Brushless motors (BLDC motors) are widely used in various industries, such as power tools, electric vehicles, drones and other equipment due to their advantages of high efficiency, low maintenance and long life. However, sometimes brushless motors will “lose control”, that is, the motor cannot operate normally, or there will be abnormal conditions such as unstable speed and overheating. In this case, it is crucial to find out the cause and restore control in time. X-TEAM will introduce common reasons why brushless motors lose control and provide practical solutions.
- Common reasons why brushless motors lose control
1) Driver failure
Brushless motors are usually controlled by electronic drives (ESC). If the driver fails, the motor will not work properly. Common faults include burnout of the drive circuit, excessive current or voltage, abnormal PWM signal output, etc.
2) Power supply problems
The unstable power supply or insufficient voltage of the brushless motor can easily cause the motor to lose control. Power supply problems may cause the driver to not get enough voltage, so that it cannot properly control the operation of the motor.
3) Loss or error of control signal
The control system of brushless motor usually relies on sensors or feedback mechanism to determine the position and speed of the motor. If the sensor is damaged or the signal is lost, the driver cannot accurately adjust the working state of the motor, resulting in motor loss of control.
4) Problems with the motor itself
Faults in the motor itself, such as winding short circuit, magnet shedding, bearing wear, etc., will affect the operation of the motor. When these problems occur in the motor, it may cause the motor to fail to start or run normally.
5) Excessive load
The motor is overloaded or the load changes drastically, which may cause the motor to fail to maintain a stable speed or lose control. Excessive load causes the motor to overload, resulting in the driver being unable to provide sufficient power, and then failure.
6) Excessive temperature
Overheating of the motor or driver can lead to performance degradation or even loss of control. High temperature not only reduces the efficiency of the motor, but also may damage the internal components of the motor, such as capacitors, windings, etc.
- Practical solutions to restore motor control
1) Check and replace the driver
If a driver failure is found, first check whether the driver’s circuit is damaged and ensure that the current and voltage are normal. If the driver is damaged, it must be replaced with a new one. Check the function of the driver regularly to prevent the accumulation of faults.
2) Check the power supply voltage
Make sure that the power supply provides enough voltage to the motor and that the power supply is stable. Use a multimeter or other electrical tool to check the power supply output to ensure that the power supply voltage is within the operating range of the motor and drive. If the power supply voltage is too low or unstable, consider replacing a more efficient power supply device.
3) Check the control signal and sensor
If the motor’s control signal is lost or the sensor fails, check the motor’s feedback system to ensure that the sensor is working properly. Common sensor problems include position sensor (Hall sensor) failure, loose wire connection, etc. If the sensor is damaged, it should be replaced in time.
4) Check the motor health
Regularly check the mechanical parts of the motor to ensure that key components such as windings, brushes, and magnets are working properly. If the motor is physically damaged (such as winding short circuit, magnet detachment, etc.), the motor must be repaired or replaced. Clean the dust inside the motor regularly to avoid dust and debris causing short circuits or mechanical failures.
5) Reduce the load
Check the load of the motor to ensure that the load matches the rated power of the motor. If the load is too large, it may cause the motor to overload and cause loss of control. Adjust the load, or choose a more suitable motor to cope with higher load working conditions.
6) Reduce the operating temperature
If the motor or driver is out of control due to excessive temperature, it can be improved by adding heat dissipation measures. For example, use fans, heat sinks or increase the cooling system of the motor to keep the operating temperature of the motor and driver within a safe range. Ensure that there is sufficient ventilation around the motor to avoid damage caused by overheating.
- Measures to prevent brushless motors from losing control
1) Regular maintenance and inspection
Regularly check the operating status of the motor and driver to detect potential problems and repair them in time. Clean and lubricate the various components of the motor to ensure that they are in the best working condition.
2) Use reliable quality components
Choose high-quality power supplies, drivers and controllers to avoid failures caused by low-quality components. High-quality components can not only improve the stability of the system, but also extend the service life of the motor.
3) Reasonable design of the motor system
When designing the motor system, consider the matching of the load and the motor to avoid overload operation. In addition, a reasonable temperature control system should be designed to ensure that the motor and driver will not lose control due to high temperature.
The reasons for the loss of control of the brushless motor may involve multiple aspects such as power supply, motor, driver, control signal and load. By systematically troubleshooting these possible problems and taking appropriate solutions, you can effectively restore the control of the motor and ensure its normal operation. Regular maintenance, reasonable design and high-quality component selection will help avoid the brushless motor from losing control and improve the stability and reliability of the motor system.
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