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What’s the difference between a brushless motor and a brushed motor? — An Expert Guide to the 5 Core Distinctions in 2025

Dic 12, 2025

Resumen

The distinction between brushed and brushless direct current (DC) motors represents a fundamental divergence in electromechanical engineering, primarily centered on the method of commutation. A brushed DC motor utilizes a mechanical system, comprising carbon brushes and a segmented commutator, to physically reverse the current direction in the rotor windings, thereby sustaining rotation. This design, while simple and cost-effective, introduces mechanical wear, electrical noise, and inherent inefficiencies due to friction and sparking. In contrast, a brushless DC (BLDC) motor achieves commutation electronically. It employs a permanent magnet rotor and stationary windings (stator), with an external electronic controller using sensors (such as Hall effect sensors) to detect the rotor's position and energize the stator coils in a precise sequence. This elimination of mechanical contacts results in significantly higher efficiency, a longer operational lifespan, reduced maintenance requirements, and a superior power-to-weight ratio. These characteristics make brushless motors the preferred technology for high-performance, high-reliability applications, including electric vehicles, drones, and advanced industrial automation.

Principales conclusiones

  • Brushed motors use physical contacts (brushes) to operate, leading to wear and tear over time.
  • Brushless motors use an electronic controller for a frictionless, more efficient operation.
  • The lifespan and reliability of brushless motors are significantly greater than their brushed counterparts.
  • Understanding what's the difference between a brushless motor and a brushed motor is key to optimizing performance.
  • Brushless motors offer a better power-to-weight ratio, ideal for portable and high-performance devices.
  • While initially more expensive, brushless motors often have a lower total cost of ownership.
  • The choice depends on the application's specific needs for cost, longevity, and control precision.

Índice

The Foundational Principle: A Deep Dive into Commutation

Before we can meaningfully explore the nuances that separate these two families of motors, we must first establish a common ground of understanding. At the heart of every electric motor lies a beautiful principle of physics: the interaction between electricity and magnetism. When an electric current flows through a wire, it generates a magnetic field around that wire. If you place this wire within another magnetic field, it will experience a force. This force, known as the Lorentz force, is the fundamental driver of motion in nearly all electric motors.

What is an Electric Motor at its Core?

Imagine a simple motor. You have a stationary part, the stator, which typically houses magnets that create a constant magnetic field. Then you have a rotating part, the rotor, which is wrapped with coils of wire. When we pass a current through these coils, the rotor itself becomes an electromagnet. The north pole of the rotor's electromagnet is repelled by the north pole of the stator's permanent magnet and attracted to its south pole. This attraction and repulsion create a torque, causing the rotor to turn.

But here is the puzzle: once the rotor's poles align with the opposite poles of the stator, the forces of attraction are maximized, and the rotation would stop. For continuous motion, we need to cleverly and continuously switch the direction of the current in the rotor's coils. This act of switching the current to keep the rotor perpetually "chasing" a shifting magnetic field is called commutation. The method by which a motor achieves this commutation is the single most important factor that answers the question, "What's the difference between a brushless motor and a brushed motor?"

The Role of Commutation: Switching the Field

Think of it like a donkey chasing a carrot on a stick. If the carrot were fixed, the donkey would quickly reach it and stop. To keep the donkey moving, you must always keep the carrot just ahead of it. In a motor, the rotor is the donkey, and the magnetic field created by the stator is the carrot. Commutation is the mechanism that keeps moving the carrot. It systematically reverses the polarity of the rotor's electromagnetic field, ensuring that just as it's about to align with the stator's field, the target shifts, forcing it to continue its rotation. Without commutation, you would have a simple electromagnet, not a motor capable of continuous work.

Mechanical vs. Electronic Commutation: The Defining Line

This brings us to the great divide. The two types of motors we are discussing are defined by how they perform this critical act of commutation.

A brushed motor uses a wonderfully simple, albeit mechanical, solution. It has physical, conductive blocks—the brushes—that are spring-loaded to press against a segmented ring on the rotor's shaft, known as the commutator. As the rotor spins, the brushes slide from one commutator segment to the next, physically rerouting the electrical current and reversing the polarity of the coil's magnetic field every half-turn. It is an ingenious, self-contained mechanical system.

