Brushless motors (BLDC motors) are widely used in power tools, home appliances, robots, drones and other equipment due to their high efficiency, reliability and low maintenance. However, in actual use, the starting problem of brushless motors often becomes a problem that troubles users. Starting difficulties not only affect the performance of the equipment, but may also cause motor damage or increase battery loss. Therefore, understanding the causes of brushless motor starting problems and checking from multiple aspects such as power supply and controller can effectively solve the starting problem and improve the operating efficiency and service life of the motor.
- Common causes of brushless motor starting difficulties
The starting of brushless motors depends on the power supply stability of the power supply, the precise control of the controller and the state of the motor itself. If there is an abnormality in any link during the starting process, the motor may not start smoothly. Common problems include:
1) Unstable or insufficient power supply voltage
The starting of brushless motors requires certain voltage and current support. If the battery voltage is too low or the power supply is unstable, the motor cannot obtain sufficient starting power, and the starting failure or uneven starting may occur.
2) Controller failure or setting problem
The controller is the core component for the starting and operation of brushless motors. If the controller fails or is improperly set, the motor may not start correctly. For example, overload protection, overheating protection, incorrect startup parameter settings, etc., will interfere with the motor’s starting process.
3) Faults in the motor itself
The brushless motor may have problems such as damaged windings, loose wiring, and asymmetric magnetic fields, which will cause excessive resistance or inability to rotate when the motor starts.
4) Battery problems
Battery performance degradation is another common cause, especially the capacity decay of lithium batteries. When the battery voltage is reduced or the battery is low, the motor cannot get enough power, resulting in difficulty in starting.
5) Excessive external load
In some application scenarios, the load connected to the motor is too large, which can also cause difficulty in starting. Excessive load may cause the motor to be unable to overcome inertia when starting, and may even cause motor overload protection.
- Comprehensive inspection from power supply to controller
To effectively solve the starting problem of brushless motors, you first need to conduct a comprehensive inspection from all aspects such as power supply, battery, and controller.
1) Check the power supply voltage and battery status
Brushless motors have high voltage requirements, especially when starting. If the battery voltage is too low, the motor will not get enough starting current. First, check whether the battery voltage meets the specifications and ensure that the battery is fully charged. If the battery is aged or the voltage is abnormal, consider replacing the battery. In addition, check the battery connection wires and connectors to ensure that there is no looseness or poor contact.
2) Check the settings and status of the controller
The settings of the controller directly affect the starting process of the motor. If the starting parameters of the controller are not set properly, it may cause a startup failure. First, check whether the controller supports the starting mode of the brushless motor and ensure that the startup parameters are correct. For example, whether the settings of the starting current limit, starting time, etc. are reasonable. At the same time, check whether the controller’s overload protection, overtemperature protection and other functions are triggered by mistake, causing the controller to suspend power supply or limit the motor output.
In addition, the electrical connection of the controller needs to be checked for normality. Confirm whether the wiring between the controller and the motor is firm and whether the output end of the controller is damaged or has poor contact.
3) Check the health of the motor body
The motor itself may also be the source of the startup problem. First, check whether the motor windings have problems such as open circuits and short circuits. You can use a multimeter to test each winding of the motor to confirm whether there is abnormal resistance. Next, check whether the motor rotor has a fault that hinders rotation, such as stuck or excessive wear.
If the motor has not been used for a long time, you should also check whether there is dust or corrosion inside the motor, which may also cause the motor to start unsmoothly.
4) Check the external load
The external load is an important factor affecting the motor start. If the load connected to the motor is too large, the motor may not be able to overcome the inertia of the load when starting, resulting in failure to start. Check the load of the equipment to ensure that the load is within the tolerable range when the motor starts. If the load is too large, you can consider reducing the load or optimizing the design to reduce the burden at startup.
5) Check the starting method of the motor
There are generally many ways to start brushless motors, such as “trapezoidal wave drive” and “sine wave drive”. Different drive methods have different effects on starting performance. Check whether the controller matches the motor to ensure that the controller can provide a suitable drive method and start mode. If not, you may need to replace the adapter controller or adjust the drive parameters.
Brushless motor starting problems usually involve multiple aspects, including the power supply, battery, controller, and the condition of the motor itself. By troubleshooting from multiple angles such as power supply voltage, battery status, controller settings, motor body, and external load, you can find the root cause of the problem and take corresponding solutions. Regular inspection and maintenance of motors and related systems can not only avoid startup problems, but also extend the service life of motors and equipment and improve the overall efficiency of the system.
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