In industrial automation, smart manufacturing, and electric vehicle applications, Sensored Motors are widely used for their precise position feedback and stable torque output. However, after long-term operation or under harsh conditions, various faults may occur that affect performance or even stop operation entirely. This article analyzes the common faults, causes, and troubleshooting methods of sensored motors, helping engineers quickly locate and resolve issues to maintain stable system performance.
Hall Sensor Signal Abnormalities
Sensored motors rely on Hall sensors to detect rotor position for accurate commutation control. When Hall signals are distorted, missing, or phase-shifted, the driver cannot correctly determine the rotor position, causing the motor to jitter, rotate erratically, or fail to spin.
Common causes:
Sensor damage or aging;
Poor cable connections or broken signal wires;
Electromagnetic interference from nearby equipment.
Troubleshooting:
Use an oscilloscope to check the three Hall signal waveforms for uniform timing;
Verify that the Hall sensor power supply voltage is stable;
Ensure the signal cable shielding is properly grounded to reduce interference.
Incorrect Driver Parameter Configuration
Proper matching between the motor and driver is critical. If driver parameters such as pole pairs, Hall angle, or phase sequence are set incorrectly, the motor may fail to start or run unstably.
Common causes:
Parameters not recalibrated after changing the motor;
Auto-identification function not executed properly;
Phase wires and Hall sensor signals are out of sync.
Troubleshooting:
Re-enter motor parameters in the driver software to match the nameplate data;
Run the automatic detection or Hall calibration process;
If the motor spins in the wrong direction or shakes, try adjusting the phase wiring order.
Power Supply Faults or Instability
Fluctuating or insufficient power supply can directly affect motor operation. Low voltage may trigger undervoltage protection, preventing startup; excessive voltage may trigger overvoltage protection or damage components.
Troubleshooting:
Use a multimeter to check whether the input voltage is within the rated range;
Inspect power terminals for loose connections;
If alarms occur frequently, check the driver’s protection codes for overvoltage, undervoltage, or overcurrent.
Control Signal Errors
In automated systems, sensored motors are usually controlled by PLCs or main controllers. If the start, direction, or speed signals are incorrect or not received, the motor will not respond.
Common causes:
Incorrect logic level for start or enable signals;
Reversed or loose control wires;
Incorrect communication settings (baud rate, address, or protocol mismatch).
Troubleshooting:
Use indicator LEDs or diagnostic software to verify signal input status;
Ensure control logic levels meet the driver’s input requirements;
For serial or CAN communication, check that protocol settings are consistent.
Mechanical Jamming or Overload
Even with normal electrical control, the motor can fail to spin if mechanical parts are jammed or the load exceeds rated torque.
Common causes:
Damaged or unlubricated bearings;
Stuck transmission mechanisms;
Excessive load or inertia.
Troubleshooting:
Manually rotate the motor shaft to check for resistance;
Reduce the load and test again;
Regularly lubricate bearings and remove dust or debris from mechanical assemblies.
Driver Protection Mode Activated
Modern motor drivers include overcurrent, overtemperature, and short-circuit protection. When triggered, the driver automatically cuts off power output to prevent damage, making the motor stop running.
Troubleshooting:
Check driver alarm indicators or software error logs;
Inspect for short circuits, overloading, or poor heat dissipation;
After fixing the issue, power cycle the system to reset protection mode.
Conclusion
The stability of a sensored motor depends on the coordination between the sensor system, driver control, power supply, and mechanical components. When faults occur, users should troubleshoot systematically from the electrical, control, and mechanical levels while using the driver’s diagnostic tools. Regular maintenance, proper parameter configuration, and clean wiring environments can significantly extend motor lifespan and ensure long-term, efficient, and reliable operation.