Limitations and Alternatives
While commutators are widely applied in direct current machines, up to several thousand kilowatts in rating, they have limitations.
Brushes and copper segments wear. On small machines the brushes may last as long as the product (small power tools, appliances, etc.) but larger machines will require regular replacement of brushes and occasional resurfacing of the commutator. Brush-type motors may not be suitable for long service on aerospace equipment where maintenance is not possible.
The efficiency of direct current machines is limited by the "brush drop" due to the resistance of the sliding contact. This may be several volts, making low-voltage direct-current machines very inefficient. The friction of the brush on the commutator also absorbs some of the energy of the machine. By contrast to direct current motors, induction motors which do not use commutators or brushes are much more energy efficient. (For further information, see: Copper in energy efficient motors).
Lastly, the current density in the brush is limited and the maximum voltage on each segment of the commutator is also limited. Very large direct current machines, say, more than several megawatts rating, cannot be built with commutators. The largest motors and generators, of hundreds of megawatt ratings, are all alternating-current machines.
With the widespread availability of power semiconductors, it is now economical to provide electronic switching of the current in the motor windings. These "brushless direct current" motors eliminate the commutator; these can be likened to AC machines with a built-in DC to AC inverter. In these motors, rotor position determines when the stator windings switch polarity. Operating life is limited only by bearing wear, if other factors are not adverse.
Read more about this topic: Commutator (electric)
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