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Electrical motors are excellent tools utilized in various ways, making things more straightforward in our daily lives and a broad range of industrial applications. However, when these motors fail, the operation typically comes to a standstill till they’re functioning perfectly. The diagnosis for electrical motor breakdown might range from the ordinary to the utterly strange.
While the list of probable fault reasons might go on endlessly, we’ll look at some of the most prevalent causes of malfunctions in electric motors.
Common Causes of Electric Motor Failures
To assist you better in addressing and understanding the most common electric motor failures, we have listed the usual causes by consulting with an expert.
1. High Temperatures And Overheating
Most motor failures and deterioration can be due to exposure to extreme heat. Your first concern should be to ensure that your motor runs in the range of functioning temperature.
In most cases, electrical motor failure results in excessive heat generation. Research shows that exposing the insulation in the motor windings to an additional 10° C of heat will reduce the operating life in half. Even a slight increase in temperature might cause problems over time.
2.Accumulation of Dust And Debris
When it comes to protecting electric motors from dust and pollutants, enclosures are used commonly. However, if the enclosures are not Ingress Protected to the appropriate grade, tiny particles can still get inside.
Just as with any other machine, this exposure may cause damage to electrical motor parts, which can ultimately result in failure. Based on the type of contamination involved, the damage might vary from component degradation due to corrosion to interruption in the current, among other possibilities.
3.Sudden Power Surges
Like all other electric equipment, electric motors require sable electricity to operate efficiently. It is quite likely that a device has failed if the supplied voltage and current exceed the limit set by the device or motor in question. That’s why many industries have installed variable speed drives to reduce the impact of any unanticipated spikes in electrical power. Consider seeing an expert if your electric motor lacks variable speed drives.
4.Wear And Damage of Bearing Over Time
Bearings are essential to the operation of an electric motor, but they are often disregarded. Overheating, poor lubrication, and excessive drag are just some of the problems that might cause one of these tiny bearings breaks. Bearing problems can be caused by various factors, the most prevalent of which are motor imbalance, extreme load management, and poor fitting.
More Interested: PREDICTIVE MAINTENANCE
Bearing failures in electric motors account for 13% of all actual failures. You can detect early bearing deterioration or failure indicators by monitoring the motor continuously. This is an excellent technique to determine whether your electric motor’s bearings are damaged before it becomes a headache.
5.Humidity and Moisture
We can’t say that electrical equipment gets along well with moisture. And, it’s almost impossible to keep your facility dry and free of moisture and humidity. Your electrical motor’s insulation can be damaged by moisture (and greater exposure to water), affecting the motor’s overall life and putting your life in danger.
For this reason, it is crucial to choose a location where to store your motor safely. Moreover, try to install humidity-control and monitoring devices near the motors.
Several variables and possible causes might disrupt an electric motor and impair its performance in the long run. The key to ensuring your equipment continues to operate at peak performance for as long as possible is to adapt long-term preventive maintenance as well as predictive maintenance to your facility.
If you are experiencing a motor problem, contact a specialist immediately. If not, contact us before you face a problem with your 3-phase electrical motors.
Often the driving component of an application, electric motors play a central role in machinery in every industry. A failure in this critical piece of machinery could be catastrophic to the business, with the potential for high costs and a long period of downtime.
Understanding the common problems that can occur with electric motors can allow you to put measures in place to avoid failure and give your electric motor the best possible chance of achieving its maximum possible service life.
1. Low resistance
Low resistance is the most common cause of failure in electric motors. It is also often the most difficult to overcome. Under conditions such as overheating, corrosion or physical damage, degradation of the insulation of the internal windings of the motor may occur. This then causes insufficient isolation between the motor windings or conductors, leading to short circuits, leakages and eventually motor failure.
Regularly inspect the insulation of the windings for signs of wear and replace before low resistance leads to failure. If you are unsure, consult an expert.
2. Overheating
Overheating is generally caused by either a high temperature in the operating environment or poor power quality. It is responsible for around 55% of insulating failures in electric motors. For every 10 degrees Celsius that the temperature of a motor rises, the insulation life is reduced by half.
To avoid overheating, ensure that electric motors are kept as cool as possible. This can be done by maintaining as cool an operating environment as possible and regularly checking the temperature of the motor.
3. Electrical overload
Electrical overload is also commonly referred to as overcurrent. It is caused by an excessive flow of current within the windings of the motor, which exceeds the design current that the motor is able to carry efficiently and safely.
Overcurrent is often the result of a low supply voltage, which results in the motor drawing in more current in an attempt to maintain torque. Electrical overload can also be caused by short-circuited conductors, or an excessive voltage supply.
It is important to install effective overcurrent protection which is able to detect overcurrent and interrupt supply to protect the motor.
4. Vibration
Vibration can be extremely damaging to electric motors, frequently causing premature failure. It is often caused by the motor being positioned on an uneven or unstable surface. However, vibration can also be a result of an underlying issue with the motor, such as misalignment or corrosion.
Electric motors should be regularly inspected for vibration using a motor analysing tool.
Ensure that electric motors are positioned on a flat and stable surface. If vibration still occurs, check for signs of wear, as well as misalignment or loose bearings. Consider contacting a specialist if the source of vibration cannot be easily identified.
5. Contamination
Electric motors frequently operate in environments where dust, dirt and chemicals are present, which may find their way inside the motor, leading to contamination and motor failure. These contaminants can dent bearing raceways and balls, leading to high levels of vibration and wear. They may also block the cooling fan, limiting the motor’s ability to regulate its temperature and increasing the chances of overheating.
As contamination is one of the leading causes of failure in electric motors, it is essential to prevent it from entering the motor. Luckily, this is relatively easy.
Ensure that work areas, tools and fixtures are kept as clean as possible at all times to help eliminate the chances of contamination entering the motor. When laying out the workspace, try to position motors away from applications such as grinding machines which product large quantities of harmful contamination.
Electric motors are the driving component of a vast range of applications across every industry, and regular inspection is essential to reduce the risk of premature failure. If you are in doubt about the condition of your motor, it is always advised to contact a specialist for further investigation.
At ACORN, we have a dedicated couplings and drives division who are on hand to provide you with expert advise and guidance when you need it the most. Contact our knowledgeable couplings and drive division to discover how they could help you to improve the efficiency and reliability of your electric motor.
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