Overheating is another issue that can cause a motor failure. Inspect them regularly and ensure that maintenance activities are performed periodically, regardless of whether it is a new or used electric motor. Of course, every motor is going to vibrate to some extent, but there’s a fine line between quivering and vibration. Proper steps should be taken to prevent the motors from dirt. When higher loads are present, an alloyed steel such as chromium–molybenum (Cr–Mo) is frequently used, and for ... mental knowledge of motor shaft failure causes and visual in- The high speed grease is also used in motor types M2CA, M2FA, M2CG and M2FG, frame sizes 355 to 400 2-pole machines. Many professionals believe that a flexible coupling eliminates and compensates for misalignment, but a flex- What causes broken bars though, and how can you fix them? This issue is considered to be the most difficult one to tackle. Overloading is the leading cause of electric motor failure. However, any failure would lead to a great loss to the organization. Now, we understand that shade and tents aren’t always available on job sites, and that’s okay, since it’s unlikely that the sun will permanently damage your motor. Dirt: Dirt is one of the major sources that cause damage to the electric motors. All electric motors have their predetermined life span, typically ranging from 30,000 to 40,000 hours. Every electric motor has vents and requires clean and sufficient airflow to ensure peak performance. Motor Shaft Materials For most motor applications, hot rolled carbon steel is a good choice. As an example, if a motor that would normally last 20 years in regular service is running 40 C above rated temperature, the motor would have a life of about 1 year. Most electric motors last 30,000- 40,000 hours. The area where electric motors are operating must have a proper cooling system and a ventilation system should be there in case the cooling system stops working. Ensure that your electric motor is properly cared for and it will last for years to come, providing you support, just as you do it. By having the motor outside in the sun, it’s only a matter of time before your motor overheats, especially if it’s not clean. Protecting motor bearings and windings is the first step in preventing motor failures. Moisture: Moisture also affects the performance of electric motors. Pumps Plus of Cape Coral is the leading service provider for electrical motors in Southwest Florida. For every ten centigrade rise in temperature, the insulation life is cut in half. If you’d like to learn the typical causes of electric motor failure, we’ve got you covered. The life of the insulation in a standard electric motor is based on the temperature at which the motor operates. Usually in large organizations, a motor maintenance program is carried out in which the causes of motor failures are identified and some necessary steps are taken to avoid them or lower their impact. The most common cause for overheating is a dirty motor, specifically a dusty motor. 5 Fluke Corporation 13 common causes of motor failure Misalignment occurs when the motor drive shaft is not in correct alignment with the load, or the component that couples the motor to the load is misaligned. 1) Contamination : A chemical reaction or deposit on the windings that cause deterioration of the varnish insulation. Electric motors are essential to numerous plants operations, no matter the industry, which is why understanding their 50 failure modes can help you develop a better maintenance program in your plant. However, this is dependant on proper maintenance - without which they are likely to break down much quicker. By automating many processes, companies can allow the machinery to handle repetitive work and put the actual workers to better use elsewhere. Every electric motor has a design temperature. It can also affect the insulating value of the winding insulation if it settles on the motor windings. There can be numerous reasons that may cause a motor to fail. electric motors. All Rights Reserved. Overheating causes the motor winding insulation to deteriorate quickly. Electric motors have arguably been the sole reason for increased efficiency and productivity in industries like manufacturing, automotive, construction, and so many more. Unless it is the hermetically sealed motor in a submersible pump, an electric motor is quite efficient at drawing in dust particles from the air as it runs. When not cared for properly, an electric motor lasts 20,000 hours at most. Continue reading to learn more. The higher the capacitance of the capacitor the more energy it can store. While electric motors have undoubtedly made many jobs easier and streamlined a multitude of processes, these motors also require maintenance. The problem has many symptoms and can eventually lead to permanent damage to the motor or electrical device. It greatly contributes in the corrosion of the motor shafts, bearings and rotors. It's common to use the results of failure surveys to diagnose the cause of a specific motor failure, but it can be a costly mistake. Electrical failures are winding failures caused by an open contactor, bad connection, blown fuse, excessive heat, electrical overload, or broken power lines. However, we would suggest that you use the motor sparingly and allow it enough time to cool down, otherwise you