What are some common sensor failures and their solutions for manual stator slot wedges for brushless motors?

What are the common sensor failures and their solutions for brushless motor manual stator slot wedge machine?

Brushless motor manual stator slot wedge machine common sensor failure and its solution

First, the common sensor failure

1、Hall sensor signal abnormality

Phenomenon: groove wedge machine positioning is not allowed, motor speed fluctuation or stop.

Cause:

Hall element physical damage (such as vibration, impact caused by fracture).

Electromagnetic interference or poor wiring contact (signal line near the strong current line).

Environmental temperature and humidity exceeds the standard (high temperature leads to signal drift, moisture triggers short circuit).

Solution:

Detection: Use a multimeter to measure the voltage of the Hall signal line, the normal value should be 0V or 5V alternately; check the wiring or replace the Hall components when abnormal.

Shield interference: Hall signal line using twisted shielded wire, away from the motor power line.

Replacement of the sensor: If the Hall component is damaged, disassemble the alignment of the magnetic pole direction, welding and testing the signal waveform.

2, photoelectric sensor failure

Phenomenon: slot wedge insertion position detection failure, equipment malfunction.

Cause:

Lens contamination (dust, oil blocking the optical path).

Light source aging (LED brightness decline).

Mechanical vibration caused by the optical path offset.

Solution:

Cleaning and maintenance: Wipe the sensor lens with anhydrous alcohol regularly.

Align the light path: Adjust the alignment of the transmitter and receiver to ensure that the light spot covers the detection area.

Replacement of components: Replace the LED module when the light source is not bright enough.

3、Position sensor calibration deviation

Phenomenon: Inconsistent or offset depth of slot wedge insertion.

Cause:

Loose sensor installation or mechanical vibration resulting in displacement.

Parameter drift after long-term use (temperature and humidity changes affect).

Solution:

Tighten the installation: check the sensor fixing screws and use anti-loosening shims.

Software calibration: Recalibrate the sensor zero point through the controller, and adjust the threshold parameters by referring to the equipment manual.

Second, the troubleshooting process

1, preliminary troubleshooting:

Check the sensor supply voltage (such as Hall sensors need 5V stable power supply).

Observe the status of the sensor indicator (some photoelectric sensors come with a working status light).

2, signal testing:

Oscilloscope detection: Observe the Hall sensor output waveform is regular (normal square wave).

Analog trigger: manually block the photoelectric sensor, detect whether the signal is normal jump.

3, environment optimization:

Control environmental temperature and humidity (recommended working temperature - 20 ℃ ~ 70 ℃, humidity <85%).

Avoid strong magnetic field interference (such as welding machines, inverters away from the sensor).

Third, preventive maintenance recommendations

1, routine maintenance:

Clean the surface of the sensor every week, check the terminals for oxidation.

Check the fixed status of the sensor every month to prevent loosening.

2, spare parts management:

Standing Hall sensors, photoelectric modules and other wearing parts to shorten downtime.

Record the sensor replacement cycle (recommended every 2 years or 100,000 times after the operation of preventive replacement).

3、Operation standardization:

Avoid plugging and unplugging the sensor connector with electricity to prevent electrostatic breakdown.

Mark the installation direction of the sensor when disassembling to avoid reverse installation.

※ If you still can't solve the problem by the above ways and means, please contact the technical specialist of Xinhui Mechanical and Electrical Equipment Co.