Why do motors need rewinding?

What is motor rewinding?

If you’ve been told that your electric motor needs rewinding, that means the coils are shorted, grounded, or otherwise damaged. … Insulation failures can take several different forms, including windings that have shorted turn-to-turn or phase-to-phase, coil-to-coil, or grounding at the edge of the slot.

What does a motor rewinder do?

Your duties have you working to rewind and produce coils; replace and prepare components, such as the stator core for winding or the wound motor for dipping; test the engine to ensure that repairs were successful; and perform final inspections.

How much does rewinding a motor cost?

Obviously, the cost of a rewind can vary with the degree of internal damage, but a typical price for a 100-hp induction motor that we will use as an example is between $2,500 and $2,700—or $2,600 average per IPS Washington Service Center price guidelines.

How rewinding of motor helps in increasing efficiency of motor?

When rewinding a motor, smaller diameter wire will increase the resistance and therefore I2R losses; larger diameter will have the opposite effect. If the original wire was aluminum, changing to the same size copper wire will also reduce resistance and loss.

What causes motor windings to fail?

Insulation failures, including winding that is shorted phase-to-phase or turn-to-turn, has a shorted coil, is grounded at the edge of the slot or in the slot, or has a shorted connection — all of which are typically caused by contaminants, abrasion, vibration or voltage surge. …

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Is rewinding a motor hard?

An electric motor rewind is a delicate process, and removing the dirt, old insulation and grime accumulated after years of use within a motor is a difficult dirty practice (in most cases).

What is the operation in the rewinding process?

Given the sheer number of different motors and winding patterns, the rewinding process can vary greatly. However, it generally involves cutting the original windings out of the motor’s stator or armature and replacing them with new coils made from wire of the same basic type and gauge.

When should you rewind an engine?

When Should I Rewind My Electric 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. …
  2. Poor Winding Resistance. …
  3. Problems with Insulation Resistance.

How often should a motor be rewound?

So long as the shell exists, a motor can be repaired and reconditioned. The key is to remember that eventually that motor will need a burnout and rewind before it is insulated again. Then, with proper maintenance and smart reconditioning, there is no limit to how many times you can have that motor repaired.