Will a brushed DC motor overheat during use?

1. Main Causes of Overheating

Excessive Load: When the mechanical load on the brushed DC motor exceeds its rated value, the current rises significantly, and internal power loss is converted into heat.

Poor Heat Dissipation: Prolonged operation or high ambient temperature prevents timely heat dissipation, leading to temperature accumulation.

Winding Short Circuit: Damaged circuit insulation causes an abnormal increase in local current, generating a large amount of heat.

Bearing Wear: Increased friction not only consumes mechanical energy but also converts some energy into heat.

2. Manifestations and Hazards of Overheating

The brushed DC motor casing temperature rises, becoming noticeably hot to the touch.

Efficiency decreases, output torque decreases, and speed fluctuates.

Insulation materials age faster, and prolonged high temperatures shorten the motor's lifespan.

3. Prevention and Solutions

Appropriate Selection: Select a motor with sufficient power margin based on the actual load and operating environment.

Improved Heat Dissipation: Install heat sinks, fans, or improve ventilation to ensure timely heat dissipation.

Reduced Load: Avoid prolonged full-load operation during the design phase; use soft start or graded load when necessary. Regular Inspection: Monitor current and temperature, and promptly replace worn bearings and inspect winding insulation.

4. Monitoring Methods

Install temperature sensors on the brushed DC motor housing or key components to achieve real-time temperature alarms in conjunction with the control system.

Regularly check the distribution of hot spots using a thermal imager, and address any uneven heat dissipation promptly.