Detailed explanation of DC brushless motor faults

With the development of the industrial industry, brushless DC motors, as a commonly used type of electric motor, have become increasingly widely used due to their high efficiency, high speed, and low noise. At the same time, their equipment maintenance and upkeep are also receiving more attention. So, what are the common faults of brushless DC motors? Let's take a detailed look.

When the servo brushless motor does not work or cannot start, it may be caused by poor contact of the power line, power failure, or driver failure. This problem can be solved by checking the power line and replacing the power supply. At the same time, it is also necessary to check whether the driver and controller are working properly.

DC brushless motors generate a certain amount of heat during operation. If the temperature is too high, it may cause the motor to overheat and be damaged, resulting in a high temperature rise fault. The cause of this fault may be poor air circulation, unreasonable radiator design, or excessive load. The solution is to increase the heat dissipation area of the radiator, improve air circulation, and reduce the load.

When insulation failure occurs, the brushless DC electrical insulation may be damaged due to factors such as humid environment and dust, causing the motor to malfunction. To avoid insulation failure, the motor should be cleaned regularly and a dry working environment should be maintained.

Brush wear, traditional brushed motors require regular replacement of brushes, while brushless motors do not have brushes. However, the carbide ring of the brush in brushless motors may experience wear and damage. Once the electric brush is found to be worn, it needs to be replaced in a timely manner.

Motor vibration, which may be caused by rotor imbalance, loose connecting components, or faulty bearings. The methods to solve this problem include rebalancing the rotor, tightening the connecting components, or replacing the bearings. Speed controller failure, the speed controller (driver) of the brushless motor may also malfunction, causing the motor to fail to operate normally. In this case, you can try resetting the speed controller or replacing the faulty component.

The last one is the most common form of failure, bearing failure. The bearings of DC motors may malfunction due to long-term use or improper use. Bearing failures can cause the motor to produce noise, increase vibration, or prevent the rotor from rotating freely. After the motor bearings fail, the radial vibration of the motor will drive changes in the motor air gap, and the load torque will also fluctuate, resulting in changes in current. The solution to this problem is to replace worn or damaged bearings.

In summary, common faults of brushless DC motors include motor failure, bearing failure, high temperature rise, insulation failure, brush wear, motor vibration, and speed controller failure. For these faults, we can solve them by checking the power circuit, replacing bearings, improving heat dissipation, maintaining a dry environment, and regular maintenance.