In modern automation equipment, robotics, electric vehicles, and drones, Sensored Motors are widely used for their fast response and precise control performance. Unlike sensorless motors, sensored motors rely on Hall sensors to detect the rotor’s position in real time, enabling efficient drive control and accurate speed adjustment. However, during long-term operation or under complex working conditions, sensored motors may experience various problems that affect system stability. This article summarizes the most common issues and provides practical troubleshooting methods for users and maintenance engineers.
Motor Fails to Start
This is one of the most frequent problems, usually caused by:
Damaged or miswired Hall sensors – Sensored motors depend on Hall signals to determine rotor position; incorrect or missing signals prevent proper startup.
Incorrect driver settings – Improper current limits, startup angles, or acceleration parameters in the driver can cause the motor not to spin.
Power supply issues – Low or unstable voltage may interrupt motor operation.
Solution: Use a multimeter to verify Hall signal output, ensure stable power input, and recalibrate driver parameters using configuration software.
Motor Vibration or Unstable Operation
If the motor vibrates or stalls intermittently, the cause often lies in feedback errors or magnetic field misalignment.
Cause 1: Hall signal interference or misalignment – Sensor installation errors lead to incorrect phase detection and torque fluctuation.
Cause 2: Improper current loop tuning – Poor PID tuning within the controller causes delayed current response.
Solution: Verify proper Hall sensor alignment, fine-tune PID parameters, and recalibrate pole pairs and sensor positioning if necessary.
Motor Overheating or Burnout
Continuous high-load operation or poor ventilation may cause winding temperatures to exceed safe limits, leading to insulation damage or motor burnout.
Common causes:
Excessive current limit or poor heat dissipation;
Overpowering by the driver causing energy loss;
High ambient temperature.
Solutions:
Reduce the current limit;
Check fan operation and clear heat sink obstructions;
Enable over-temperature protection within the driver.
Abnormal Noise or Unusual Sounds
Abnormal noise usually results from mechanical wear or electromagnetic interference.
Mechanical causes: Bearing wear, rotor imbalance, or loose mounting;
Electrical causes: Hall signal jitter or low PWM frequency.
Solution: Lubricate bearings regularly, tighten all motor mountings, and increase PWM frequency in the driver to minimize electromagnetic noise.
Unstable Speed or Slow Response
If the motor exhibits delayed acceleration or unstable speed, the issue may stem from driver mismatch or signal delay.
Possible causes:
Driver model not matched to motor parameters;
Communication delay or unstable control signals.
Solution: Ensure the driver and motor are compatible, check communication cables and grounding, and update firmware when available.
Routine Maintenance and Prevention
Inspect Hall sensor, phase, and power cables every three months;
Clean dust and heat sinks every six months;
Monitor current and temperature regularly to prevent overload;
Use the manufacturer’s configuration software to back up driver settings.
Conclusion
Sensored motors deliver reliable and precise performance, but their complex electrical and sensing systems require careful maintenance. By routinely checking Hall sensor signals, optimizing control parameters, improving heat dissipation, and pairing the motor with a suitable driver, users can extend service life and reduce fault rates. Mastering these common issues and solutions is key to ensuring long-term, efficient, and stable operation of sensored motor systems.