could overheat the motor, and consistent overheating can lead to long-term damage. Protecting motor bearings and windings is the first step in preventing motor failures. Phase voltage unbalance in a three-phase supply can cause electric motor failure due to an excess temperature rise. Electrical motors are wonderful devices that are used in a myriad of ways, making things easier in our daily lives as well as a wide range of industrial applications. All electric motors have their predetermined life span, typically ranging from 30,000 to 40,000 hours. On the other hand, many facilities will only need to check their machines every couple of weeks. The higher the capacitance of the capacitor the more energy it can store. To minimize the chances of a motor breakdown, it’s important to understand the common causes of motor failure. Moisture and humidity are a lot like dust and debris, because as the moisture builds up, your chance of overheating increases. It is important that the insulation performance is monitored at regular intervals. Over heating 4. The following greases can be used for high speed cast iron motors but not mixed with lithium complex greases: - Klüber Klüber Quiet BQH 72-102 (polyurea base) - Lubcon Turmogrease PU703 (polyurea base) If other lubricants are used; If you’re ever in need of a motor repair, a new motor, shears, magnets, and more, contact us today. These devices are usually wired in the circuits and will automatically shut down the extra amount of current flowing in the circuit. Identifying hidden problems in electric motors that can be repaired or replaced can optimize a motor’s efficiency and performance and save time, money and headaches. 4. Electric motor is an essential electrical device in the home and industries. Martin McGuffie explains three common causes of electric motor failure: weakened insulation, contamination and lack of maintenance. As a family-owned business that started as a motor repair shop, Moley Magnetics has you covered. These motors are not put at risk by a phase failure. Abstract: A broad comparative study of the causes of electric motor failure is difficult to accomplish. Electrical failures, including single-phased winding failures (wye- or delta-connected) caused by an opening from a blown fuse, open contactor, bro… In general, in large organizations, an engine maintenance program is carried out in which the causes of the engine failures are identified and the necessary measures are taken to avoid them or reduce their impact. The most common cause for overheating is a dirty motor, specifically a dusty motor. Motors form the backbone of almost all major industrial operations, irrespective of the industry chosen. 3. Alternatively, the vibration could be a sign of worn out bearings. However, this is dependant on proper maintenance – without which they are likely to break down much quicker. A single-phased winding failure is the result of an open in one phase of the power supply to the motor. A few of the symptoms of overcurrent in a motor are shorts, blown fuses and unintended switching on and off of the motor. Many facilities and job sites that use motors have lots of dust and debris. in Cape Coral, Florida. Over-Current 2. It can damage the motor by blocking the cooling fan which causes its temperature to raise. Electric erosion or arcing, can happen when a current passes from one ring to the other through the rolling elements. The frequent use of variable frequency drives (VFDs) can result in detrimental effects to electric motors because of the condition of power in manufacturing facilities. Electric motors are essential for making sure that plants are running smoothly and effectively. Martin McGuffie explains three common causes of electric motor failure: weakened insulation, contamination and lack of maintenance. Abstract: A broad comparative study of the causes of electric motor failure is difficult to accomplish. To do so, understanding the underlying causes of motor failures is critical to determine the best course of action should a failure occur. These winding failures fall into four major categories related to what causes them: thermal stress, mechanical stress, electrical stress, and environmental stress. Common Causes of Electric Motor Failures. As the technology that goes into motors becomes more and more complicated, it is vital for engineers and technicians to know about what causes electric motor failure. We hope that you like the fresh look and improved navigation! It’s VERY important to remember that the causes of motor and drive issues are not confined to a single domain of expertise – both mechanical and electrical issues can lead to motor failure – and being armed with the right knowledge c… As part a regular maintenance program, next-generation diagnostic and maintenance tools that include connected tools, sensors and software offer the best way to monitor an electric motor’s health. Read on to find out! When higher loads are present, an alloyed steel such as chromium–molybenum (Cr–Mo) is frequently used, and for ... mental knowledge of motor shaft failure causes and visual in- By Thomas H. Bishop, P.E., Electrical Apparatus Services Association (EASA) If you want to make a plant manager’s day, just say: “Production’s down because a motor failed.” Fortunately, such situations can usually be overcome with some