With the more and more widespread use of DC brushless motors, their performance has also improved to a certain extent. However, various failures will also be encountered in the process of using the BLDC motor. Common problems with brushless motors include Overheating, Power loss, Difficulty starting or controlling the motor, Failure due to wear and tear, and Short circuits.

• Overheating:

• Excessive heat is the main cause of brushless motor failure.[1][2]
• Checking for external wiring errors, such as misconnecting the Delta connection to the Y connection, which can cause the current to be very small. Additionally, high velocities can cause the motor to pull a lot of current and make a lot of noise, which can be a problem if the motor is not operational above a certain RPM.[6]

• Power loss:

• This may be caused by a variety of factors, such as improper power switch operation, blown fuses, or other issues with the connected device.[3]
• Check the power switch of the connected device to ensure it is turned on properly. Check the front fuse and the fuse of the motor main circuit or control circuit to ensure they are not blown. Check the contact resistance between the brush and the commutator to ensure there is no serious brush wear or insufficient spring pressure. Check the short-circuit comparison resistors R9 and R10 of the controller to ensure they are properly set.[7][8]

• Difficulty starting or controlling the motor:

• this may be caused by issues with the motor or the electronic speed controller (ESC), such as damage or poor connections.[4]
• Check the motor and electronic speed controller (ESC) for damage or poor connections. Check the voltage of pin 3 of the MCU to ensure it is greater than 3.2V. If the voltage is insufficient, the motor may not turn. Check the short-circuit comparison resistors R9 and R10 of the controller to ensure they are properly set. Check for voltage dependency, which can limit the motor velocity due to back-EMF. [1]Test the motor for short circuits. If there is a shorted turn, the motor cannot be used and will generate high temperatures, causing the motor to fail and possibly damage the ESC. Check the Hall sensor mapping to ensure it is correct. [4]

• Failure due to wear and tear:

• like any mechanical device, brushless motors may eventually fail due to normal wear and tear over time.[1]
• Regularly scheduled maintenance for all of your electronics, including brushless motors. Test your brushless motors regularly to ensure they are in perfect working order. If the motor fails any of the tests, contact a professional motor repair service, such as Global Electronic Services, to repair or replace the motor. Replace any worn-out parts or parts that are in danger of wearing out during the repair process. [4]Check the contact resistance between the brush and the commutator to ensure there is no serious brush wear or insufficient spring pressure. [2]If the motor is voltage-dependent, check the back-EMF and perform measurements at different voltage levels to identify the problem. [3]

• Short circuits:

• testing for short circuits is an important part of troubleshooting brushless motors.[4][5]
• Test the motor for short circuits by using a multimeter to check the resistance between the motor’s terminals. If the resistance is too low or zero, there may be a short circuit. Check the wiring and connections of the motor to ensure there are no loose or damaged wires that could cause a short circuit. If there is a shorted turn in the motor, it cannot be used and will generate high temperatures, causing the motor to fail and possibly damage the electronic speed controller (ESC). Replace any damaged or worn-out parts during the repair process. [4][10]
• If the motor is voltage-dependent, check the back-EMF and perform measurements at different voltage levels to identify the problem.[1]