Motor failure is one of the common problems in manufacturing plants, and it happens at the worst time – when not anticipated. Even with the best performance monitoring and maintenance, the truth is that, at some point, the motor will fail. So, do you replace or repair it? It is a major decision that is likely to have serious implications on the performance of your facility. This post is a comprehensive guide to help you make the right decision.

Start with Motor Failure Review

Before you can make the main decision to repair or replace the motor, the first step is to review its status. What is the state of the motor? It is also crucial to determine the cause of failure. Addressing the source of the problem can help to reduce or avoid related failures in the future. Some of the main causes of motor failure include:

• Contaminated windings
• Failed insulation
• Insufficient lubrication
• Overheating
• Overloading

Catastrophic Failure

If your motor suffered a catastrophic failure, it might have caused serious damage to the core parts, such as the windings, stator core, shafts, and bearings. In such a situation, replacing the motor might be a better idea, especially where the stability of the equipment is crucial for the running of your facility.

Catastrophic failure might also have resulted in damages to the rotor can of the motor. For example, does the motor have melted bars or signs of surface smearing caused by contact with the stator? While surface smearing is, in most cases, possible to repair economically, other major damages, such as melted bars and broken end rings, might not.

If the old motor’s shaft, frame, or other major mechanical parts are damaged, it is also possible to replace them economically. However, you need to factor in the costs and determine whether it is viable to repair the motor or replace the mechanical parts.

Evidence of Previous Major Damages

At times cases of serious damages are only discovered when the motors are disassembled, either because of the latest failure or during routine checkups and testing. If these instances of previous major damages are noted, you need to assess the extent of damage and weigh between replacement and repairs. Some of these issues can be avoided by adopting predictive maintenance. For example, you can use programmable logic controllers to note when the performance of the motor starts declining. Then, use that as an indicator that something might be wrong.

For example, you might notice a damaged rotor core, missing stator core iron, or damaged bars. Here, you should only consider repairs if the previous damages were mild and related costs are low. However, replacement might be the better option if the previous failures severely damaged the motor. Even when the cost of repairs might appear low, it might be a good idea to go for replacement when the risk of further intensive damages is high.

Consideration for More-Efficient Motors

Notably, the points we have looked at above are the main ones used when deciding whether to repair or replace a motor. However, it is also crucial to think about the latest developments, especially the newer energy-efficient models.

When we talk about energy-efficient motors, we mean the models that are listed by the Federal Regulations (EPA) and NEMA Premium. Therefore, before making your decision to repair the old motors, it will be a smart move to think about a more energy-efficient replacement.

Even when you prefer the new and more energy-efficient motors, it is still advisable to compare the costs with that of repairing the old model. For example, the new motor might require modifications and replacement costs. However, it is likely to have more cost-saving benefits in the long term.

The Bottom Line

If your conveyor belt, drill, or other equipment, runs on old motors, failure can result in serious downtimes, disruptions, and losses. Make sure to comprehensively review them to not only decide whether repairing or replacing is the better idea but also establish if they suit your energy needs.

While the cost of repairs and replacement plays a huge role in determining the ultimate decision to repair or replace motors, make sure to think about the long-term advantages. Again, if acquiring the replacement might take long, it might not be a good idea to incur major downtime running for weeks or months. So, go for a replacement.

Note that whether you prefer to go for repairs or replacement, it is important to use top-quality products from trusted dealers. Visit us to see the wide range of motors and motor accessories that you can trust. Besides, it is important to ensure your new or repaired motor is maintained in top conditions all the time. You might also want to repair the motor and commence plans for replacement in the coming months.