When the performance of an electric motor begins to deteriorate, you must make a complicated choice: either replace the motor entirely or prolong the life of the motor with “rewinding” techniques.
The choice of whether to rewind or replace your motor can be a difficult decision. While the cost of replacement is much higher, the additional investment may be worth it. On the other hand, if your motor is only a few years old, then a rewind could help improve its performance and save you money — money that would otherwise be spent on a new motor.
Here are some questions to ask yourself to help you decide whether you will benefit from rewinding your electric motor.
Does Your Motor Need Rewinding?
Deciding whether your machine could benefit from a rewindcan be difficult, but a careful evaluation from a service professional can help identify whether your motor is showing signs of wear, deterioration, or inefficiency — all factors that might make rewinding necessary. Take note of the following red flags, which can help you to determine if a motor rewind is right for your motor.
1. Signs of Deterioration
General signs of deterioration, including burns, broken parts, and contamination (like moisture or rust) can all indicate that your motor would benefit from a rewind. Although many electric motors can last a long time, they are vulnerable to eventual wear and tear.
Rewinding your motor is an appealing option if you don’t have the funding or resources to buy a new machine. This is because rewinding can cost as low as 40% of purchasing a brand-new motor. Rewinding is also appealing if you own large electric motors, which can be very expensive to replace.
If a technician notices during an inspection that the laminations within the machine aren’t damaged, then they also might suggest you rewind your motor.
2. Poor Winding Resistance
A professional will often measure winding resistance if an electric motor isn’t performing at its best. This winding resistance test can determine whether shorted coils in the motor are causing a problem. The optimum winding resistance level is listed on the nameplate of the electric motor or in the documentation provided by the manufacturer. If the numbers don’t match the measurements taken by a professional, this indicates a rewind may be necessary.
Though it’s possible to replace a motor with winding resistance problems, rewinding is a more cost-effective and environmentally-friendly option because it recycles motor core materials. The environmental impact of rewinding is minimal when compared to the carbon costs of creating a new motor.
3. Problems with Insulation Resistance
A majority of winding faults cause problems in an electric motor due to issues with insulation resistance. Many of the components within an electric motor are affected by heat, and low insulation resistance can lead to low lubrication, damaged components, and other issues.
Low insulation resistance is a problem that happens naturally over the course of a motor’s life and is triggered by contamination, vibration, and power surges. Rewinding an electric motor can improve insulation resistance and can improve the efficiency of your motor at the same time.
Hiring a professional to rewind your electric motor can yield incredible results. Using new techniques along with high-standard resins and insulating tapes can help improve electrical motor efficiency. The key to a successful rewind is to make sure that you select a rewinding team with the right techniques and skills.
How to Decide When You Should Rewind a Motor
Only you can decide whether to rewind your motor or replace it entirely. While most malfunctioning motors can benefit from the rewinding process, some motors can be so deeply damaged or beyond their performance lifespan that the only realistic option is a replacement. If you notice signs of deterioration, problems with insulation resistance, or evidence of winding resistance, ask yourself:
- Do you need to keep costs low?
- Is efficiency important do you?
- Do you want to protect the environment?
If you answer “yes” to each of these questions, then rewinding could be the answer.
If you want to know more about rewinding your motor, reach out to the experts at Sloan Electric for an assessment and professional support.