A motor sin escobillas, as its name implies, does away with this physical contact entirely. It achieves commutation electronically. This requires a bit more sophistication. The motor needs an external "brain"—an electronic speed controller (ESC)—which uses sensors to know the exact position of the rotor. Based on this positional information, the controller uses transistors to direct current to different coils arranged around the stator, creating a rotating magnetic field that the rotor's permanent magnets then follow. It is a digital, frictionless, and precise method of moving the carrot. This single difference in commutation strategy is the wellspring from which all other differences in performance, lifespan, and cost flow.

Core Distinction 1: Architectural Design and Internal Mechanics

The contrasting approaches to commutation necessitate fundamentally different physical layouts. Examining the anatomy of each motor type reveals a story of their respective strengths and weaknesses. The arrangement of parts is not arbitrary; it is a direct consequence of whether the commutation is handled internally by mechanical means or externally by electronic intelligence.

Anatomy of a Brushed Motor

In a traditional brushed DC motor, the architecture is arranged as follows:

  • Stator: The outer casing of the motor, which holds two or more permanent magnets. These create a stationary magnetic field.
  • Rotor (or Armature): The rotating core, which consists of an iron laminate core wrapped with coils of copper wire (the windings). This is the part that becomes an electromagnet when current is applied.
  • Commutator: A segmented copper ring fixed to the rotor's axle. Each segment is connected to an end of one of the rotor coils. It spins along with the rotor.
  • Brushes: Stationary blocks of a conductive material, typically carbon or graphite, that are held against the commutator by springs. They deliver electrical power from the source to the spinning commutator segments and, by extension, to the armature windings.

The key feature here is that the windings are on the moving part (the rotor), and the power must be delivered to them via the physical, sliding contact of the brushes and commutator.

Anatomy of a Brushless Motor (BLDC)

A brushless DC motor essentially turns the brushed design inside-out:

  • Stator: This is the stationary outer part, but unlike in a brushed motor, the stator of a BLDC motor contains the wire windings. The heat generated by the current flowing through the wires is created in the static outer part of the motor.
  • Rotor: This is the rotating core, and it houses two or more permanent magnets. There are no windings on the rotor and no need to deliver current to it.
  • Hall Effect Sensors: In many BLDC motors, these tiny sensors are embedded in the stator. They detect the position of the rotor's magnets as they pass by, feeding this information back to the electronic controller.
  • Electronic Speed Controller (ESC): This is an external circuit board, not part of the motor itself, that acts as the brain. It takes the input from the Hall effect sensors and precisely switches the current in the stator windings to create the rotating magnetic field.

Here, the windings that generate heat are on the stationary stator, and the permanent magnets are on the rotor. This inversion is a direct result of eliminating the need for brushes.

A Tale of Two Rotors: Why "Inside-Out" Matters

This "inside-out" design of the brushless motor is a masterstroke of engineering with profound consequences. In a brushed motor, the current-carrying windings are on the spinning rotor. As they generate heat (a natural byproduct of electrical resistance), this heat is trapped within the core of the motor. It is difficult to dissipate, limiting the amount of power the motor can handle continuously without overheating.

In a brushless motor, the heat-generating windings are on the stationary stator, which forms the outer casing. This makes it vastly easier to manage heat. The motor's casing can be finned or attached to a heat sink, allowing the heat to dissipate directly into the surrounding air. This superior thermal efficiency means a brushless motor can be run at a much higher power level for its size compared to a brushed motor. This directly translates to a higher power-to-weight ratio, a characteristic that is absolutely vital in applications like drones, electric bicycles, and high-performance RC vehicles.

Característica Brushed DC Motor Brushless DC (BLDC) Motor
Commutation Method Mechanical (Brushes & Commutator) Electronic (Controller & Sensors)
Windings Location Rotor (Armature) Estator
Magnets Location Estator Rotor
Key Components Stator, Armature, Commutator, Brushes Stator, Rotor, Controller, Sensors
Moving Contacts Yes (Brushes on Commutator) No
Control System Simple (Direct DC Voltage) Complex (Electronic Speed Controller – ESC)
Gestión térmica Poor (Heat trapped in rotor) Excellent (Heat dissipated from stator)

Core Distinction 2: Operational Efficiency and Power Density

Efficiency, in the context of an electric motor, is the measure of how much of the electrical energy put into it is successfully converted into useful mechanical work (rotation). The energy that is not converted into work is lost, primarily as heat. The difference in efficiency between brushed and brushless motors is not minor; it is a significant performance gap rooted in their fundamental designs.

