controller · powered wheelchair · 電動輪椅 ·Jan 10, 2025

Electric Wheelchairs - Brushed vs. Brushless Motor Controllers

Electric Wheelchairs - Controllers for Brushed and Brushless Motors

We've previously discussed the main differences between brushed and brushless motors. Brushless motors offer advantages such as being lighter, more compact, and requiring less maintenance. The motor is what provides the power and performance for an electric wheelchair. The controller manages responsiveness, operation, and commands. It's like our brain, controlling how quickly reactions occur. The quality difference directly impacts this responsiveness.

Brushless motor controllers (require two controllers): The upper controller receives commands, while the lower controller (computer box) breaks down the commands, draws power from the battery, and transmits information to the motor. These are more akin to computers and digital systems.
Brushed motor controllers are traditional controls (usually a single unit suffices) and are analog.

Electric Wheelchair Operation Requirements

In practical operation, electric wheelchairs differ slightly from ordinary electrical appliances, requiring precise control. This is because on crowded streets, we are more sensitive to changes in speed and power, which directly affects safety and user confidence.

	Brushless Motor Controller		Brushed Motor Controller
Common Type	Digital Control	UK PG BLDC	Domestic	UK PG
Appearance & Connectivity	Controller cables are thinner, require a computer box (drive) to amplify the signal		Controller cables are thicker, directly connected to the battery and left/right motors
Other Functions	Some brands offer Bluetooth control (forward, back, left, right)	Patented Soft Start Also allows for fine-tuned operation	Some brands offer rear control (only controls forward/back)	Patented Soft Start Also allows for fine-tuned operation
Operational Feel	May experience "jerking," stuttering, especially with cheaper controllers that aren't responsive enough	Very smooth	Smooth, but on slopes, when high power is needed, may feel out of control. May break after a period of use or impact.	Very smooth and durable

PG is a leading brand in electric wheelchair controllers. Many controllers are modeled after PG, mimicking its appearance, but with significant differences in responsiveness and durability. To identify genuine PG controllers, refer to:How to Differentiate Genuine UK PG Controllers for Electric Wheelchairs

Brushed motor controller cables are usually thicker and commonly used in medium to large electric wheelchairs.

Brushless motor cables are thinner and require an intermediary computer box. They are commonly used in lightweight electric wheelchairs.

英國 CW PG BLDC nVR2 無刷摩打控制器組-上控 (英國製 Made-in-England) | 好好醫療用品

英國 CW PG BLDC nVR2 無刷摩打控制器組-下控 (英國製 Made-in-England) | 好好醫療用品

Principles of Motor Control:

Brushed Motor Controller: Essentially, it directly transmits current to the motor/electric machine, so brushed motor controllers have thicker cables, faster response times, and can handle higher power output.

Brushless Motor Controller: In addition to the upper joystick control, brushless motors also require a "driver," commonly known as the lower controller. This can be understood as a small computer. This lower controller amplifies the signal from the upper controller and then instructs the battery to discharge power to the motor. At the same time, it receives feedback such as the motor's rotational speed and other signals (for example, most brushless electric wheelchairs will show a warning on the upper control if the manual/electric lever is not in the correct position).

User experience with brushed motor controllers:

When a signal is given, i.e., when operating, the current instantly reaches the motor, providing extremely fast and linear response. The control feels continuous.

User experience with brushless motor controllers:

Because it needs to go through computer feedback and decoding, some inexpensive brushless motor controllers may feel like they "jump" incrementally during use. This is because brushless motors typically have lower power and current, and some controllers are not responsive enough, which can lead to slight rollback on slopes.

Controller Selection Summary and Recommendations:

Before purchasing, test and compare different controllers to understand your needs.

The latest, international brands, patented, or certified lightweight electric wheelchairs using brushless motors and controllers (e.g., PG) will offer faster response, smoother operation, no rollback on slopes, and safer, more stable control. Examples include ultralight electric wheelchairs such as Quickie Q50R Carbon & Joy Rider.

For greater power output, such as when the electric wheelchair needs to be driven with high force, carrying heavy loads, or climbing slopes, the battery and controller output will increase, and the current will increase. In these situations, a brushed motor with a worm gear gearbox and a thick-cabled PG controller are usually better choices. For example: high-performance electric wheelchairs series.

Related articles:

Electric Wheelchairs - Brushed Motor vs. Brushless Motor Comparison

How to Differentiate Genuine UK PG Controllers for Electric Wheelchairs

Internationally recognizedrecommended lightweight electric wheelchairs - Genuine PG control vs. domestic versions