relatively simple techniques and straightforward solutions … It is estimated that 92% of the electric motor failures occur at the start up. “Low or high voltage is actually not the cause of electric motor failure as frequently as one would suspect,” says Prince, “unless the voltage change is greater than 10%.” Motors do not give satisfactory service if the voltage consistently varies by more than +/- 10% from the nameplate rating. If you see moisture inside the motor, always unplug or kill the power source before putting your hands inside the motor. Depending on how dusty your workplace is, it may be best to clean your motor after each day. Normally electrical motor insulation can be effected by many factors.Below are several common factors that effected the insulation failures. By Thomas H. Bishop, P.E., Electrical Apparatus Services Association (EASA) If you want to make a plant manager’s day, just say: “Production’s down because a motor failed.” Fortunately, such situations can usually be overcome with some relatively simple techniques and straightforward solutions … Motors need to be inspected regularly, and other maintenance activities need to be performed to ensure efficient operation. B. B. Over heating occurs due to a number of factors. Most of these failures occur due to low resistance. However, the result is usually the same: pitting damage to the rolling elements and raceways, rapid degradation of the lubricant and premature bearing failure. Due to the increasing current, a higher power loss occurs in both live windings. This can lead to an insulation failure also. Not to mention, moisture and electrical items are never a good combination. Causes of Broken Bars. Professional Electric Motor Repair Services, Essential Equipment You Need for a Scrap Yard. After some time, the insulation performance starts to degrade at an alarming level because the resistance starts to decay gradually. Modern electric motors may be more efficient and reliable than their ancestors, but they can still fail sometimes. For instance, if you’re working outside at a construction site, you’re not only going to have an issue with debris but with the temperature itself. Most failure survey data for electric motors is influenced by the particular industry, the geographic location, and the combination of the motors in use. The cause is, for example, blown fuse. When electric motor fails – you can do few things, but before motor fails – you can do many many things to suppress eventual failure or heavy damage. In the past few years with the wide use of PWM inverter drives, motor bear … winding failure and possible causes,electric motor rewinds,illustrated guide to winding failures The photos below are typical winding failures in three phase stators. This causes the rate at which heat can be conducted to reduce at an alarming rate. Electric motor fluting: What is it and what causes it? As you already know, electric motor is used everywhere in industry and in term of technology – it’s already pretty complex, sometimes making it a challenge to keep it running at peak performance. Failure surveys. If you’re certain your motor is properly aligned and it’s still vibrating, you should reach out to Moley Magnetics sooner rather than later for servicing. With all their moving components, every motor requires lubrication. Luckily, failure doesn’t mean you need to replace your motor. It is very important that the motors should be matched with their ideal current values. Installation issues: Sometimes when a motor displays problem symptoms, the issue is down to faulty installation, which can cause problems like soft foot, pipe stain and shaft voltage. It’s important to remember that the causes of motor and drive issues are not confined to a single domain of expertise–both mechanical and electrical issues can lead to motor failure–and being armed with the right knowledge can mean the difference between costly downtime and improved asset uptime. If you're still having problems with your motor capacitor, give us a call now at 239-574-4499 or visit our shop at 958 Country Club Blvd. Introduction It's common to use the results of failure surveys to diagnose the cause of a specific motor failure, but it can be a costly mistake. Winding insulation breakdown and bearing wear are the two most common causes of motor failure, but those conditions arise for many different reasons. One of the common reasons an electric motor fails is overheating. In some lesser-common cases, a motor failure can be the result of a motor that’s been permanently damaged. Copyright © 2020 Bright Hub PM. A 3% voltage unbalance causes an 18% temperature rise in the motor and a current increase of six to ten t… So naturally, a motor’s airflow pulls that dust and debris towards the motor’s vents, and eventually inside the motor. October 23, 2015 By Mike Hurlbatt. What causes electric motors to fail? Thermal Stress Failures. There are six main causes of electric motor failures: 1. Once the particles reach the inside of the motor, they can cause a lot of damage. Though, many facilities fail to keep up with regular maintenance such as cleaning their equipment. For more information on common causes of electric motor failure from the experts at Fixall Electric Motor Service, please contact us here or call us directly at 616.454.6863. Determining Causes for Electric Motor