The Energy Thief: Friction and Heat in Brushed Motors

The mechanical commutation system of a brushed motor is its greatest weakness in terms of efficiency. There are several sources of energy loss:

  1. Friction: The brushes are physically pressed against the spinning commutator. This constant sliding contact creates friction, which resists the motor's rotation and converts electrical energy directly into wasted heat. The energy required to overcome this friction is a permanent tax on the motor's performance.
  2. Electrical Resistance: The carbon brushes themselves have a higher electrical resistance than a direct copper wire connection. This causes a voltage drop across the brushes, leading to power loss in the form of heat (I²R loss).
  3. Arcing: As the brushes move from one commutator segment to the next, for a brief moment, a tiny electrical spark or arc is generated. This arcing not only contributes to the erosion of the brushes and commutator (a maintenance issue we will discuss later) but also represents wasted electrical energy, released as light and heat.

Together, these factors mean that a typical brushed DC motor might have an efficiency in the range of 75-80%. This means that for every 100 watts of electrical power supplied, 20 to 25 watts are lost as heat.

The Efficiency Gains of Brushless Design

By eliminating the brushes and commutator, the brushless motor immediately eradicates the primary sources of loss found in its counterpart.

  • There is no friction from brushes.
  • There is no electrical arcing from commutation.
  • The only remaining friction comes from the bearings that support the rotor shaft, which is a factor common to both motor types.

Consequently, brushless motors operate with much higher efficiency, typically in the range of 85-95% or even higher for specialized designs. An efficiency of 95% means only 5 watts out of every 100 are lost to heat. This is a dramatic improvement and has far-reaching consequences. For example, in a battery-powered device, a 15% improvement in motor efficiency can directly translate to a 15% increase in runtime or a corresponding reduction in the required battery size and weight. This is precisely why the transition to brushless motors has been a revolution for electric vehicles, from e-scooters to full-sized cars.

Maximizing Torque and Speed Control

The efficiency of a motor is not a single number; it varies depending on its speed and the load it is under. Brushless motors generally maintain their high efficiency across a much wider range of speeds and loads compared to brushed motors. The electronic controller of a BLDC motor allows for extremely precise control over speed and torque. Because the controller knows the rotor's exact position, it can time the delivery of current to the coils to produce the maximum possible torque for a given amount of current. This results in a flatter torque curve, meaning the motor can produce consistent torque from a standstill all the way up to its maximum speed. Brushed motors, by contrast, tend to produce their maximum torque at a specific point in their RPM range.

The superior power-to-weight ratio, or power density, is a direct outcome of this efficiency. Because a brushless motor wastes less energy as heat and its design allows for better heat dissipation, a smaller, lighter brushless motor can produce the same amount of mechanical power as a much larger and heavier brushed motor. This is a game-changer for applications where size and weight are paramount, such as in handheld power tools, medical devices, and especially in the burgeoning field of personal electric mobility, where components like a powerful Motor de cubo de 14 pulgadas must be both potent and lightweight.

Parameter Brushed DC Motor Brushless DC (BLDC) Motor
Typical Efficiency 75% – 80% 85% – 95%+
Primary Losses Brush friction, Arcing, Electrical resistance of brushes Copper losses (windings), Bearing friction
Power-to-Weight Ratio Lower Higher
Torque at Low Speeds Good, but less controllable Excellent, highly controllable
Speed Range Limited by brush/commutator mechanics Wider, limited by controller/bearings
Heat Dissipation Poor (heat generated in the internal rotor) Excellent (heat generated in the external stator)

Core Distinction 3: Lifespan, Reliability, and Maintenance Demands

If efficiency tells the story of how well a motor performs its job, then lifespan and reliability tell the story of how long it can continue to do so. The presence or absence of mechanical brushes creates a stark contrast in the long-term viability and maintenance profile of these two motor technologies. The inquiry into "what's the difference between a brushless motor and a brushed motor" often begins with performance but ends with a consideration of longevity and total cost of ownership.

