Electric motor repairs

Electric motor diagnostics, winding resistance measurements and rewinding, energy saving solutions

The wide range of applications for electric motors is a major advantage of these devices, not only in the home but also in industry. Electric motors power most of the equipment used in industry: grinding machines, compressors, higher torque water pumps and many others.

Repair and diagnosis of electric motors are essential procedures to ensure their long-term and efficient operation. When carried out correctly, these processes can prevent costly breakdowns, reduce downtime and optimise energy consumption.

Electric motor diagnostics

Diagnostics assesses the performance of the motor to detect early signs of failure, such as:

  • unusual noise
  • excessive vibration
  • overheating
  • reduced power
There are several methods for testing an electric motor
  • Insulation resistance measurement. This method allows to assess the condition of the insulation between the windings and the motor housing to avoid short circuits or insulation failures.
  • Winding resistance measurements. The resistance of each winding shall be checked to ensure that they are the same. Differences may indicate that the windings are worn or damaged.
  • Vibration analysis. Performed to identify mechanical defects such as worn bearings, worn bearing bores, rotor imbalance.
  • Thermography. This method allows the detection of thermal anomalies that may indicate internal problems in the electric motor.
Ways to repair electric motors

Winding rewinding

When windings fail, they can be replaced with new ones, which restores the performance of the motor.

Repair of mechanical parts

  • Bearing replacement. Worn or damaged bearings are often the source of overheating and vibrations. Replacing them restores stable engine performance.
  • Shaft balancing: If the shaft is unbalanced, the engine can run inefficiently, cause additional load and wear faster.

Preventive care

  • Regular inspections. Timely diagnostics can prevent serious failures.
  • Proper cooling. Ensuring that the engine does not overheat is an important part of preventive maintenance.
  • Lubrication: Proper maintenance and lubrication of bearings reduces friction and increases engine durability.

Proper repairs and diagnostics ensure that your engine will run long and efficiently – reducing the risk of breakdowns.

Ways to optimise electric motors

Installing frequency converters

Frequency inverters allow you to vary the speed of the motor according to the load requirements. Instead of running at a constant speed all the time, a frequency converter allows you to control the speed at which the motor rotates, reducing energy consumption.

This can reduce energy consumption by up to 30-50%, especially in industrial systems with variable loads.

Using energy-saving motors

IE4 motors (high efficiency class motors) are designed to consume less energy but operate at the same capacity as standard motors.

Replacing older, lower efficiency motors with newer models can result in significant energy savings, especially in long-term use.

Selecting the right motor size

Oversized motors consume more energy than necessary, so it is important to choose the right motor size for the actual load demand.