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4.1 Common Failures of Brushed DC Motors
- Stuck movement & insufficient power
Root cause: Worn-out carbon brushes and carbon deposits on the commutator create poor electrical contact, resulting in reduced power transmission.
- Abnormally loud operating noise
Uneven brush wear or eccentric rotor causes friction noise and operational vibration.
- Frequent overheat shutdown
Long-term high-frequency operation and excessive contact resistance of brushes lead to excessive motor temperature rise.
Maintenance Tips
Brushed motors are consumable repairable components. Regular carbon dust cleaning and brush replacement can extend service life. Annual inspection every 1–2 years is recommended for harsh working environments.
4.2 Common Failures of BLDC Brushless Motors
- Failure to start/stop & disorderly motion
Mostly caused by faulty Hall sensors or damaged drive controllers; no mechanical wear occurs inside the motor itself.
- Uneven speed & positioning deviation
Faulty electronic control programs or signal interference to sensors lead to inaccurate speed regulation and positioning.
- Slight abnormal noise
Caused by worn gearboxes; the motor body has no wearable mechanical parts.
Maintenance Tips The main body of BLDC motors barely suffers wear. Around 90% of malfunctions stem from electronic control systems. No mechanical maintenance is required; only regular inspection of wiring and controller status is needed