The Wear and Tear Components: Brushes and Commutators

The brushes in a brushed motor are, by design, sacrificial components. They are made of a softer material (carbon) than the copper commutator they rub against. Every rotation of the motor grinds away a microscopic amount of the brush material. The electrical arcing that occurs during commutation further accelerates this erosion.

Eventually, the brushes wear down to a point where they no longer make effective contact with the commutator, and the motor will cease to function. The carbon dust generated by this wear can also coat the inside of the motor, potentially causing short circuits if it builds up excessively. The lifespan of a brushed motor is therefore fundamentally limited by the life of its brushes, which can range from 1,000 to 5,000 hours of operation depending on the quality, load, and speed. For many applications, this means the brushes are a regular maintenance item that must be inspected and replaced periodically. The commutator itself also wears down over time from the constant friction and arcing, and its surface may need to be resurfaced or replaced in a major overhaul.

The "Set and Forget" Nature of Brushless Motors

Brushless motors, by eliminating the single greatest point of failure, offer a revolutionary improvement in lifespan and reliability. With no brushes or commutator to wear out, the operational lifetime of a brushless motor is limited only by the durability of its bearings. High-quality ball bearings can last for tens of thousands of hours, often exceeding 20,000 or 30,000 hours of continuous operation.

This makes brushless motors ideal for applications where maintenance is difficult, expensive, or impossible. Consider a cooling fan inside a complex piece of electronics, a pump in a sealed medical device, or the hub motor of an electric scooter. In these cases, the ability to install the motor and have it run reliably for the entire lifetime of the product is a massive advantage. This "set and forget" characteristic dramatically reduces the total cost of ownership, as the expenses associated with downtime, labor for maintenance, and replacement parts are all but eliminated. This is a primary reason why industrial automation and mission-critical systems have almost universally adopted brushless technology.

Environmental Factors: Dust and Sparking Hazards

The physical nature of brushed commutation introduces other reliability concerns. The constant electrical arcing generates electromagnetic interference (EMI), or electrical "noise." This can interfere with sensitive electronic components nearby, making brushed motors unsuitable for many modern electronic applications without extensive shielding.

Furthermore, the sparks themselves represent a significant hazard in environments where flammable gases or fine combustible dust may be present, such as in a grain mill, a paint shop, or a chemical plant. A single spark from a motor brush could be catastrophic. Brushless motors, with their sealed designs and lack of internal arcing, are inherently safer and the only viable choice for such hazardous-duty applications. They are also more resilient to operating in dusty or dirty environments, as there are no open contacts for debris to foul. The robust and enclosed design, often seen in products like an Motor de cubo de 11 pulgadas, ensures reliable performance even in challenging outdoor conditions.

Core Distinction 4: The Brains of the Operation: Control Systems

The way we command a motor to start, stop, and change speed is dictated entirely by its underlying commutation method. Herein lies another crucial difference: the simplicity of controlling a brushed motor versus the sophisticated intelligence required to operate a brushless one. This distinction impacts the overall system cost, complexity, and the level of precision that can be achieved.

The Simplicity of Brushed Motor Control

Controlling a brushed motor is wonderfully straightforward. Because the commutation is handled mechanically and internally, all you need to do is apply a DC voltage across its two terminals. The motor will start to spin. The speed of the motor is roughly proportional to the voltage you apply—more voltage means more speed. Reversing the direction of rotation is as simple as reversing the polarity of the voltage.

This simplicity is a significant advantage in low-cost applications. Toys, small appliances, and basic automotive components (like power window motors) have long used brushed motors precisely because the control circuitry is minimal and inexpensive. A simple switch or a variable resistor is often all that is needed.

The Brains of the Operation: The Brushless Motor Controller (ESC)

A brushless motor cannot run by simply connecting it to a DC power source. It is fundamentally a three-phase AC motor that requires a dedicated controller to operate from a DC supply. This controller, commonly known as an Electronic Speed Controller (ESC), is a sophisticated piece of digital electronics.

The ESC's job is to act as an intelligent inverter. It takes the DC power from the battery or power supply and, using a bank of high-power transistors (typically MOSFETs), converts it into a three-phase AC waveform. It doesn't just create a simple AC signal; it must precisely time the energizing of each of the motor's three stator windings in perfect sequence to create a magnetic field that rotates smoothly and efficiently pulls the rotor's magnets along with it. To do this, the ESC must know the rotor's position at all times.

