When to Repair or Replace a Worn Motor

Introduction

Are you aware that the number of micro to large electric motors in use globally is expected to be 2.25 billion? With so many motors in use worldwide, plenty need maintenance or replacement. Due to the high expense of the motor, motor maintenance is a contentious topic. Unless you need to repair a motor often or it is operating inefficiently, it is frequently far less expensive than replacing a motor.

Electric motors are used by various businesses today to increase the productivity of their operations. Although motors have undoubtedly made a huge difference in how businesses operate, businesses must also upkeep their motors to prevent disruption. You must understand how and where to determine if an electric motor fails to save more downtime and inefficiencies. If you understand what to seek in a motor, you may act early and save your motor from breaking down and being harmed.

You are wasting your cash if you repair a motor frequently before its current condition demands a component replacement. Furthermore, some damage may go undiscovered for a long period before needing replacement rather than repair when things ultimately go wrong.

Never a nice thing; motor failure usually happens when you least expect it. The only positive factor is the opportunity to assess your replacement and repair choice. You must be aware of the available repair alternatives and use a rational approach when deciding whether to repair or replace a motor to take full advantage of this opportunity. It is obvious that repairing an existing motor is considerably better for the environment than just throwing it away, yet sometimes, replacement is the sole choice.

How to Identify a Worn Motor

1) Examine the Shaft and Bearings

The motor’s bearings are among the parts that fail the most often in a motor. The bearings must be replaced over time because of normal wear and tear. Regular bearing inspections are necessary because utilizing any motor having worn-out bearings may harm the machine and decrease the effectiveness of the motor.

It is simple to examine bearings. To make sure the bearings move freely and smoothly, you just need to rotate them. Pushing and tugging the shaft to which the bearings are attached is another method of inspecting the bearings. The shaft should be capable of moving freely, and the bearings should be able to spin easily. You may need to replace the bearings if you notice any grinding, scraping, or sense of friction. When the friction is minimal, the oil may be all the bearings need.

2) Stronger Vibrations

You can experience more frequent and intense vibrations concerning the motor. If you notice excessive vibration, it is one of the first warning indications that it could be time to get a new one. This occurs due to improper operation of the motor’s internal components. As a result, vibrations will spread to surrounding components and endanger the workplace.

3) Very High Temperatures

Several factors might cause the motor to overheat. You must be aware that a case of extreme overheating might cause damage to the motor or even cause it to fail, whether it is because of an excessive current draw, a lack of ventilation to keep it cool, or friction brought on by worn components.

Whatever the cause, as long as you’ve observed that the motor is growing hotter than normal, it’s time to get it looked at by an expert before this breaks down entirely without any maintenance.

4) Power Surplus

When you start your motor and witness lights blinking, you will understand that overloading has occurred. If the situation isn’t too serious, you may quickly resolve this problem by hooking into a source of power that meets the necessary wattage and amperage specifications. Don’t forget to check that not too many computers are running simultaneously.

5) Using Up More Energy

Your electric motor-powered equipment is likely working harder to function effectively if it comes out that they are suddenly using more power than they typically do, resulting in dead batteries and an increase in electricity costs.

This indicates that the appliance’s different parts must be maintained immediately since they are worn out.

6) Use a Multimeter to Examine the Motor Windings

Naturally, an electric motor’s windings are essential to its mechanics. Regularly checking the windings for damage is necessary, but measuring their resistance is even more crucial. To test the windings, you will need a multimeter in the first place. Examine the motor’s wires and terminals by setting the multimeter to detect ohms. Check the windings for any open or short circuits in the circuit and in the windings. You must switch the multimeter towards ohms and unplug the motor from the point of its power supply to check your motor for shorts to ground. Then, examine each wire closely and search for infinite readings. In this case, if you receive a zero reading, you could have a cable problem. You should examine each cable separately to see whether it is defective and ensure no lead is in contact. You will be able to identify the problematic cable by testing each one separately. Conversely, if every cable gives an endless reading, there is a motor issue; thus, you should call a repair service.

7) Check the Power with a Multimeter

The efficiency of an electric motor depends on its power source. You may test the power supply using the preceding paragraph’s multimeter. Depending on the kind of motor, there may be differences in the procedure and optimal ratings for evaluating power supply. You should test the cables to ensure they comply with each motor’s required voltage ranges. The information you need for testing power will be included in your user handbook, along with instructions. While testing an electric motor’s parts, things rapidly get intricate, and if you’re inexperienced, errors are simple to make.

8) Be Sure That the Fan is Stable and in Good Condition

Too many individuals neglect to check and maintain the fan on their electric motor. Your motor’s efficiency depends on the fan since it maintains the motor’s temperature to remain cool to run for extended periods. As expected, particles and dirt may quickly block the fan, reducing airflow and trapping heat. While the fan’s exterior may seem quite clean, the fan might be slowed by dirt and particle buildup within. You must test the fan to ensure it revolves freely when you withdraw the fan covering to clean. Also, the fan and motor must be tightly fastened; otherwise, the fan won’t operate correctly, and the motor will overheat and fail.

