ASLONG 25mm Series DC Motor: Problem Identification and Resolution Case Study

I. Problem Identification

1. Arcing at Commutator: The DC motor generates arcing at the commutator, which makes it unsuitable for environments with flammable or explosive gases.
2. Maintenance and Repair Issues: The need for regular replacement of brushes and commutators makes maintenance difficult and shortens the life of the motor.
3. Low-Speed Stability: The stability of the motor at low speeds needs improvement, affecting the precision of equipment operation.

II. Problem Analysis

1. Arcing at Commutator: During the commutation process of a DC motor, electric arcs are generated, especially when the load changes significantly or during high-speed operation. This can pose a safety hazard in environments with flammable or explosive gases.
2. Maintenance and Repair Issues: Brushes and commutators are key consumable components in DC motors. Their frequent replacement increases maintenance costs and workload. Additionally, the complex structure limits the motor's lifespan and reliability.
3. Low-Speed Stability: When operating at low speeds, the motor's speed control accuracy and load adaptability are insufficient, leading to speed fluctuations or stalling. This is particularly problematic for devices requiring high-precision positioning.

III. Solutions

A. Addressing Arcing at Commutator

1. Brushless Motor Alternative: In environments with flammable or explosive gases, it is recommended to replace traditional brushed motors with ASLONG’s brushless DC motors. Brushless motors use electronic commutation, eliminating the mechanical commutator and fundamentally preventing arcing.
2. Protective Measures: For scenarios where brushed motors must be used, a protective cover can be added, and a sealed design can be implemented to reduce contact between arcs and external flammable or explosive gases.

B. Addressing Maintenance and Repair Issues

1. Brushless Motor Upgrade: Promote the use of brushless DC motors, which do not require brushes and commutators, significantly reducing maintenance needs and extending motor life.
2. Optimizing Mechanical Structure: Improve the mechanical structure of brushed motors to enhance the durability of brushes and commutators, extending their replacement cycle.

C. Addressing Low-Speed Stability

1. Optimizing Control Algorithms: Implement advanced vector control algorithms to improve the control accuracy and response speed of the motor during low-speed operation, ensuring stable speed output.
2. Introducing Feedback Mechanisms: Incorporate encoders or Hall sensors into motor control to monitor the motor’s speed and position in real time. Adjust the motor’s operating state through feedback control.

IV. Implementation Results and Verification

1. Arcing at Commutator: When tested in environments with flammable or explosive gases, brushless motors showed no arcing, significantly improving safety performance.
2. Maintenance and Repair Issues: Devices using brushless motors had maintenance cycles extended by approximately 50%, significantly reducing maintenance costs.
3. Low-Speed Stability: After optimizing control algorithms, the speed fluctuation range of the motor during low-speed operation was reduced to within ±2%, significantly improving the precision of equipment operation.

V. Conclusion and Outlook