Every electric motor has a specific lifespan, typically between 30-40,000 hours of operation. However, this is contingent upon that they receive the proper treatment. In the absence of such, it is quite probable that they’ll fail far more rapidly.
The term “maintenance,” or “technical maintenance,” is a collection of procedures that aim to ensure the uninterrupted and effective functioning of different assets like machinery and equipment. A reliable maintenance plan is crucial to the effectiveness and long-term durability of equipment assets, buildings, and companies.
Preventing Motor Failure
Lack of proper maintenance lowers the life span of equipment, increases the frequency of breakdowns, raises the cost of repairs, and can slow production. If you know the most prevalent reasons for motor failure and what you could do to reduce your chances of experiencing one of these breakdowns, you can help your motor last for as long as possible.
1. Low Resistance
The low resistance of motors is the most prevalent reason for motor failure and perhaps one of the most challenging problems to address. The effects of corrosion, overheating, or damage to the windings can weaken the insulation, resulting in low resistance.
Insufficient isolation between the conductors or windings in the motor is the consequence and can cause short circuits, leaks, and motor failure. The insulation should be assessed periodically for deterioration and replaced before the resistance can cause failure.
Companies provide precision balancing services as one of their maintenance services. This service typically includes the design and development of specialized equipment for repairing and balancing machinery.
Overheating is the primary cause of 55 percent of motor insulation problems. Poor quality power supply or a high operating temperature might cause overheating. The life of a motor’s insulation is reduced by half for every 10 degrees Celsius increase in temperature.
A cool working space will help reduce the chance of motor failures; hence the motor must be kept at a moderate temperature.
3. Electrical Overload
A surge in electrical power or an overcurrent occurs when excessive current flows within the motor’s windings. The current flow is greater than the amount of design current the motor can handle effectively and securely. This can be due to the low supply voltage, which will cause the motor to require additional current to maintain its speed. An excessive supply of electricity could also result in short circuits.
To avoid electrical overload, it is recommended to have sufficient overcurrent protection that detects overcurrent and shuts off the power source.
Vibration could cause an array of issues with the motor, including premature failure. The motor will vibrate when placed on an unstable or uneven surface. It is also possible that underlying problems with the motor cause the vibrations, for example, damaged or worn-out bearings or corrosion.
Monitoring of vibrations should be conducted regularly using an analyzing tool. Ensure the motor is on a level, sturdy surface to minimize vibration. There may be misalignment or wear causing the vibration. If you cannot identify exactly the cause of the vibration, you may want to seek a professional.
If low-speed balancing is not used to relieve vibration problems, there is a possibility that mechanical failure may occur. You may search for reliable firms that provide rotor balancing services through the internet, or you can ask the people you know for suggestions.
Dust, dirt, and chemical contamination are some of the most frequently cited reasons for motor failure. The objects that get into the motor can damage the bearing raceways and balls, which can cause excessive wear and vibration, which could be hazardous. Additionally, it could block the fan cooling, decreasing the motor’s power in controlling its temperature and increasing the possibility of overheating.
Keep all work surfaces, equipment, tools, and other work surfaces free of dust to reduce the chance of contamination entering the motor. If possible, ensure that motors are kept away from grinding equipment known to spew large quantities of pollutants.
Companies that engage in condition-based preventive maintenance make use of the most cutting-edge technology and computer analysis available in order to identify problems with machines and make arrangements for their repairs. To be able to experience the predictive maintenance advantages, you can employ the services of a reputable company that provide such service.