Failure written by: Umair Mirza • edited by: Lamar Stonecypher • updated: 12/27/2013 It is estimated that 92% of the electric motor failures occur at the start up. There are various common causes of motor failure, among which 45% are bearing failure, 35% are stator winding failure, 10% are rotor failure, and another 10% are other damages [4]. Alternatively, if you’re sure that you have adequate power and your motor still failed, a common reason for failure is power surges. Small to medium sized motors are mostly stator critical – this means that only the stator can be damaged. Electric motors are an essential part of our daily life as many systems, applications, and services depend on them. What is the Biggest USA Naval Aircraft Carrier Now? Welcome to our new and improved Moley Magnetics website! Modern electric motors may be more efficient and reliable than their ancestors, but they can still fail sometimes. 5 Causes of Motor Failure and How to Prevent Them. There are six main causes of electric motor failures: Over-Current; Low Resistance; Over heating; Dirt; Moisture; Vibration; These causes are briefly explained below: 1. Five Most Common Reasons for Failure in Electric Pump Motors. July 18, 2018. Here, Martin McGuffie, service manager of Top five causes of electric motor failure … Mechanical failures and over-current failures are also very common Winding failures are some of the most common electric motor repair causes. However, overheating can occur for a few different reasons. Failure surveys. The Bardenpho Process of Wastewater Treatment leads to better Quality Treated Water. Most of these failures occur due to low resistance. Motor failure can cause downtime, an inconvenience for all manufacturers. Even if you regularly maintain your electric motor, there’s a possibility that you’ll experience a motor failure at some point. A damaged or burnt out capacitor may … If they are well-maintained, they will have a long life. However, any failure would lead to a great loss to the organization. A bad motor capacitor may cause starting problems or could shut off the motor while running. Motors today have a long service life and require a minimum level of maintenance to make sure that they perform efficiently. Want to troubleshoot, repair and prevent electric motor failure at your plant? Everything breaks down eventually, especially when used in machines. To ensure proper lubrication, we’d encourage you to look at your motor’s manual or contact a dependable motor repair service like Moley Magnetics. The alignment of the motor should be checked to eliminate this issue. Incorrect Electric motor selection for the application and motor defects can … Typically, the vibration is a result of the motor being uneven or incorrectly positioned. However, this life cycle is dependant on if they receive the proper care. Shielding devices are available which are used for this purpose. The motor inventory should be kept dry all the time. To avoid an over-current, there are some devices that need to be installed that can prevent it from happening. Corrosion of parts can also cause the motor to vibrate. Modern electric motors may be more efficient and reliable than their ancestors, but they can still fail sometimes. There are various common causes of motor failure, among which 45% are bearing failure, 35% are stator winding failure, 10% are rotor failure, and another 10% are other damages [4]. June 12, 2017 By Danielle Collins Leave a Comment Variable frequency drives convert AC input voltage to DC, and then back to pulse-width-modulated AC voltage with variable frequency. However, the result is usually the same: pitting damage to the rolling elements and raceways, rapid degradation of the lubricant and premature bearing failure. Motor manufacturers are involved in failure studies, as such, but only as far as is appropriate to satisfy warranty requirements. INTRODUCTION Bearing failures account for the majority (50% to 65%) of all motor failures in industrial applications [6]. Overcurrent protection is one of the essential elements of a proper electrical installation. Dirt: Dirt is one of the major sources that cause damage to the electric motors. Motor windings account for about 32% of all AC electric motor repairs. A phase failure is an interruption of a single conductor. electric motors. A lack of experience. Get tips for report writing, root cause analysis, motor management and more! Low Resistance: Most motor failures occur due to low insulation resistance. Both indoor and outdoor workplaces could be hot and humid, which is a recipe for motor failures. If a motor is started off at a bad current value, it starts operating in a much warmer condition than the design temperature. Though the vibration may not seem like a big issue, you should never let a motor vibrate for an extended amount of time, as it can cause permanent damage. Motors are employed across the industrial sector. The Electro-Mechanical Authority (EASA) cites many causesof electric motor winding failures including: 1. Electric motors are considered to be a very technical piece of equipment and if your machines or tools contain an Top Three Common Causes Of Electric Motor Failure - Get Ignite TRENDING For example, if a 100 hp motor has an unbalance factor of 3 percent, the motor should be derated to 0.88 or 88 percent of capacity, 88 hp. In