What to do with broken DC motor leads?

Here are some steps and methods to deal with broken DC motor leads:

Disconnect the power: First, confirm that the motor and related equipment have been completely disconnected to avoid electric shock or equipment damage.

Check the location of the break: Carefully check the location of the lead break to determine whether the lead itself is broken or the connection point is broken.

Strip insulation: If the lead is broken in the middle of the wire, it is necessary to strip the insulation at both ends of the break to expose the wire. Use the proper stripping tool to avoid damaging the wires.

Soldering the wires: Use solder and a soldering iron to re-solder the two sections of wire together. Make sure the solder joints are firm and avoid false or cold soldering.

Insulation: After soldering, wrap the soldering points with heat shrink tubing or insulating tape to ensure the insulation and mechanical strength of the wires.

Reconnection: If the leads are disconnected at a connection point, the leads need to be reconnected to the terminal. Make sure the connection is tight, either by using a terminal crimping tool or by soldering.

Test the motor: After the repair is complete, re-energize and test the motor to ensure that it is running properly and that there are no abnormal sounds or overheating.

Secure leads: To prevent leads from breaking again, use wire clips or ties to secure leads to minimize vibration and stress.

These steps apply to most DC motor lead breaks. However, in practice, they should be handled according to the specific situation and equipment instructions.

If you are not familiar with electrical repairs, it is recommended to seek professional help to ensure safety and repair results.