This is an important procedure since poorly maintained electrical equipment do cause calamitous equipment failure. This may result to destruction of property and loss of lives in some situations. Motor testing and preventive maintenance help in early detection of various motor components which deteriorate with time before they ultimately become a potential hazard. Generally, a good electric motor repair and maintenance program extends the life of the motor.
A Guide to DC Electric Motor Repair and Maintenance Program
These programs encompass the following key processes: motor inspection, lubrication, replacement of parts, testing and cleaning. This ensures that both the motor and the associated equipment operate efficiently and optimally. In a good repair and maintenance program, you should:
· Review the service history of the motor
· Inspect noise and vibration
· Carry out visual inspection of various components
· Carry out winding tests
· Maintain brushes and commutator
· Lubricate various components
A Guide to DC Electric Motor Repair and Maintenance Program
These programs encompass the following key processes: motor inspection, lubrication, replacement of parts, testing and cleaning. This ensures that both the motor and the associated equipment operate efficiently and optimally. In a good repair and maintenance program, you should:
· Review the service history of the motor
· Inspect noise and vibration
· Carry out visual inspection of various components
· Carry out winding tests
· Maintain brushes and commutator
· Lubricate various components
Review the Service History of the Motor
You have to review the motor’s service history. These details are contained in the equipment maintenance log. In a situation where such information is not available, the only option will be to interview either the customer or the operator to be able to determine the kind or maintenance or service the motor may require. Such information will be helpful when it comes to establishing: various parts which need complete maintenance, kinds of safety hazards which may hamper the maintenance process, the cause of the problem, choose the maintenance personnel who are needed to help in the maintenance process etc. All repair and maintenance process begin from this stage.
Inspect Both Noise and Vibrations
This is yet another important process in the electric motor repair and maintenance process. You should disconnect the motor from the drive shaft and run it normally. Try to identify the existence of unusual noise and vibrations. Normally, this is an indication that the DC motor could be having either electrical or mechanical imbalances; there could be brush chattering; existence of bent shafts; loose windings or bad bearing. Shorted windings and uneven air gaps can also cause noise and vibrations.
To establish whether vibrations and noise are either due to mechanical or electrical imbalance; power up the motor and allow the motor to run at a normal speed and disconnect it from power. If either the noise or vibrations exist when unpowered the problem could be mechanical otherwise, it could be an electrical problem.
Carry Out Visual Inspection
Physically check and record anomalies of the motor in de-energized state. For instance, a motor which appears to be corroded or dirty is a clear indication that the motor was being used in a rough environment. This inspection should include burned smell from the windings or varnish which is used to insulate the DC motor winding. Other observations such as overheating are also an important factor to consider.
DC Motor Winding Test
Assemble the DC motor carefully and inspect all the internal components before you begin the motor winding test. In the electric motor repair and maintenance process, motor winding test is very important. Try to establish the kind of winding failures or abnormalities the DC motor could be having in relative to the winding failure. You should inspect the windings physically to check whether they are dirty, clean or corroded. Before you use any detergents on the windings, refer to the manufacturers’ manual to establish the kind of solvents manufacturer’s recommend.
Normally, a megger test is used to test the insulation winding of DC motors. The resistance reading depend on very many factors which may include either the size of the motor or the type of wire used. You can also refer to the manufacturer’s manual. When there are low readings, then it implies that there could a problem which should be indicated.
You have to review the motor’s service history. These details are contained in the equipment maintenance log. In a situation where such information is not available, the only option will be to interview either the customer or the operator to be able to determine the kind or maintenance or service the motor may require. Such information will be helpful when it comes to establishing: various parts which need complete maintenance, kinds of safety hazards which may hamper the maintenance process, the cause of the problem, choose the maintenance personnel who are needed to help in the maintenance process etc. All repair and maintenance process begin from this stage.
Inspect Both Noise and Vibrations
This is yet another important process in the electric motor repair and maintenance process. You should disconnect the motor from the drive shaft and run it normally. Try to identify the existence of unusual noise and vibrations. Normally, this is an indication that the DC motor could be having either electrical or mechanical imbalances; there could be brush chattering; existence of bent shafts; loose windings or bad bearing. Shorted windings and uneven air gaps can also cause noise and vibrations.
To establish whether vibrations and noise are either due to mechanical or electrical imbalance; power up the motor and allow the motor to run at a normal speed and disconnect it from power. If either the noise or vibrations exist when unpowered the problem could be mechanical otherwise, it could be an electrical problem.
Carry Out Visual Inspection
Physically check and record anomalies of the motor in de-energized state. For instance, a motor which appears to be corroded or dirty is a clear indication that the motor was being used in a rough environment. This inspection should include burned smell from the windings or varnish which is used to insulate the DC motor winding. Other observations such as overheating are also an important factor to consider.
DC Motor Winding Test
Assemble the DC motor carefully and inspect all the internal components before you begin the motor winding test. In the electric motor repair and maintenance process, motor winding test is very important. Try to establish the kind of winding failures or abnormalities the DC motor could be having in relative to the winding failure. You should inspect the windings physically to check whether they are dirty, clean or corroded. Before you use any detergents on the windings, refer to the manufacturers’ manual to establish the kind of solvents manufacturer’s recommend.
Normally, a megger test is used to test the insulation winding of DC motors. The resistance reading depend on very many factors which may include either the size of the motor or the type of wire used. You can also refer to the manufacturer’s manual. When there are low readings, then it implies that there could a problem which should be indicated.
Maintain Brush and Commutator
In DC electric motor repair and maintenance, ensure that all brushes and commutator are functioning properly. When there is an excessive brush wear, then it will be a clear indication that the DC motor is not commutating as required. De-energize the motor and rotate the armature. There should be enough spring tension and brushes should rotate freely. You can also refer to the manufacturer’s technical manual. When you decide to replace any of these components, they must be the exact components as indicated on the manufacturer’s technical manual.
Grease and Replace the Bearings
There are a number of factors to consider when going about this process too. Some of these factors may include the operating environment and the application of the DC motor. There are sealed bearings which do not require any lubrication and they are mostly used in low horsepower DC motors. The bearings should be cleaned, lubricated and the worn out ones must be replaced. As you grease the motor, you must not over grease it since too much grease can cause overheating and churning.
In DC electric motor repair and maintenance, before you carry out any procedure, it must conform to the specifications of the manufacturer.
In DC electric motor repair and maintenance, ensure that all brushes and commutator are functioning properly. When there is an excessive brush wear, then it will be a clear indication that the DC motor is not commutating as required. De-energize the motor and rotate the armature. There should be enough spring tension and brushes should rotate freely. You can also refer to the manufacturer’s technical manual. When you decide to replace any of these components, they must be the exact components as indicated on the manufacturer’s technical manual.
Grease and Replace the Bearings
There are a number of factors to consider when going about this process too. Some of these factors may include the operating environment and the application of the DC motor. There are sealed bearings which do not require any lubrication and they are mostly used in low horsepower DC motors. The bearings should be cleaned, lubricated and the worn out ones must be replaced. As you grease the motor, you must not over grease it since too much grease can cause overheating and churning.
In DC electric motor repair and maintenance, before you carry out any procedure, it must conform to the specifications of the manufacturer.