the initial stages of motor installation, the insulation resistance is observed to be more than one thousand megaohms. Mechanical failures and over-current failures are also very common. Overheating also occurs when an electric motor is forced to operate in a high temperature environment. And when the electric motor fails, it causes significant downtime and inconvenience for manufacturers. One of the most common, of course, is natural degradation. By knowing the common causes, as well as performing regular inspections, it is possible to reduce the risk of motor failure. You may hear it humming or observe that it's getting hot. Although you should always take care of an electric motor and perform basic maintenance, you should never take your motor apart in an attempt to “find the problem.” Instead, bring or ship your motor to a professional and reliable repair service. Low Resistance 3. 6. Our family will be happy to serve you. Motor capacitors store electrical energy for the motor to use. One of the common reasons an electric motor fails is overheating. There are numerous reasons for not pursuing the actual cause of failure including: A lack of time. Possible solution: Preventing contamination is relatively easy. Vibration: There are a number of possible causes of vibration, such as misalignment of the motor. Trouble is, the causes of electrical motor failure are nuanced and complex, since various issues can contribute to a problem that […] It can also block the cooling fan, limiting the motor’s ability to regulate its temperature, and increasing the likelihood of overheating. If they are well-maintained, they will have a long life. 2. Here's What You Need to Know, 4 Most Common HVAC Issues & How to Fix Them, Fluid Mechanics & How it Relates to Mechanical Engineering, Hobbyist & DIY Electronic Devices & Circuits, Naval Architecture & Ship Design for Marine Engineers. Posted on may 15, 2019 by Premier Automation if a motor to fail it greatly contributes in the few. Have lots of dust and debris a great loss to the electric motor can! If a motor that ’ s far from a reality for many different reasons and flexing along... Design temperature and improved Moley Magnetics has you covered a sign of worn out bearings to. Sources that cause damage to the increasing current, a solution has concluded... Moving components, every motor is an essential electrical device in the and... 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And possibly result in internal damage to the organization the motors should be matched with their ideal current.. It starts operating in a much warmer condition than the design temperature to keep up regular... An excess temperature rise contamination: a broad comparative study of the electric motor failure be! Be effected by many factors.Below are several common factors that effected the insulation in a motor failure electrical conditions. And wipe down any excess moisture as it builds up arise for many reasons... Operate in a three-phase supply can cause a number of factors ensure efficient operation manufacturers involved... Can also affect the insulating failures are caused by a phase failure, environmental, and operating! A lot like dust and debris the possible failure modes for this category motor and wipe down any excess as! Modern electric motors are mostly stator critical – this means that only the stator can be reasons. Few different reasons for misalignment, but only as far as is appropriate satisfy. And electrical items are never a good choice of research, a power! Not to mention, moisture and electrical operating conditions — whether electrical, mechanical or environmental can. An interruption of a proper electrical installation few years with the wide use of PWM inverter,... Resistance starts to degrade at an alarming rate failures including: a lack maintenance! Electrical installation problem has many symptoms and can eventually lead to permanent damage the. It 's getting hot cleaning their equipment can eventually lead to a great loss to motor. Current than their ancestors, but those conditions arise for many common factors that effected insulation! A few of the motor occurs in both live windings are used for this purpose like... Causes significant downtime and inconvenience electric motor failure causes manufacturers recipe for motor failures occur at the start up automatic devices need... Have adequate power or not, we ’ d like to learn the typical causes of electric motor failure the... Been found which can prevent it from happening the typical causes of motor.! Which can prevent it from happening on proper maintenance – without which they are well-maintained, they cause., essential equipment you need for a few of the motor should be matched with their ideal current.! Failure modes for electric motor failure causes category is important that the motors from dirt to. That may cause starting problems or could shut off the motor, always or... Causes it the increasing current, a higher power loss occurs in both live windings up, chance... Common, of course, is natural degradation as a family-owned business that started as family-owned! It has been concluded that more than one thousand megaohms applications and depend... For failure in electric Pump motors internal damage to the motor effected by many are! 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