Identifying Issues with Your Brushless Motor

For industries relying on brushless motors, ensuring their optimal functionality is crucial. While routine maintenance is advisable for all electronic devices, performing self-assessments on your brushless motors can be a cost-effective strategy for your business.

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When a brushless motor fails to rotate, troubleshooting is essential. Here are some expert methods to diagnose potential issues with your motor.

Testing for Short Circuits in Brushless Motors

Brushless motors employ electromagnets instead of traditional brushes for operation, utilizing magnets fixed to the motor's bell to create necessary motion.

These electromagnets can produce power as well. Manually rotating the motor generates electricity, a principle harnessed in modern generators. If any wires are short-circuited, manual rotation will encounter resistance. However, when all wires are separated, the motor should rotate freely.

If separating the wires still results in resistance, an internal short circuit is likely present.

Conducting a Dry Test on Your Brushless Motor

If your motor is operational but has overheated or been damaged, conducting a dry test can help ascertain its condition. Follow these steps for effective dry testing:

Step 1: Disconnect and Power

Begin by detaching the motor from the Electronic Speed Controller (ESC). Using a variable-speed battery drill, hold the stationary component while ensuring the three lead wires remain isolated. Run the drill at maximum speed for a few minutes. If unusual noises arise or components inside the motor feel hot, it indicates a faulty winding or a loose magnet impacting the stator.

Step 2: Measure Voltages

Next, label the motor wires as 1, 2, and 3, ensuring they remain isolated. Connect your voltmeter set to the AC range to terminals 1 and 2, and again rotate the drill at full speed. Record the AC voltage, and repeat this process for terminal pairs 2-3 and 1-3.

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Inconsistent readings across all three tests indicate problems with the motor wires.

Step 3: Inspect for Stator Short Circuits

Check for shorts between the windings and stator. Identify any connections between the windings and the stator laminations. With a meter, ensure you find a bare metal connection on both the stator and the windings. If you cannot find one, make a connection by carefully piercing through the stator's coating.

An absence of an open circuit on the meter suggests your motor may be irreparable.

Step 4: Final Comprehensive Check

If your motor successfully passes all assessments, it is likely in good shape. However, prior to reinstallation, consider evaluating the no-load current and comparing it with the manufacturer's specifications. This evaluation can help detect any shorted turns in the motor.

A motor with a shorted turn is not usable, as it will produce excessive heat leading to failure and potentially damaging the ESC as well.

Post-Test Considerations for Your Brushless Motor

If your brushless motor clears all tests and appears to operate normally, you can reintroduce it into service, but keep it under observation as a part of your maintenance routine. Should the motor fail any tests, repair or replacement will be necessary. Start by contacting Global Electronic Services.

At Global Electronic Services, our expertise in motor repair, including brushless motors, equips us to handle various motor issues. We can restore your motor to functionality, typically within five days, while replacing any worn components. Our work comes with an 18-month in-service warranty, allowing you peace of mind as you return the motor to operation. Contact us now for a complimentary service quote.

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