The Role of Hall Effect Sensors in Precision Control

This is where Hall effect sensors come into play. These are small semiconductor devices that can detect the presence and polarity of a magnetic field. In a "sensored" brushless motor, three Hall effect sensors are placed within the stator, typically 120 degrees apart. As the rotor's permanent magnets spin past them, the sensors send a digital signal (a sequence of high and low voltages) back to the ESC. This signal acts as a precise, real-time map of the rotor's position.

The ESC's microprocessor reads this 3-bit code from the sensors and uses a lookup table to determine exactly which stator coils to energize next to maintain smooth rotation and optimal torque. This closed-loop feedback system allows for incredibly precise control over the motor's speed and position, which is essential for robotics, CNC machines, and high-performance electric vehicles where smooth startup and low-speed torque are critical.

Sensorless BLDC Control: A Modern Alternative

In some applications, particularly where cost and component count are paramount (like in some drones and cooling fans), a "sensorless" control method is used. Instead of relying on Hall effect sensors, a sensorless ESC cleverly deduces the rotor's position by monitoring the back-electromotive force (back-EMF).

Back-EMF is a voltage that is generated in the un-energized winding of the motor as the rotor's magnets sweep past it—the motor essentially acts as a generator. The ESC can measure this back-EMF on the third wire and use the timing of its zero-crossings to calculate the rotor's position and speed. While this method is brilliant and reduces the motor's complexity and cost by eliminating the sensors and their wiring, it has a drawback. At very low speeds or a standstill, there is no rotation and therefore no back-EMF to measure. This can lead to jerky startups or difficulty operating at a crawl. For this reason, sensored motors are still preferred for applications requiring high torque and smooth control from a dead stop. This deep dive into control systems helps to fully appreciate what's the difference between a brushless motor and a brushed motor from a systems-level perspective.

Core Distinction 5: The Economics and Application-Specific Choice

Ultimately, the decision between a brushed and a brushless motor is an engineering trade-off. It balances initial cost against long-term performance, efficiency, and reliability. There is no single "better" motor; there is only the "right" motor for a specific job. Understanding the economic and application-driven factors is the final piece of the puzzle.

The Initial Cost Equation: Brushed vs. Brushless

On a simple unit-for-unit basis, a brushed DC motor is significantly cheaper than a brushless DC motor system. The reasons are straightforward:

  • Motor Complexity: The brushed motor is a simpler mechanical device to manufacture.
  • Controller Requirement: The brushless motor is inoperable without its mandatory, complex electronic speed controller (ESC). The cost of the ESC must be factored into the total system cost.

For a manufacturer producing millions of inexpensive toys, the cost savings of using a simple brushed motor and no controller are immense. The choice is clear. However, as the performance requirements of the application increase, this simple cost calculation begins to change.

Total Cost of Ownership: A Longer-Term Perspective

For more demanding applications, a more sophisticated analysis—the Total Cost of Ownership (TCO)—is necessary. TCO considers not just the initial purchase price but also the ongoing operational costs over the product's lifetime.

  • Energy Costs: A brushless motor's higher efficiency means it consumes less electricity to perform the same amount of work. For a device that runs continuously, like an HVAC fan or an industrial pump, the energy savings over several years can easily outweigh the higher initial cost of the brushless system.
  • Maintenance and Replacement Costs: A brushed motor will eventually require brush replacement. This involves the cost of the replacement parts and, more significantly, the cost of the labor and downtime required to perform the maintenance. A brushless motor, with its bearing-limited lifespan of tens of thousands of hours, may never require any maintenance at all, eliminating this entire category of expense.
  • Battery Costs: In battery-powered applications, the higher efficiency of a brushless motor allows for the use of a smaller, lighter, and less expensive battery to achieve the same runtime. In many cases, the cost savings on the battery pack can offset the higher cost of the brushless motor itself.

When these factors are considered, the initially more expensive brushless motor system often proves to be the more economical choice in the long run for any application that is not a low-cost, disposable item.

