Electric motors are the foundation of innumerable pieces of equipment and instruments, ranging from industrial machinery to household appliances. Still, we do not understand the overall importance when these parts are running smoothly. Every machine needs regular care & maintenance. Still, they end up breaking down at some point.
As an industry pioneer, LEDL introduced India’s first Synchronous Reluctance Motor in 2016, delivering IE4 & IE5 efficiency classes for cleaner, lower-loss operation.
Top Signs to Look Out for
- Unusual Noises
Electric motors usually work quietly during operation. If you come across unusual noises during operations, it could mean worn-out parts, loose parts, or some internal damage.
It is important to look into these signs. This is because delayed attention would lead to severe problems in the long run.
- Overheating or Burning Smell
When your induction motor starts generating excessive heat or emits a burning smell, it poses a significant threat to your optimal motor performance. If your equipment feels extremely hot to the touch, it may be a sign of poor ventilation, machine overloading, or insulation failure. When electric motors get continuously overheated, it eventually shortens the device’s lifespan or causes other irreversible damage, while also indicating safety hazards.
- Decreased Performance
Like every machine, industrial motors eventually reach a point where they fail to deliver the same performance and efficiency over time. After good usage, they may take longer to perform tasks, thus hampering efficiency and productivity. It may be due to a loss of torque, worn bearings, higher energy consumption, or the inability to maintain a consistent speed. Worn-out components may increase friction, resulting in reduced performance and layered power output.
- Excessive Vibrations
When electric motors start vibrating more than usual, it may be a red flag indicating some misaligned or damaged belts, bearings, rotors, or other parts. Whenever you notice excessive vibration, stop using it immediately, as it may pose a health and safety hazard, too. Contact a technician as soon as possible and get the damaged parts repaired or replaced.
- Startup Delays
If you find the motor struggling or failing to start, it is indicative of some grave issues with the bearings, windings, or starting components. Taking longer than usual to start may also put additional stress on the motor, which leads to faster wear and tear of its parts. Most importantly, it hampers your work productivity and efficiency.
- Increased Energy Consumption
Increased energy consumption even under the same load is a warning sign indicating that a motor is about to get damaged. The most obvious sign of more power consumption is when you see a sudden rise in your monthly electricity bills. Worn-out machine parts, faulty windings, or some sort of internal resistance are linked to an inefficient and failing motor, causing it to draw more energy than necessary. The best solution for this is regular servicing and replacing older components to ensure long-term savings.
- Tripping Circuit Breakers
Adding as an extension to the previous point, failing motors may cause circuit breakers to trip more frequently. This indicates that the motor is drawing more power than usual. You should be alert when you find short circuits more often, winding damage, and sudden insulation breakdown. All such issues require immediate attention, preferably repair or replacement of the damaged components, to increase their energy efficiency.
- Requiring Frequent Repairs
Is your motor demanding frequent repairs to remain operational? Is it experiencing sudden breakdowns more often than usual? Instead of investing in frequent repairs or upgrades, it’s more cost-effective to replace the motor altogether. A new motor would not only save you from repetitive and unnecessary repair costs but also improve efficiency.
- Visible Wear and Tear
There are visible signs too, such as wear and tear of certain components. Don’t ignore the physical warning signs like scorched windings, burnt smells, oil leakages from cracks, or broken seals, which strongly indicate a deteriorating motor. If not addressed on time, these issues may worsen over time, leading to potential safety hazards.
- Contamination
Continuous exposure to dirt, debris, dust, and chemicals can damage the motor component and result in corrosion of its parts, affect the bearing function, and cause insulation breakdown. Contaminated electric motors, therefore, gradually start showing signs like unusual noises, overheating, burnt odors, and reduced efficiency. Therefore, regular cleaning, proper sealing, and placing the moor in the appropriate place are vital to prevent severe contamination damage.
How to Decide Between Repairing or Replacing Your Electric Motor?
Our goal should be to focus on developing and maintaining more energy-efficient products through regular care and maintenance. However, machine breakdowns are inevitable, in which case, they require either repairs or replacements to ensure business continuity. As a golden rule of thumb:
- You should repair a motor only if the issue is minor, including lubrication issues, worn-out bearings, or loose connections. In these cases, simple repairs or maintenance would do the job.
- However, your motor needs replacement if it has received severe internal damage, is not as energy-efficient as before, or is outdated compared to many modern motor models. Also, replace your motor when frequent repairs are no longer working.
LEDL is Your Trusted Partner for Reliable Motor Solutions.
When it comes to ensuring the highest electric motor performance, LEDL can be a reputable name in this field. We offer a wide range of high-end, efficiency-class electric motors, Synchronous Reluctance Motors (SynRM), and customized solutions to meet the specific requirements of HVAC manufacturers, OEMs, and various industrial applications. Our comprehensive servicing, repair, and replacement support encompasses everything from fault diagnosis and routine maintenance to complete upgradation. With our expert technical assistance, LEDL ensures you get the right solution to ensure operational and cost efficiency.
Final Words
Electric motors are crucial investments that make up a significant portion of your revenue. Therefore, they deserve proper care and regular maintenance to extend their lifespan and durability. Pay attention to the warning signs and red flags, and address potential threats and problems promptly. To avoid unexpected breakdowns and to reduce potential safety hazards, consult a professional technician to evaluate the root cause of the issue and to analyze whether servicing or replacement would be the right choice.
