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Avoid splicing motor power cables when ever possible. Ideally, motor power cables should run continuous between the drive and motor terminals. The most common reason for splicing is to incorporate high-flex cable for continuous flexing applications.

In simple DC and universal motors, the rotor spins inside the stator. The rotor is a coil connected to the electric power supply and the stator is a permanent magnet or electromagnet. Large AC motors (used in things like factory machines) work in a slightly different way: they pass alternating current through opposing pairs of magnets to create a rotating magnetic field, which "induces" (creates) a magnetic field in the motor rotor, causing it to spin around. You can read more about this in our article on AC induction motors. If you take one of these induction motors and "unwrap" it, so the stator is effectively laid out into a long continuous track, the rotor can roll along it in a straight line. This ingenious design is known as a linear motor, and you will find it in such things as factory machines and floating "maglev" (magnetic levitation) railroads.

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There are two ways to overcome this problem. One is to use a kind of electric current that periodically reverses direction, which is known as an alternating current (AC). In the kind of small, battery-powered motors we use around the home, a better solution is to add a component called a commutator to the ends of the coil. (Do not worry about the meaningless technical name: this slightly old-fashioned word "commutation" is a bit like the word "commute". It simply means to change back and forth in the same way that commute means to travel back and forth.) In its simplest form, the commutator is a metal ring divided into two separate halves and its job is to reverse the electric current in the coil each time the coil rotates through half a turn. One end of the coil is attached to each half of the commutator. The electric current from the battery connects to the motor electric terminals. These feed electric power into the commutator through a pair of loose connectors called brushes, made either from pieces of graphite (soft carbon similar to pencil "lead") or thin lengths of springy metal, which (as the name suggests) "brush" against the commutator. With the commutator in place, when electricity flows through the circuit, the coil will rotate continually in the same direction.

The first thing you will need to discover is whether you are dealing with a three-phase motor. You may already know this from the application, but another giveaway is that the lead wires of most three-phase motors are single colors, not multiple colors, and usually identified with numbers. If, on the other hand, the motor diameter is less than seven inches and has a terminal board, it is most likely a single-phase motor.

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