When a motor fails, or begins to show signs of deterioration, engineering teams and maintenance experts must come together to determine how to address the problem. In some cases, repairing the motor outright may be possible, where other outcomes require either the replacement of the motor, or assistance through a process known as “rewinding”. Many industry practitioners find that sending the motor away for rewinding can be more economically viable than replacing the model completely. However, some people are still convinced that the process of rewinding decreases motor efficiency.
The truth is, when it comes to rewinding a motor, the process, techniques, and materials used can all have an impact on the outcome in terms of efficiency. For instance, if the coil from the stator core is stripped at a high temperature prior to rewinding, the electrical characteristics of the core steel can change, leading to higher losses in iron, and lowered efficiency. However, in the same vein, so long as the engineer is capable of rewinding the motor according to manufacturer specifications, then it is possible to achieve original performance levels. In fact, some studies suggest that there may even be an opportunity to improve efficiency.
Motor Rewinding and Improved Efficiency
So long as an experienced engineer carries out the process, the belief that rewinding a motor leads to inefficiency could be an outdated concept. In fact, advancements made over the years in regards to disciplines, techniques, quality assurance, and materials have all allowed for the dependable match, and even improvement of electrical motor efficiency.
High-standard insulating tapes and quality resins have allowed for the improvement of thermal dissipation during the rewinding procedure. Automated technology designed to form coils ensures better operation and installation of motors. Many industry experts agree that rewinding a motor can improve uptime and reliability, while lowering potential operating costs.
Rather than reducing efficiency, a Green Motor Practices Group study found that modern rewinding techniques and expert craftsmanship lead to better results. Though a knowledgeable service center can rewind motors efficiently, it’s important to ensure that you’re working with the right company beforehand. Ask for information about the repair, checking details all the way from winding resistance, to potential core-loss results taken from previous projects.
The Pros and Cons of Motor Rewinding
Like any technical procedure, it’s worth noting that results can vary, and the decision of whether to consider rewinding will depend on your motor, and your specific circumstances. There are some disadvantages to the rewinding technique that individuals should be aware of, for example, only an expert should attempt rewinding, meaning that you can’t save time with a DIY attempt, even if you think you’re sure of what you’re doing. What’s more, even after the rewinding process, there is still a chance that a malfunctioning motor will not begin working again, particularly if the problem was serious. In these circumstances, you’ve paid for a time consuming task without a preferable outcome. However, there are also a number of benefits to rewinding that you should also consider carefully.
Choosing rewinding can be a more affordable alternative to replacing a motor entirely. After all, when you replace a motor, you need to purchase a new motor that fits your need, and pay for a trained mechanic to fit the system for you. At the same time, there’s a guarantee of a perfect fit, as you know that the motor you get back will already fit your application. In some circumstances, it can be difficult to track down a unit that’s well suited to the available space, especially if it’s been a number of years since you bought the first motor.
Choosing Whether to Rewind
As with any other crucial maintenance decision, it will be down to you to determine whether attempting a rewind on your damaged or malfunctioning motor is worthwhile. In some cases, you may prefer to ask someone to come and look at the motor and determine the primary reason for the failure before choosing whether to rewind, so that you can preferably enhance your chances of a successful outcome. However, it’s important to keep in mind that you should no longer assume that the rewinding process will reduce your motor efficiency.
With the right experts at hand, using the correct materials, and following the available guidelines for your specific motor, it’s possible for rewinding or repairing services to help lower operating costs, improve motor uptime and reliability, and help your investment last longer.