedic's external rotor motors, while larger air purifiers generally employ EBM fans.
Additionally, air circulation fans have begun gaining traction in recent years. Their current value remains relatively high, with finished products typically priced at 700-800 yuan each, and premium models reaching 2000-3000 yuan.
VII. Compressors
Since a refrigerator's compressor speed determines its internal temperature, inverter compressors can adjust their speed based on temperature readings. This allows the refrigerator to adapt to current conditions, maintaining a more stable internal temperature. Consequently, food preservation is significantly enhanced. Most inverter refrigerator compressors utilize BLDC motors, resulting in higher efficiency, lower noise levels, and extended service life during operation.
This sector was previously dominated by Japanese, Korean, and Taiwanese manufacturers, but since 2010, domestic players have rapidly gained ground. It's reported that one Shanghai-based manufacturer now ships nearly 30 million units annually.
With the advancement of domestic semiconductor firms, domestic suppliers can now provide virtually all components-from main control MCUs and pre-driver gate drivers to power MOSFETs.
Another key area is air conditioner compressors. Inverter air conditioners have become widely accepted, and the trend toward inverter technology is undeniable. Domestic air conditioner production is substantial. According to the National Bureau of Statistics, 2018 saw 360 million AC motors and approximately 96 million BLDC motors manufactured for air conditioners. Moreover, BLDC motor production for air conditioners has been increasing annually.
VIII. Power Tools
Power tools rank among the most widely used hardware and electromechanical products. Their lightweight design, portability, high productivity, and low energy consumption make them indispensable for drilling, cutting, and grinding operations across diverse industries including construction, decoration, woodworking, metal fabrication, and other manufacturing sectors.
With continuous technological advancements and the growing acceptance of DIY concepts, the application scope of power tools continues to expand. Many traditional manual tool operations are increasingly being replaced by power tools, which are also transitioning from industrial applications into household use. The demand for power tools is rising year by year.
The shift toward brushless motors in power tools began quite early. As early as 2010, some international brands introduced power tools equipped with brushless motors. With the maturation of lithium-ion battery technology and increasingly affordable prices, the volume of cordless handheld tools has grown year by year, now rivaling corded tools in popularity.
Statistics indicate that brushless technology has largely been adopted for electric wrenches in China. However, drills, high-voltage tools, and garden tools have not yet fully transitioned, though they are in the process of doing so.
This shift is primarily driven by the energy efficiency and high performance of brushless motors, enabling handheld power tools to operate for longer durations. Many international and domestic manufacturers, such as Bosch, Dewalt, Milwaukee, Ryobi, and Makita, are investing significant resources into product development.
Domestic power tool development is also advancing rapidly, particularly in the Jiangsu-Zhejiang region, which hosts numerous manufacturers. In recent years, the cost of brushless motor control solutions in this area has dropped significantly. Many manufacturers have initiated price wars, with reports indicating that a brushless motor control solution for a power tool now costs around 6-7 yuan, and some even as low as 4-5 yuan.
IX. Pumps
The water pump industry is relatively traditional, featuring diverse product types and solution variations. Even for drive boards of identical power ratings, multiple options exist on the market, with prices ranging from under 2 yuan to 40-50 yuan.
In water pump applications, medium-to-large power pumps predominantly use three-phase asynchronous motors, while micro-miniature pumps primarily employ AC two-pole pumps. The current heating system upgrades in northern China present a favorable opportunity for technological innovation in pump solutions.
From a purely technical perspective, brushless motors are well-suited for pump applications, offering advantages in size, power density, and even cost.
10. Personal Health and Wellness
Two representative products in personal health care are Dyson's viral hair dryer and the massage gun.
Since Dyson introduced its high-speed digital motor hair dryer, it has ignited the entire hair dryer market.
According to Qian Zhichun from Jingfeng Mingyuan, current domestic hair dryer solutions primarily follow three approaches: First, benchmarking Dyson with ultra-high-speed brushless motors, typically operating at around 100,000 RPM, with some reaching up to 160,000 RPM; Second, the U-motor replacement approach, which offers similar RPMs to U-motors but with advantages in lighter weight and higher air pressure; Third, the external rotor high-voltage approach, where the motor primarily replicates Nedic's design.
Current domestic imitation products are no longer simple copies; they generally achieve patent avoidance and incorporate certain innovations.
Fascia gun shipments have surged dramatically in recent years. It's said that fitness trainers and sports enthusiasts now commonly carry fascia guns. These devices utilize vibrational mechanics to transmit vibrations deep into fascia and muscle tissue, achieving fascia relaxation and reducing muscle tension. Some consider fascia guns essential tools for post-workout recovery.
However, the market for these devices is now highly competitive. While their designs appear similar, prices range from over 100 yuan to more than 3,000 yuan. The market price for the BLDC motor control boards used in these guns has dropped to around 8 yuan, with some even available for approximately 6 yuan. This has led to a rapid decline in fascia gun prices.
It's said that one home appliance manufacturer, on the brink of bankruptcy, was instantly revived by the fascia gun product alone. They're now thriving quite comfortably.
Of course, beyond these two products, other items like men's electric shavers and women's beauty devices are also trending toward brushless motor adoption.
Conclusion
Overall, BLDC motors remain in their infancy, yet their applications are already flourishing. Beyond the examples mentioned here, they are found in service robots, AGVs, robotic vacuums, blenders, cooking appliances, dishwashers, and more. In truth, motors permeate countless aspects of our daily lives, with numerous future applications still waiting to be explored. This concludes our analysis of BLDC motors. I hope it proves helpful.