In the field of electric stair-climbing hand trucks, the three core demands of users are “whether it can climb stairs stably, whether it can achieve long-lasting battery life, and whether it requires little maintenance and replacement”. Compared with traditional brushed motors, brushless motors not only specifically address the pain points in stair-climbing scenarios, but also enable “efficient operation and low-cost operation and maintenance” in hand trucks through precise technical adaptation.
How Brushless Motors Solve Stair-Climbing Pain Points
Electric stair-climbing hand trucks require frequent starts and stops in stairwells and may be exposed to complex environments such as dust and moisture. Brushless motors address these challenges through their technical characteristics.
- Adapting to Complex Stair-Climbing Conditions
Stair climbing places extremely high demands on the stability of motor torque. Brushed motors rely on mechanical contact between carbon brushes and commutators for current conduction, and frequent starts/stops cause rapid wear of the carbon brushes. In contrast, brushless motors adopt electronic commutation technology, eliminating mechanical contact structures and maintaining stable rated torque output.
- Meeting High-Frequency Operation Needs
Electric stair-climbing hand trucks mostly rely on lithium batteries for power supply, so battery life directly determines the workload. Brushed motors suffer from high mechanical friction losses, while brushless motors—through optimized magnetic circuit design and electronic commutation control—achieve longer battery life with the same battery capacity. This eliminates the need for mid-operation recharging and significantly improves work efficiency.
- Reducing Maintenance Costs
Replacing the carbon brushes of brushed motors requires equipment downtime. However, brushless motors only need routine maintenance and no component replacement. The theoretical service life of brushless motors is approximately 3–5 times that of brushed motors, with almost no maintenance-related downtime.
- Adapting to Multi-Scenario Operations
Electric stair-climbing hand trucks may be used in various complex environments, which imposes requirements on the motor’s protection capabilities. The carbon brush structure of brushed motors cannot achieve high protection levels, whereas brushless motors can enhance their protection rating through sealed designs. This prevents damage and enables adaptation to operational needs across multiple scenarios.
Differences Between Brushless Motors and Carbon Brush Motors
In the field of electric stair-climbing hand trucks, Carbon Brush motors and brushless motors differ significantly in performance, making them a key reference factor for users when making purchasing decisions.
| Comparison Item | Carbon Brush Motor | Brushless Motor |
| Structural Complexity | Simple structure, composed of stator, rotor and carbon brushes | Complex structure, requiring electronic controllers, permanent magnet rotors and position sensors to achieve commutation |
| Manufacturing Cost | Low cost, suitable for low-budget scenarios | Higher cost, as electronic controllers and permanent magnets increase production expenses |
| Efficiency & Energy Consumption | Low efficiency, energy loss caused by carbon brush friction | High efficiency, no mechanical friction loss, and lower energy consumption |
| Service Life & Maintenance | Short service life; requires regular replacement of carbon brushes and collectors, with high maintenance costs | Long service life (2–10 times that of brushed motors); no need to replace carbon brushes, with low maintenance costs |
| Operating Noise | Generates noise due to carbon brush friction, not suitable for quiet scenarios | Runs quietly, no mechanical contact noise, suitable for precision equipment |
| Electromagnetic Compatibility | Carbon brush friction produces electric sparks, which easily cause electromagnetic interference | No electromagnetic interference, suitable for scenarios involving wireless communication equipment |
| Speed Regulation & Control Precision | Wide speed regulation range but low precision, relying on mechanical commutation | Enables high-precision speed regulation with the cooperation of a controller, and has fast response speed |
Conclusion
For electric stair-climbing hand trucks, brushless motors are deeply aligned with the demands of stair-climbing scenarios through their technical characteristics—from resolving stair-climbing jams and extending battery life to reducing maintenance costs and adapting to multiple scenarios. For users, choosing a hand truck equipped with a high-quality brushless motor is not only a way to improve work efficiency, but also a key decision to reduce long-term operation and maintenance costs and ensure operational safety.
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