Electric Motor Repair and Rewind is a process used to restore and refurbish electric motors that have malfunctioned or have worn-out components. These services help to extend the lifespan of motors, reducing the need for costly replacements. Here’s an overview of the key steps involved in electric motor repair and rewind:
1. Initial Inspection and Diagnosis
The motor is inspected to determine the cause of failure, which could range from electrical issues (like winding faults), mechanical wear (bearings, shafts), or environmental damage (dirt, moisture).
A thorough inspection is done to assess the motor’s overall condition.
2. Disassembly
The motor is carefully disassembled, and all components are removed, including the stator, rotor, bearings, and windings.
During this phase, any visible damage to parts like the housing, bearings, or other mechanical parts is noted.
3. Cleaning
Components are thoroughly cleaned to remove dirt, dust, oil, and other contaminants. This can involve high-pressure air cleaning, solvent washing, and sometimes ultrasonic cleaning.
This step ensures that no debris will interfere with the motor’s proper function once reassembled.
4. Winding Inspection and Rewinding
The stator windings are inspected for damage. If they are worn, damaged, or burned out, they will need to be rewound.
The old windings are carefully removed, and the core is cleaned and prepared for new wire.
New winding coils are made, which match the motor’s original specifications, ensuring that it will function as it did when it was first manufactured.
Insulation material may also be replaced or repaired during this process.
5. Testing of Components
The repaired motor parts, such as the stator windings and rotor, are tested for electrical integrity using tools like megohm meters, which check for insulation resistance.
The motor’s bearings, shafts, and other moving parts are checked for wear and smooth operation.
6. Reassembly
After the rewinding and testing, the motor is reassembled carefully. Each component is put back in place, and the motor is lubricated to ensure smooth operation.
The rotor is balanced to avoid vibrations during operation.
7. Final Testing and Commissioning
The motor is tested under load conditions to ensure it operates as expected. This includes checking the voltage, current, insulation resistance, and operational performance.
The motor is also tested for temperature to ensure that it does not overheat.
8. Quality Control
A final inspection is conducted to make sure all parts of the motor function properly and meet performance standards.
If necessary, adjustments are made to the motor’s settings or components.
Electric motor rewinding should be done by experienced professionals who are knowledgeable about the motor type and its specific requirements to ensure long-term reliability and performance.