Choosing the Right Motor for Your Application

Let's consider some practical scenarios:

  • A Child's RC Car: The primary constraint is cost. Performance and longevity are secondary. A simple, low-cost brushed motor is the perfect choice.
  • A High-End Cordless Drill: The user demands high power, long battery life, and a compact, lightweight design. The tool needs to be reliable for professional use. A motor sin escobillas is the only logical option. The benefits of higher power density and efficiency are paramount.
  • An Electric Scooter: This application demands high torque for acceleration, high efficiency for maximum range, and extreme reliability with zero maintenance. A brushless design, often in the form of a specialized Todo en una máquina, is the industry standard. The reliability and power density are non-negotiable for a personal transportation device.
  • A Disposable Medical Pump: Designed for a single, short-term use. The absolute lowest cost is the only driver. A brushed motor is the appropriate choice.
  • A Mars Rover Wheel Actuator: The application demands absolute reliability in a harsh environment where maintenance is impossible. Efficiency is critical to conserve limited solar power. The choice is unequivocally a high-reliability motor sin escobillas.

This thought exercise demonstrates that the context of the application is everything. The debate over brushed versus brushless is not about which is superior in a vacuum, but which set of characteristics best aligns with the priorities of the end product.

While brushed motors will always have a place in simple, low-cost devices, the overarching trend across almost all industries is a definitive shift towards brushless technology. The relentless demand for greater energy efficiency, longer battery life, smaller product sizes, and higher reliability has made the advantages of brushless motors irresistible.

In the world of electric vehicles (EVs), from e-bikes to high-performance cars, brushless motors are not just an option; they are the enabling technology. The same is true for the rapidly growing fields of robotics and drone technology. As the cost of sophisticated electronics continues to fall, the price gap between brushed and brushless systems narrows, further accelerating this transition. Understanding the core principles we've discussed is no longer just an academic exercise; it is essential for anyone involved in designing or working with the technologies that will shape our future.

Preguntas más frecuentes (FAQ)

Can I directly replace a brushed motor with a brushless one?

No, not directly. A brushed motor runs on two wires and requires only a simple DC voltage. A brushless motor has three wires and requires a specific three-phase signal generated by an Electronic Speed Controller (ESC). To make the swap, you must replace the brushed motor with a brushless motor and add a compatible ESC between your power source and the new motor.

Why do brushless motors have three wires?

The three wires correspond to the three sets of electromagnetic coils (or phases) inside the motor's stator. The electronic controller energizes these three phases in a specific, rotating sequence to make the motor turn. A simple analogy is that it's the minimum number of phases needed to create a smoothly rotating magnetic field.

Are brushless motors always the better choice?

Not always. For extremely low-cost, disposable, or simple applications where high performance, efficiency, and long life are not priorities, the simplicity and low initial cost of a brushed motor can still make it the more sensible choice. Think of cheap toys or a simple science fair project.

What is a "hub motor" and is it typically brushed or brushless?

A hub motor is an electric motor that is built directly into the hub of a wheel, eliminating the need for chains, belts, or gears. The vast majority of modern hub motors used in electric bikes, scooters, and skateboards are brushless. The high efficiency, high power-to-weight ratio, and maintenance-free reliability of brushless technology are perfectly suited for this application.

My power tool is losing power and sparking a lot. What's the problem?

If you have a tool with a brushed motor, excessive sparking and a loss of power are classic symptoms of worn-out brushes. The brushes have likely eroded to the point where they are no longer making good, consistent contact with the commutator. They will need to be replaced.

Conclusión

The journey from a brushed to a brushless motor is a tale of technological evolution, trading mechanical simplicity for electronic sophistication. The core distinction, the method of commutation, dictates everything that follows. The brushed motor, with its elegant but wearing mechanical contacts, offers a low-cost, simple solution that has served us well for over a century and will continue to find its place in applications where cost is the primary driver. However, its inherent limitations in efficiency, lifespan, and reliability are significant.

The brushless motor, by offloading the task of commutation to an intelligent electronic controller, represents a paradigm shift. It unlocks superior efficiency, a vastly extended operational life, higher power density, and quieter, more precise control. While the initial investment is higher due to the required controller, the long-term benefits in energy savings, reduced maintenance, and enhanced performance make it the definitive choice for the demanding applications that define modern technology—from the electric vehicles that are reshaping our cities to the precision robots that are revolutionizing industry. The question is no longer if a technology will transition to brushless, but when. The principles discussed here provide the framework for making that decision, ensuring that the chosen motor is not just a component, but a perfectly matched solution for the task at hand.

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