Even though some of the preventive actions we discussed are straightforward, you must learn to determine whether any electric motor is malfunctioning. Having a trustworthy specialist to call on when you need support is important since certain motor testing techniques can necessitate their assistance. Even though many auto repair companies claim to be professionals, very few truly are. Thus, how would you possibly know which business to choose? The related service provider’s history, expertise, and integrity hold the key.

When a Motor Needs to Be Repaired

If a motor does malfunction, you aren’t required to replace it. An easy repair or substitute component may often bring your motor back to life. Your issue will be resolved shortly by this repair, continuing production. Keep in mind that not all failures are caused by the motor; sometimes, the gearbox malfunctions, necessitating the services of a gearbox expert.

1) The Motor’s Size

The expense of a prospective replacement depends on the overall size of the motor. However, we usually strive to give any motor repair option first. As a general rule, we will always opt for electric motor repair if the repair expense is lower than the replacement expense.

2) The Intensity of the Fracture or Damage

Getting an electric motor repaired is usually recommended if the harm to the motor isn’t excessively severe. If just a portion of the motor needs repair, it is a considerably more economical and ecologically beneficial option. We may also provide suggestions as to what may have caused the damage and assist you in developing a preventive measure to ensure several more seasons of trouble-free functioning.

3) Previous Catastrophic Failure

Occasionally, after only disassembly, while the components are examined and tested, proof of a previous catastrophic failure is found. A broken rotor core, a bent shaft that has bent again, and fractured or lost stator core iron are a few examples. Prefer to repair once more if prior attempts were successful and there are no signs of further degeneration.

Nevertheless, replacement may be necessary if the motor has already suffered a catastrophic failure that caused degradation. The few exceptions are situations in which it is possible to effectively and affordably restore the harm caused by both failures.

If you decide to repair or substitute the motor, figure out what contributed to the failure to avoid it happening again.

When a Motor Needs to be Replaced

Repairing your motor effectively won’t be possible after it has worn out and broken too many times. While it may be doable to repair your motor, doing so can be more expensive than replacing it. When that happens, you should start looking for a replacement, maybe an improvement from your current model. Think of the malfunction as a chance to update your whole setup.

1) Criticality and Scope of the Motor

Replacing an electric motor may be the best action if an inefficient or underperforming motor puts your business in danger of an impending operation or production disruption. By reducing production line downtime, this decision might ultimately save you time and money.

2) Catastrophic Failure

In the event of a catastrophic failure, compare the price of replacing the motor with repairing it. These failures often severely harm the windings, stator core, rotor, and end brackets. Under these circumstances, a replacement can be the most cost-effective choice, particularly if the motor’s appropriateness for the operation is in doubt.

The damage to the rotor comes in many forms, such as elevated bars or broken end rings on manufactured designs, as well as surface smearing from contact with the stator. Smearing on surfaces is often inexpensively fixable. Unless the motor is big or has unique characteristics, other types of rotor repairs might not be practical.

The shaft or other mechanical components might sustain damage that necessitates their replacement. Furthermore, unless the motor is particularly big or has specific characteristics, the expense of buying or fabricating a new shaft or acquiring a fresh frame may end up repairing a poorer appealing option than replacing the motor.

3) Energy-Conserving or Efficient Motors

The development of power-efficient motors in recent decades brought forth a new decision: swapping out a failing electric motor with a better energy-efficient one. Generally, energy-efficient motors include more recent, premium-efficient versions and those regulated by federal law. The same repair concerns apply to these electric motors and those with conventional efficiency.

Qualified service providers may fix any kind using industry-standard practices without impacting the efficiency rating. Based on the anticipated lifespan of the motor or process, think about the return on investment for a higher power-efficient replacement before fixing a standard-efficiency motor.

To accomplish this, compare the prices of repairs and replacements (together with the cost of any adjustments required for the new motor), and calculate the energy reductions for the anticipated operating hours. Remember that motors that run continuously will save more energy than those that run 8 hours per day. While bigger motors (250 hp and higher) already tend to be quite efficient, the changes in effectiveness among standard and higher efficiency versions are minimal for these capacities.

The second thing to consider is if you have the funds in your budget if the return-on-investment evaluation demonstrates that replacement is better than repair. Or else, you may still choose repair if it is less expensive than buying a new motor. The availability of a new motor is the next important consideration, assuming you have the money for one. If all the cases go in your favor, then certainly proceed with the replacement option.

Conclusion

The choice to replace or repair a motor has become much more critical due to the huge expense of plant downtime, the wide price range of motors, and a variety of innovative techniques for locating and correcting flaws.

As it’s usually preferable to prevent problems than fix them, many factories currently undertake frequent condition-monitoring studies to determine how a motor unit can malfunction. The only way to keep this from happening is to prepare beforehand.

You should be well-positioned for future earnings now that you know the finest motor maintenance and replacement procedures. Even when you have complete malfunctions, you should be prepared to handle the issue effectively to minimize revenue loss.

This entry was posted on June 5th, 2023 and is filed under Uncategorized. Both comments and pings are currently closed.