Brushless motors (BLDC motors) are widely used in various modern electrical equipment due to their advantages such as high efficiency, long life, and low noise. However, during use, many users may encounter the phenomenon of brushless motor tripping during operation. Motor tripping not only affects the normal operation of the equipment, but may also cause equipment damage or other safety hazards. Therefore, understanding the common causes of brushless motor tripping and mastering effective repair methods are the key to ensuring the stable operation of the motor.
- Common causes of brushless motor tripping
1) Overload protection triggering
When the brushless motor is overloaded, the current exceeds the set rated value, which may trigger the overload protection mechanism and cause the circuit to trip. This situation usually occurs when the motor is started or when the load increases suddenly. When the motor continues to run under high load, excessive current can easily cause the motor temperature to rise, and the protection circuit will automatically cut off the power to prevent motor damage.
2) Unstable power supply voltage
The fluctuation or excessive high or low power supply voltage, especially when the power grid is abnormal, may cause the motor control system to fail to work properly. If the voltage is too low, the motor cannot get enough power; if the voltage is too high, it may cause excessive current, thus triggering overcurrent protection and causing tripping.
3) Drive circuit failure
If there is a problem with the drive circuit of the brushless motor, such as damage to the switching element, loose wiring or short circuit, the motor may not start or run normally, or even cause the motor controller to trip. Failure of components such as capacitors and transistors in the motor driver may also cause excessive current and trigger the protection mechanism.
4) Internal motor failure
Failure of the brushless motor itself, such as winding short circuit, poor contact or insulation damage, may cause abnormal current when the motor is running, thereby triggering trip protection. Especially when the motor runs at high load for a long time or starts and stops frequently, the damage inside the motor may be more serious.
5) Excessive starting current
When the brushless motor starts, the current may instantly reach several times the rated current. If the starting current of the motor exceeds the tolerance of the power supply and protection circuit, it may trigger overcurrent protection and cause tripping. Especially in the absence of soft start control, the risk of tripping is higher when the starting current is large.
- Quick fix for brushless motor tripping
1) Check the load
First check the load of the motor to confirm whether there is an overload. You can prevent the motor from tripping due to overload by reducing the load or increasing the motor capacity. If the motor load is too large, you can consider re-adjusting the working parameters to avoid the motor running at full load for a long time.
2) Check the power supply voltage
Check whether the power supply voltage is stable and ensure that the power supply voltage is within the rated operating range of the motor and drive circuit. If the power supply voltage is unstable, you can use a stabilized power supply or add a voltage regulator to ensure that the motor has a stable power supply.
3) Troubleshoot the drive circuit problem
Check whether the motor drive circuit is working properly. Check whether the wiring is loose and whether the capacitor and transistor are damaged. If the drive circuit is found to be faulty, you can replace the relevant components or reconnect the circuit to restore normal operation.
4) Check the internal state of the motor
Regularly check whether the motor windings and wiring are damaged or short-circuited. Especially for motors that run for a long time, check whether the insulation of the motor is intact. If there is a fault inside the motor, the motor may need to be repaired or replaced.
5) Use soft start technology
If the motor starting current is too large, you can consider using a soft starter. The soft starter can effectively limit the starting current and avoid tripping due to excessive current. In addition, using a frequency converter to control the start and stop of the motor can also effectively control current fluctuations and reduce the occurrence of tripping.
6) Set a reasonable overload protection threshold
In the motor control system, it is very important to reasonably set the threshold of overload protection. The overload protector should be adjusted according to the rated power and load characteristics of the motor to avoid tripping due to occasional small load changes.
There are many reasons for tripping during the operation of the brushless motor, which may be closely related to factors such as load, power supply, circuit failure, and the motor itself. To solve the tripping problem, you first need to start with checking the motor load, power supply voltage, drive circuit, internal faults, etc. By timely troubleshooting, adjusting working parameters, and using soft start technology, you can effectively avoid the occurrence of tripping and ensure the smooth operation of the brushless motor. Regular inspection and maintenance are effective measures to prevent motor tripping and are also the key to ensuring the long-term stable operation of the motor.
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