24V brushless DC motors (BLDC motors) are widely used in home appliances, robots, power tools, fans and other fields because of their high efficiency, reliability and low maintenance requirements. However, although brushless motors are more durable, some common faults may still occur during use, affecting their normal operation. Understanding the causes of these faults and taking corresponding solutions will help extend the service life of the motor and ensure the normal operation of the equipment.
Common faults and cause analysis
- Fault phenomenon of motor not starting or difficulty starting: the motor does not respond after power is turned on, or it takes a long time to operate normally when starting.
1) Possible causes:
The power supply voltage is insufficient or unstable, causing the motor to fail to start.
The controller or driver of the motor fails and fails to output current correctly.
The motor winding is open or shorted, causing the motor to fail to work properly.
The Hall sensor of the brushless motor fails, affecting the position detection of the motor rotor, causing the control system to fail to control the motor correctly.
2) Solution:
Check the power supply voltage to ensure that the battery is sufficient and the voltage is stable.
Check the controller and driver to confirm whether there is any fault or damage.
Check the motor windings to ensure that there is no open circuit or short circuit.
Check whether the Hall sensor is working properly and replace the damaged sensor if necessary.
- The motor speed is unstable or jittering. Fault phenomenon: The motor speed fluctuates greatly during operation, or there is obvious jitter at low speed.
1) Possible reasons:
There is a problem with the speed regulation part of the motor controller, resulting in unstable control signal.
There are worn or damaged parts inside the motor, which affects its running smoothness.
The load is too heavy, exceeding the rated working range of the motor, resulting in unstable speed.
2) Solution:
Check and readjust the settings of the motor controller to ensure that the output signal is stable.
Check whether there are loose or damaged parts inside the motor, and repair or replace them in time.
Confirm that the load does not exceed the rated load range of the motor to avoid overload operation.
- Motor overheating Fault phenomenon: After the motor has been running for a period of time, overheating occurs, which may cause the motor to stop or be damaged.
1) Possible reasons:
The motor is overloaded for a long time, resulting in heat.
The motor cooling system is poor and cannot dissipate excess heat in time.
The motor drive current is too large, exceeding the rated working range of the motor.
2) Solution:
Avoid long-term overload operation of the motor and arrange the motor’s working cycle reasonably.
Improve the heat dissipation capacity of the motor, ensure good ventilation, and add a radiator or cooling fan if necessary.
Check whether the output current of the motor controller exceeds the standard and adjust the drive current to avoid overheating.
- Abnormal noise Fault phenomenon: The motor makes abnormal noise during operation, which may appear as humming, howling, etc.
1) Possible reasons:
The rotor or stator of the motor is unbalanced, causing vibration and noise.
There are foreign objects or dirt inside the motor, which affects the smooth operation of the motor.
The bearing is damaged or poorly lubricated, resulting in increased friction and noise.
2) Solution:
Check whether the rotor and stator of the motor are unbalanced, and repair or replace them.
Clean the inside of the motor to remove possible foreign objects or dust.
Check the condition of the bearings and lubricate or replace damaged bearings in time.
24V DC brushless motors may encounter some common faults during operation. Understanding the cause of the fault and taking appropriate solutions can effectively reduce equipment downtime and extend the service life of the motor. Regularly checking the working status of the motor and keeping the motor and control system well maintained are the key to ensuring long-term stable operation of the motor. When a fault occurs, fault diagnosis should be carried out in a timely manner, and targeted repair measures should be taken according to the specific problem.
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