Brushless motors (BLDC motors) are widely used in home appliances, industrial equipment, electric vehicles and other fields due to their high efficiency, low noise and long life. However, in actual use, the brushless motor current may sometimes be abnormal, causing the motor to fail to work properly or even damage other systems. Understanding the common causes of abnormal brushless motor current and taking effective solutions is crucial to ensure the stable operation of the motor.

1. Common causes of abnormal brushless motor current

1) Excessive load

The motor current is too large because the motor load exceeds its rated capacity, causing the motor to provide more power. When the load is too large, the motor current will increase sharply and may even exceed the motor’s tolerance range, causing the motor to overheat or the protection mechanism of the control system to be triggered.

2) Drive circuit failure

The drive circuit of the brushless motor is responsible for controlling the operating state of the motor. If the drive circuit fails, such as the current sensor fails, the power switch tube is damaged, or the driver chip fails, the motor current may become unstable or abnormal, causing the motor to fail to work according to the set parameters.

3) Unstable power supply voltage

Unstable power supply voltage is also a common cause of abnormal current. When the power supply voltage is too low, the motor cannot get enough power and the current may fluctuate abnormally; when the voltage is too high, the current is too large, which may also cause the motor to overheat or trigger the protection mechanism.

4) Motor winding problem

Short circuit, open circuit or poor contact inside the motor winding will cause abnormal current. If the winding is short-circuited, the current will become very large; if the winding is poorly contacted, it may cause current fluctuations and affect the stability of the motor.

5) Improper motor controller settings

The controller of the brushless motor adjusts the current according to the working state of the motor. If the controller parameters are set improperly (such as too high gain, too large starting current setting, etc.), it may also cause abnormal current when the motor starts or runs.

6) Insufficient motor cooling

When the motor works at high load for a long time, the temperature may be too high, resulting in excessive current. If the motor cooling system is not perfect, the motor’s overheating protection mechanism may not respond in time, resulting in abnormal current.

2. Solutions to abnormal brushless motor current

1) Reduce the load

If it is found that the excessive motor current is caused by excessive load, you should consider reducing the load or choosing a motor with higher power to meet the demand. In some applications, the burden on the motor can be reduced by adjusting the load or working mode.

2) Check and repair the drive circuit

Check the motor drive circuit to ensure that each component (such as current sensor, switch element, drive chip, etc.) is working properly. If the circuit is found to be damaged or poorly contacted, the damaged parts should be repaired or replaced in time. In addition, check whether the cable connection is tight to avoid current instability caused by looseness.

3) Stabilize the power supply voltage

Ensure that the power supply voltage is stable. In areas with large voltage fluctuations, a voltage stabilizer can be used to stabilize the voltage to prevent current fluctuations or motor damage caused by unstable power supply.

4) Check the motor windings

Regularly check the status of the motor windings, especially when the current is abnormal, to confirm whether the windings are short-circuited, open-circuited or have other problems. If the motor windings are faulty, the motor needs to be repaired or replaced.

5) Optimize the motor controller settings

Check the settings of the motor controller to ensure that the current regulation parameters are appropriate. According to the model and working requirements of the motor, the controller’s starting current, overload protection settings and other parameters can be adjusted to avoid excessive or insufficient current.

6) Strengthen motor heat dissipation

The heat generated by the motor when it is working needs to be dissipated in time, especially under high load or long-term operation, the motor’s heat dissipation system is crucial. Ensure that the motor radiator or fan operates normally, keep the motor temperature within a reasonable range, and prevent abnormal current due to overheating.

The reasons for abnormal current of brushless motors may involve load, drive circuit, power supply voltage, motor winding, controller settings and other factors. By timely troubleshooting, optimizing working parameters, and regular maintenance, the occurrence of abnormal current can be effectively avoided and the stable operation of the motor can be ensured. If you encounter a current problem that cannot be solved by yourself, it is recommended to seek the help of professional technicians to ensure the safety and long-term reliable operation of the equipment.

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