Wiring & Phase Angle of Brush Motor & Brushless Motor

Ⅰ.Wiring Method of Brush Motor & Brushless Motor

Due to the different commutation methods, not only the internal structure of the brushed motor and the brushless motor are different, but the difference in the wiring method is also very large.

1.The Wiring Method of Brush Motor

The brushed motors have positive and negative leads. Generally, the red wire is the positive pole of the motor, and the black wire is the negative pole. If the positive and negative poles are interchanged, the motor will only be reversed and will not be damaged.
2.The Wiring Method of Brushless Motor

There are three coil leads of the brushless motor and five Hall leads. These 8 wires must correspond to the leads of the controller one by one, otherwise the motor cannot rotate normally.

Ⅱ.The Judgement of Phase Angle for Brushless Motor

The phase angle of the brushless motor is the abbreviation of the phase algebraic angle for the brushless motor, which refers to the angle at which the current direction of each coil for the brushless motor changes in a energizing cycle. The common phase algebraic angles of brushless motors for electric vehicles are 120 degrees and 60 degrees.
Observe the installation position of the Hall element to determine the phase angle of the brushless motor: the installation position of the Hall element is different for the two phase angles of 120° and 60°. The arrangement of the three Halls of the 60° motor is the same, and the hall in the middle of the 120° motor needs to be turned 180° to install.
The Hall element of the brushless motor has five leads, which are the positive pole of the common power supply, the negative pole of the common power supply, the A-phase Hall output, the B-phase Hall output, and the C-phase Hall output of the Hall element. We can use the five Hall leads of the brushless controller to connect the positive and negative power supplies on the leads of the Hall element of the DC brushless motor and connect the leads of the remaining three phase sensors A, B, and C to the Hall signal lead of the controller. Turn on the power of the controller, and the controller will supply power to the Hall element, and then the phase angle of the brushless motor can be detected.
Methods as below: Use the +20V DC voltage range of the multimeter to measure the voltage of the three leads with the black test lead and the red test lead, and record the voltage of the three leads. Rotate the motor slightly, let the motor rotate through a minimum angle of magnetic pull, measure and record the voltage of the three leads again, and record 6 times of this measurement. We use 1 to indicate high potential and 0 to indicate low potential. Then, if it is a 60° brushless motor and continuously rotates 6 minimum magnetic relay angles, the measured Hall true value signal should be: 100, 110, 111, 011, 001, 000. Adjust the pin order of the three Hall element leads, so that the A, B, and C phases of the 60° brushless motor can be judged.
If it is a 120° brushless motor and continuously rotate 6 minimum magnetic pull angles, the measured Hall true value signal should change according to the law of 100, 110, 010, 001, 101, so that the power phase sequence of the Hall element leads Just be judged.
Generally, the brushless motors with 60° and 120° phase angles need to be driven by the corresponding brushless controllers with 60° and 120° phase angles, and the two phase angle controllers cannot be directly interchanged . There are two correct wiring of the 8 wires connecting the 60° phase angle brushless motor and the 60° phase angle controller, one is forward and the other is reverse.
For a brushless motor with a 120° phase angle, by adjusting the phase sequence of the coil lead and the Hall lead, there can be 6 correct wiring of the 8 wires connecting the motor to the controller. Among them, 3 kinds of connections, the motors rotate forward, and the other 3 kinds of connections, the motors reverse.
If the brushless motor reverses, it indicates that the phase angles of the brushless controller and the brushless motor are matched. We can adjust the rotation of the motor as follows: exchange the A and C of the hall leads of the brushless motor and the brushless controller wiring; at the same time, swap the wiring between the brushless motor and the main phase wires A and B of the brushless controller.
Note: Intelligent brushless controllers have appeared on the market. This intelligent brushless controllers have the function of automatically identifying the phase angle of the motor, and can simultaneously drive the brushless motors with two phase angles of 60° and 120°.

Ⅲ.Controller Installation & Lack of Phase
1.Correct Installation of The Controller

When installing the controller, the connectors connected to the controller must be placed vertically on the ground to prevent water from accumulating in the connectors. Fix the lead wire of the controller on the car body with nylon tape to prevent the lead wire and the car body from rubbing and damaging the lead wire. Try to raise the installation position of the controller as high as possible and keep it away from the ground. In addition, place the opening of the controller housing downward to prevent water from entering the controller.
2.The Lack of Phase for The Brushless Controller

The detection method of the main phase lack for the brushless controller can refer to the speed troubleshooting method of the brushless controller to detect whether the MOS tube is broken down. The Hall phase lack of the brushless controller shows that the controller cannot recognize the motor’s Hall signal. The detection method is unplugging the Hall lead of the controller and the brushless motor, using the DC voltage of the multimeter when the controller is energized, and placing the black test pen against the black wire of the Hall lead of the controller, and measuring with the red test pen other hall leads of the controller.
3.The Phase Lack of The Brushless Motor

The phase lack of the brushless motor is generally caused by the damage of the Hall element of the brushless motor. We can determine which Hall element is faulty by measuring the resistance of the output lead for the Hall element relative to the Hall ground and relative to the Hall power lead. To ensure the precise commutation position of the motor, it is generally recommended to replace all three Hall elements at the same time. Before replacing the Hall elements, we must make sure that the phase algebraic angle of the motor is 120° or 60°. Generally, the three Hall elements of the 60° phase angle motor are placed in parallel. In the 120° phase angle motor, one Hall element in the middle of the three Hall elements is placed in a 180° position.

Get the brushless motor’s discount quotation online:

Email: michael@metrontec.com

Phone/WhatsAPP: +(86) 13838306720