Inside the Tech: Understanding Brushless Motor Systems in Cordless Pruners

Exploring the Motor, Torque, and Efficiency Behind Modern Pruning Tools

1. Introduction: Why Brushless Motors Matter

Modern cordless pruners are increasingly powered by brushless DC (BLDC) motors, replacing older brushed designs. These motors deliver higher torque, better energy efficiency, lower maintenance, and longer lifespan—key advantages for garden tools used by professionals and serious hobbyists alike.

2. What is a Brushless Motor?

In a standard brushed motor, electrical commutation is done via brushes and a commutator, causing friction, wear and energy loss. In contrast, BLDC motors use electronic commutation and permanent magnets to drive the rotor, eliminating brush wear and improving overall performance.

2.1 Torque and Efficiency Metrics

Studies show that BLDC motors provide a higher torque-to-weight ratio and improved efficiency. For example:

• Ionel, D.M. “Assessment of Torque Components in Brushless Alternating-Current Motors and Constructive Recommendations” (2005) details methods for calculating torque components and demonstrates improved torque performance in BLAC/B­LDC machines.
• Vatavuk et al. “Direct Drive Brush-Shaped Tool with Torque Sensing Capability for Compliant Robotic Vine Suckering” (2023) demonstrated a BLDC tool with high torque density used in viticulture and found that the lack of gearing in direct-drive design yielded significantly better monotonic torque behavior.
  These findings translate to cordless pruners by enabling cut capacities of 25–35 mm and above with lighter tool bodies.

2.2 Efficiency Gains in Real Tools

According to motor design research “Improvement of torque-speed characteristics of brushless DC motors” (Takeuchi et al., 2014) the experimental gains include ~10-20% better efficiency under load compared to brushed variants.
This means cordless pruners with BLDC motors can achieve longer runtime, less heat buildup, smoother operation, and reduced battery strain.

3. How This Applies to Cordless Pruners

3.1 Increased Cutting Capacity

With BLDC motors, cordless pruners can consistently cut thicker branches. Tool manufacturers report that moving from brushed to brushless designs raised rated cutting diameters from ~25 mm to ~35 mm or more, thanks to greater sustained torque.

3.2 Improved Runtime & Battery Life

Because BLDC motors waste less energy (no brush friction, lower cogging losses), more of the battery’s energy goes into actual cutting. In large scale cordless garden tool reviews, BLDC-equipped units had less than 15% reduction in torque over a full battery discharge, compared to up to 30% in brushed models.

3.3 Lower Maintenance & Longer Lifespan

Brushless motors require no carbon-brush changes, fewer worn parts, and generate less heat and vibration. The direct drive study by Vatavuk et al. showed that design eliminated mechanical reduction, improving both lifespan and consistency.
For pruner OEMs like FOLIT, this leads to fewer service visits and better long-term user satisfaction.

4. Choosing a BLDC-Equipped Cordless Pruner: What to Look For

• Motor Type: Confirm “brushless” or “BLDC” in specs—avoid ambiguous terms.
• Cutting Diameter Spec: Higher diameter indicates higher torque capability (e.g., 30–40 mm).
• Battery & Motor Match: BLDC motors often paired with higher-voltage batteries (21–32 V) to fully exploit torque benefits.
• Runtime Under Load: Prefer specs showing minimal decline in performance over full charge.
• Heat & Vibration Management: Good models will mention reduced vibration or thermal sensors.
• Service & Parts Availability: Brushless motors last longer, but still require bearings and stator care—check service network.

5. The Future: Smart Motor Systems

As research evolves, motor control systems are becoming more sophisticated. For example, the paper “Optimized Cascaded Position Control of BLDC Motors Considering Torque Ripple” (Vedadi et al., 2025) shows how advanced control algorithms reduce torque ripple and improve efficiency.
In cordless pruners, this means smoother cuts, less branch-jump, more control, and integration with electronics (for example torque sensors, cut-count telemetry). Expect “smart motor + app connectivity” combinations in the near future.

6. Conclusion

Understanding brushless motor systems gives you insight into why modern cordless pruners perform better, last longer, and deliver cleaner cuts. For retailers, landscapers, and serious gardeners, choosing a BLDC-equipped pruner is more than a premium feature—it’s a performance and value decision.

By recognising motor type, torque specs, and runtime behavior, you can confidently recommend or select tools that will deliver superior results and fewer maintenance headaches.