As the humanoid robot industry accelerates, many traditional motor manufacturers are exploring how to transfer their accumulated expertise from industrial motors and automotive motors into this emerging field. However, one critical misconception must be addressed first: a humanoid robot is neither a scaled-down industrial robot nor a variation of a four-wheel vehicle. Its actuators demand motor performance far beyond the requirements of typical industrial or automotive applications.

 

Among various motor types, coreless motors play a fundamental role in enabling agile and precise movements in humanoid robots thanks to their lightweight structure, low inertia, and rapid response. Moreover, whether a coreless motor adopts a brushed or brushless architecture directly determines the performance ceiling of the humanoid robot’s entire motion system.

 

 

What Is a Coreless Motor?

 

Unlike traditional industrial robots that focus on high power and heavy payloads, humanoid robots aim to replicate human-like motion. Their fingers, wrists, neck, and even facial expressions require precise, lightweight, and rapid actuation. This means the motors driving these joints must deliver high power density, fast response, smooth operation, low noise, and high efficiency.

 

A coreless motor is specifically suited for such demands. Its rotor uses a “coreless” cup-shaped winding design, which eliminates the iron losses found in conventional iron-core motors and significantly reduces rotor inertia. As a result, coreless motors can start, stop, and reverse extremely quickly. These features make them the preferred solution for the dexterous joints of humanoid robots—especially in the hands and forearms.

 

Brushed vs. Brushless Coreless Motors

 

This is a point that many newcomers to the humanoid robot motor field often misunderstand. “Coreless” describes the motor’s structural design, while “brushed” and “brushless” refer to the commutation method.

 

These are two separate classification dimensions. A coreless motor can be either brushed or brushless—the concepts do not conflict.

 

Brushed Coreless DC Motor

 

Working Principle:

The motor switches current direction through physical contact between carbon brushes and a commutator, enabling continuous rotation of the rotor.

 

Advantages:

Simple control mechanism

Lower overall cost

No need for a complex driver circuit

 

Disadvantages:

Brush and commutator wear leads to limited lifespan

Possible sparking, making it unsuitable for explosion-proof environments

Generates noticeable operating noise

Mechanical friction reduces efficiency

 

Suitable Applications:

Ideal for cost-sensitive consumer devices or industrial applications where lifespan, noise, and reliability requirements are not extremely demanding.

 

Brushless Coreless DC Motor

 

Working Principle:

A brushless coreless motor uses electronic commutation, in which the controller adjusts the current phase based on rotor position signals. This eliminates the need for physical brushes and a commutator entirely.

 

Advantages:

Significantly longer lifespan

Higher efficiency

Higher rotational speed and faster dynamic response

Quieter operation with lower vibration

Greater reliability and reduced maintenance

 

Disadvantages:

Requires a dedicated controller and more complex drive algorithms

Higher overall cost

 

Suitable Applications:

Ideal for high-performance applications such as advanced humanoid robots, aerospace systems, and precision medical devices—fields where reliability, performance, and longevity are critical.

 

For humanoid robots aimed at commercial deployment, high reliability, and lifelike performance, brushless coreless motors are undoubtedly the current mainstream choice and the future trend.

They provide significantly longer operational lifespan, enable more agile and natural movements, and reduce failure rates, ensuring stable and reliable long-term operation.

 

Clear understanding is the first step, but transforming cutting-edge motor technology into stable and efficient products relies on equally advanced motor automation assembly solutions.

 

As a professional provider of intelligent motor equipment solutions, Honest Automation has long focused on the development and integration of customized, non-standard motor automation assembly lines. Our products are widely applied across new energy vehicles, automotive components, home appliances, full humanoid robot assembly, and low-altitude aerial vehicles.

Honest Automation is not only proficient in the assembly processes of traditional brushed and brushless motors but also deeply involved in high-precision assembly tasks, including the joint drive units of humanoid robots.

 

To meet the demands of humanoid robots for high consistency, reliability, and flexible manufacturing, Honest Automation leverages years of experience in non-standard motor automation assembly to provide customized process and assembly solutions for our clients.

 

Whether it’s motor assembly, humanoid robot core motors, or full robot assembly, we invite you to share your product requirements with us. We will conduct a detailed assessment and develop practical intelligent manufacturing solutions, helping companies smoothly transition from prototype validation to mass production delivery.