Brushless motors (BLDC motors) are widely used in industrial equipment, power tools, electric vehicles and other fields, and are favored for their high efficiency, stability and brushless advantages. However, in actual applications, sometimes the set speed of the motor cannot be achieved, which not only affects the performance of the equipment, but also may lead to a decrease in production efficiency. X-TEAM will explore the reasons and solutions for the failure of the brushless motor speed to help users effectively troubleshoot and solve the speed problem.
- Reasons why the set speed of the brushless motor cannot be achieved
1) Improper driver settings
The speed of the brushless motor is adjusted by the driver by controlling the current frequency. If the driver is not set correctly or the parameters are not adjusted according to the rated parameters of the motor, the motor may not reach the set speed. For example, if the frequency of the PWM (pulse width modulation) signal is set too low or too high, it will affect the accuracy and stability of the motor speed.
2) The motor is overloaded
If the load of the motor exceeds its rated range, the motor will not be able to reach the set speed. Excessive load will increase the power consumption of the motor, resulting in a decrease in speed or even failure to start. Especially when running under high load, the motor speed may not be maintained at the target value.
3) Insufficient power supply voltage
The drive system of brushless motors relies on a stable power supply voltage. If the power supply voltage is insufficient or the voltage fluctuates greatly, the performance of the motor will be affected, resulting in the inability to achieve the set speed. When the power supply voltage is insufficient, the driver cannot provide enough current to maintain the operation of the motor, which leads to low speed.
4) Faults in the motor itself
Faults inside the motor, such as magnet demagnetization, winding damage, or motor bearing wear, may also cause the speed to fail to reach the set value. The motor’s operating efficiency is reduced, resulting in insufficient torque, which affects the stability of the speed.
5) Mismatched control system
Brushless motors usually require a precise control system to achieve speed regulation. If the motor does not match the control system, or there is a problem with the control algorithm, the motor may not be able to accurately reach the set speed. This problem is particularly evident in applications with high speed or high precision requirements.
- The best way to solve speed problems
1) Check the driver and control parameters
Regularly check the driver settings of the brushless motor to ensure that all parameters (such as PWM frequency, maximum current, gain, etc.) match the specifications of the motor. Ensure that there are no problems with the driver software or firmware, and adjust and update them appropriately.
2) Reduce the load
Ensure that the motor load is within the rated range. The motor load can be reduced by optimizing the design or using a deceleration device to help the motor maintain a stable speed.
3) Stabilize the power supply voltage
Check the power supply system to ensure that the voltage is stable and sufficient to support the motor’s operating requirements. If the power supply voltage is unstable or the battery is low, consider replacing the battery or using a voltage stabilization device to ensure stable power supply.
4) Check for motor failure
If the motor still cannot reach the set speed, check the health of the motor itself. Check whether the motor windings are intact, whether the magnets are demagnetized, and whether the bearings are worn. If there is a fault, repair or replace the motor in time.
5) Optimize the control system
Ensure the matching of the motor and the control system, especially in high-precision applications, and select the appropriate control algorithm. Modern brushless motor control systems usually have adaptive functions that can automatically adjust the speed according to load changes to improve operating accuracy.
The problem that the set speed of the brushless motor cannot be achieved is usually related to factors such as driver settings, motor load, power supply voltage, motor failure, and matching of the control system. By properly troubleshooting these factors, adjusting the drive parameters, reducing the load, ensuring stable power supply and checking the health of the motor, the problem of speed not being reached can usually be solved. Through these effective measures, not only can the motor’s operating efficiency be improved, but also the motor’s service life can be extended to ensure the stable operation of the equipment.
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