As the core power source in industrial equipment and household appliances, once a motor fails, it may cause production stagnation or equipment failure. Open circuit failure is a common type of motor failure, especially in brushless motors and brushed motors. The occurrence of open circuit failure may affect the rotation of the motor and the normal operation of the system. X-TEAM will introduce in detail how to identify and solve the open circuit failure of the motor, and provide relevant recommendations for X-TEAM motors to help users troubleshoot efficiently.
- Definition of motor open circuit failure
Motor open circuit failure refers to the disconnection of a circuit or connection part inside the motor, resulting in the inability of current to flow, so that the motor cannot start or run unstably. Open circuit failure usually occurs in the windings, connecting wires or controller lines of the motor. This failure may manifest as problems such as the motor cannot start, unstable speed, abnormal noise, etc.
- How to identify motor open circuit failure
To identify motor open circuit failure, you first need to carefully check the motor. The following are some common diagnostic steps:
1) Check the motor start-up
The most direct manifestation of motor open circuit failure is that the motor cannot start, or it cannot run smoothly after starting. At this time, you can observe whether the motor has any abnormal noise or whether the rotor is not moving. When the motor has this situation, it is often because the current fails to flow normally through a certain circuit.
2) Use a multimeter to detect the winding
Using a multimeter to check the resistance value of the motor winding is an effective way to identify open circuit faults. By measuring the resistance of the winding, if the resistance value of a certain winding is found to be infinite or close to zero, it means that the winding may have an open circuit or short circuit problem. Under normal circumstances, the resistance of each winding should be within a certain range.
3) Check the motor connection line
The connection line between the motor and the power supply and controller is also an important part of checking open circuit faults. Use a multimeter to detect the continuity of each connection line. If it is found that no current passes through a certain line, or the line is detected to be disconnected, it can be determined that it is an open circuit fault.
4) Check the motor controller
When the motor controller fails, it may cause the motor open circuit fault to occur. By checking the signal output and input of the controller, it can be determined whether it is a problem with the controller. Abnormal signal output of the controller may also cause the motor winding to fail to obtain normal current.
- Measures to solve the motor open circuit fault
Once it is confirmed that the motor has an open circuit fault, the next step is to repair and troubleshoot. According to the recommendations of X-TEAM Motor, the following measures can be taken:
1) Repair or replace the motor winding
If the motor winding is detected to be open, you can try to solve the fault by repairing the winding or replacing the damaged part. Generally speaking, if only a local winding has a problem, it is feasible to repair it using welding technology. However, if the motor winding is severely damaged, the entire set of windings may need to be replaced.
2) Check and replace the disconnected connection wires
If the problem occurs in the connection wires between the motor and the power supply and controller, it can be solved by reconnecting or replacing the disconnected cables. Make sure that all connection ports are not loose or corroded to avoid poor contact and current interruption.
3) Replace the damaged motor controller
If the controller fails and the motor cannot operate normally, check whether the internal circuit of the controller is damaged, especially the current transmission part. If the controller is found to be damaged or unstable, you can consider replacing the controller to ensure that its output signal is stable and drives the motor normally.
4) Clean the motor and controller
During long-term use, the motor and controller may accumulate dust or dirt, affecting their normal operation. Regularly clean the dust inside the motor and around the controller to effectively avoid the occurrence of open circuit faults. In addition, ensure that the working environment of the motor and controller is dry and clean to avoid moisture or dust affecting the stability of the circuit.
- Recommendations for preventing motor open circuit faults
X-TEAM Motor recommends that the following preventive measures should be taken to avoid the occurrence of motor open circuit faults:
1) Regular maintenance inspection
Regularly check the circuit connections and electrical components of the motor to ensure that all terminals are tightened to avoid failures caused by poor contact or corrosion.
2) Avoid overload operation
Avoid running the motor under overload for a long time. Overload not only increases the risk of motor failure, but also accelerates the aging of the winding, leading to the occurrence of open circuit faults.
3) Good heat dissipation and working environment
The motor is prone to generate a lot of heat after long-term operation. Good heat dissipation conditions help to extend the service life of the motor. Avoid using the motor in high temperature, high humidity or dusty environments to ensure the stability of the motor and controller.
Motor open circuit fault is one of the common fault types of motors. Timely detection and effective solutions are essential to restore the normal operation of the motor. Through regular inspection and maintenance, open circuit faults can be effectively prevented and long-term stable operation of the equipment can be ensured. X-TEAM Motor recommends that users should handle motor failures in an orderly manner according to the fault manifestations and troubleshooting steps, and seek help from professional maintenance personnel when necessary to ensure the safety and efficiency of the motor system.
If you want to know more about “brushless motors”, you can contact online customer service. X-TEAM Brushless Motors provides OEM and ODM services for a long time to meet the different needs of different customers.