Anybody feel like helping me troubleshoot a controller board for an elliptical machine?
I've put the word "resistance" in quotes when I'm referring to the mechanical resistance the machine creates to help avoid confusion between that and Ohms flavor resistance.
It has a "resistance" control, which mechanically is a drum of magnets that is brought closer to or farther from a flywheel drum. The adjustment control has essentially a radio-control servo type thing, i.e. it's a 6V DC motor geared down for very high torque (much larger than an RC servo, but essentially the same function). Then there is a potentiometer attached to feed back position.
What's happening is if it's mechanically set for high "resistance" on the flywheel (magnets close) you can push the <down> button and it will move the servo, pull the magnets away in a controlled way (i.e. will move it one step at a time as per <down> button pushes) until it reaches the "low resistance" end of the travel. Thus the potentiometer is working properly and even the motor works properly going the one direction
So far so good.
The problem is that if it's low and you ask it go increase the flywheel "resistance", it doesn't function for that direction. I connected a multimeter to the motor leads coming from the control board and it does switch back & forth between +6V and - 6V if I manually move the potentiometer. So the controller seems to be sending appropriate voltage in concordance to the pot setting.
I suspected it isn't sending enough current. So I hooked up to the motor leads a bench power supply set to 6V. First I moved the motor back & forth manually. It works fine. Then I hooked it up in parallel to the leads coming from the controller. If I set things so it wants to move the potentiometer in the problematic direction, with the additional current of the power supply set just barely high enough to move the motor, it does move the motor until it hits the proper position, then the controller sends the opposite polarity down the motor leads and stops the motion. i.e. the additional current boost from my power supply hacks the setup so it will move the motor in the problem direction until it hits the target position, then the controller flips polarity on it's motor leads and this stops the motor. I am of course immediately unplugging things at this point to minimize the fight as much as possible.
OK that's not a very clear explanation of what's going on, but it's about the best I can do.
So anyway, I suspect there is a transistor on the controller board that is faulty and isn't amplifying current properly in the problem direction anymore. Am I on the right track? There are some through-hole transistors that are possibly the culprit, but I thought I'd try to see if somebody felt like holding my hand on this first. I'm pretty green on this electronics stuff. I can take some photos of the board and such if somebody wants to help me troubleshoot this thing. In fact I'll do that anyway, and label the wires and such, then upload it here. In the meantime, a yay on offer to help will inspire me to keep poking on this thing.
There doesn't appear to be any obvious magic smoke prison breaks.
Thanks for any help.
Sorry my articulating is so clumsy.