Neo550 stalled under no load...?

I’ve definitely seen a post about this before, but I tried searching and haven’t had much luck.

We have a Neo550 for our shooter uptake that seems to stall from stopped under minimal load. It’s connected through a 9:1 planetary gearbox, direct to an axle with 2x 2" light-gray Compliant wheels, connected by chain 1:1 to another axle with 2 more 2" wheel.

When we start the motor with no load, it doesn’t actually spin. This occurs regardless of input value. If we manually twist the motor casing a tiny bit, it will spin perfectly fine, at least until it goes back to stopped.

Any thoughts?

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The thread I saw saw like that was due to a bad crimp on one of the three motor leads.

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After quick inspection, the wiring looks fine. All powerpole connectors, so we’re going to try popping them off and inspecting more later since it’s currently attached to the mechanism and not easy to get to.

Did you accidentally reverse the ground and signal cable? When wiring, we accidentally did that, didn’t catch it, and it let out some magic smoke…

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When you get around to inspecting the power poles, take a close look at the crimps. Please excuse my MS Paint diagram:


You should feel a bit of give when the contact is fully seated. The movement allows the two mating contacts to interface well.

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We pulled the powerpole housing off of both sides of the controller <=> motor connection, and everything was visually fine. Reconnected it and it seemed to work fine now, so I guess it was a wiring problem. Weird thing because that motor worked fine when connected to a different controller, and that controller worked fine when connected to a different motor.

Negative. Wiring polarity was all good. No magic smoke

Yeah, we’re veterans with those connectors, so no issue there. Everything looked/felt fine before we took it apart

Thanks for the drawing though. I might have to “steal” it for training next year’s rookies

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Sounds like an encoder error, check the sensor wire

I have had similar issues I think. Does it behave as shown in the video in the album below?

We saw the same behavior on different motors so figured it to be a motor controller issue. We are running the most recent firmware and reset all to factory defaults and still had this issue.

Upon emailing Rev they suggested it was a crimp problem and asked for photos. I took some photos and then pried off the connectors but didn’t see any issues with the crimp job. Anyone see something that I missed in the photos?

Crimps look fine to me. I assume you checked the motor-controller side as well?

Yea, I did. I really hate not knowing what went wrong with it as we have quite a few neos and neo 550s on our robot this year.

It looks like you stripped too much insulation. See the diagram I posted above.

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