Factors That Contribute to Motor Failure and Their Prevention

Every motor has a certain lifespan, usually between 30,000 and 40,000 hours of operation. But, it is contingent on getting the proper treatment; in the absence of it, then it is highly likely that they’ll fail quicker.

“Maintenance” or “maintenance,” or “technical maintenance,” is an assortment of processes designed to ensure constant and reliable operation of different assets, including machinery and equipment. Implementing a comprehensive maintenance program is key to the performance and endurance of equipment, buildings, support, and businesses.

Preventing Motor Failure

Inadequate maintenance reduces the lifetime of equipment, increases the frequency of breakdowns, adds to the cost of repairs, and can slow production. If you are aware of the most frequent causes of motor failure and what you could do to reduce your chance of suffering one of these failures, you can make sure that your motor lasts for as long as possible.

1. Low Resistance

The low resistance of motors is the most frequent cause of motor failure and perhaps one of the most challenging problems to correct. The effects of corrosion, overheating, or damage to the windings may weaken the insulation, leading to a decrease in resistance.

Insufficient isolation between the conductors or windings of the motor can be the consequence and can lead to short circuits, leaks, and even motor failure. The insulation must be inspected routinely for symptoms of deterioration and changed before low resistance is sufficient to cause failure.

As a component of their preventative maintenance offerings, several businesses provide premier precision balancing services. Providing this service often involves the creation and development of specialized apparatus and tools for the purpose of fixing and balancing various types of machinery.

2. Overheating

Overheating is the most common reason for 55 percent of motor insulation problems. Poor power quality or an excessive operating temperature could cause overheating. The life of a motor’s insulation decreases by half for every ten degrees Celsius rise in temperature.

A cool, comfortable working environment helps reduce the risk of motor failures. The motor must be maintained at a comfortable temperature.

3. Electrical Overload

An electrical overcurrent or overload occurs when excessive current flows inside the motor’s windings. This current flow is more than the design current that the motor can manage effectively and safely. This may be caused by an insufficient supply voltage which causes the motor to require additional current to keep its speed. A high supply of electricity can also trigger short circuits.

To avoid electrical overload, it is necessary to set up proper overcurrent protection to detect overcurrent and shut off the source.

4. Vibrations

Vibration may create various issues for the motor, such as premature failure. The motor will likely vibrate when placed on an uneven or unstable surface. It is also possible that the vibrations could be caused by motor problems, like damaged or misaligned bearings or corrosion.

It is essential to monitor vibration regularly using an analyzing tool. Make sure the motor is on a level, sturdy surface to stop vibration. There might be misalignment or wear causing the vibration; if so, check for these factors. If the exact cause of the vibration is indeterminate, you might want to seek a professional.

If low-speed balance is not utilized to alleviate vibration concerns, there is a danger that mechanical failure may occur. This risk can be reduced, however, by using low-speed balancing. You might look out reputable businesses that provide turbine balancing services on the internet, or you could ask the individuals you know for recommendations.

5. Contamination

Dust, dirt, and chemical contamination are some of the most frequently cited reasons for motor failure. The objects that enter the motor may damage ball bearings and raceways, resulting in excessive wear and vibration that could pose a danger. It may also obstruct an air cooling system, thus reducing the ability of the motor to manage its temperature and raising the chance of overheating.

Maintain all work surfaces, equipment, tools, and other work surfaces clean to minimize the risk of contamination getting into the motor. If you can, ensure that motors are kept away from grinding machines known for spewing enormous quantities of pollutants.

Companies that engage in condition based monitoring and predictive maintenance make use of the most cutting-edge technology and computer analysis that is currently accessible. This helps these companies identify problems with machines and make arrangements for their repairs.