As part of our commitment to keeping you up and running, we’re pleased to provide you with the necessary information on electric motors to minimize downtime and unexpected repairs. When a motor does fail, companies have two choices: either repair or replace the motor. Choosing the wrong option can result in significant time and financial losses.
Common Customer Issues with Smaller Electric Motors
During operation, every electric motor generates heat. However, excessive heat can shorten a motor’s lifecycle by up to 50%. While the motor casing includes vents for cooling, improper use and extended duty cycles can deteriorate the wiring insulation, cause bearings to seize, and prematurely wear other motor internals such as the shaft or stator.
Electric Motor Repair vs. Replacement
Repairing an electric motor is typically 50-70% less expensive than replacing it. For example, repairing an electric motor could require anywhere from a couple of days to a couple of weeks to complete. Replacing the motor involves not only the cost of the motor but also the additional downtime required for transportation from the factory to your location.
The most common repairs performed by the Hi-Speed team include.
Rewinding replaces damaged coils to restore motor efficiency and performance.
Bearing replacement eliminates noise and vibration that cause premature failure.
Overheating can be caused by insulation breakdown, improper lubrication, or blocked cooling ports.
To make the best choice for your business and budget, start by performing a detailed cost analysis for each option.
The replacement cost analysis should include:
- Cost of the new motor
- Labor to install and calibrate
- Transport costs (if applicable)
- Special equipment costs (crane or hoist)
- Warranty
- Lost production or sales
The repair cost analysis should include:
- Parts
- Labor
- Lubrication
- Transport services (if applicable)
- Special equipment needed (cranes or hoists)
- Lost production or sales
These cost analyses will help you make the best decision based on your specific business, needs, and costs.
Electric Motor Restack vs. Rewind
Restacking involves repairing or replacing the motor’s core, specifically the laminations that make up the stator. This is typically done when the core is damaged, such as from overheating or mechanical stress. Restacking is less common than rewinding and can be a labor-intensive process. If the core damage is severe, restacking may not be a viable option, and a replacement might be more appropriate.
Rewinding is essentially replacing the old, potentially damaged windings with new ones. This process can significantly extend the motor’s lifespan and even improve its efficiency if done correctly. Conversely, a poorly executed rewind can lead to reduced performance, increased energy consumption, and even premature failure.
Motor Rewinding Process
A rewind is required when burnt windings or insulation failure is found during the inspection. While the rewind process can vary slightly depending on the motor’s construction and size, there are five essential steps.
- Disassemble the motor to remove the old windings.
- Check the wiring insulation with proper testing equipment.
- Thoroughly clean the core of dirt and other contaminants.
- Install the new windings and reassemble the motor
- Test the motor against the manufacturer’s requirements and specifications.
It’s important to note that rewinding is a delicate process that requires expertise to ensure the proper use of wire gauge, winding patterns, and insulation. A proper rewinding extends motor life by years, saving you thousands of dollars.
Electric Motor Reconditioning
Bearing failure, excessive noise, or vibration during operation can signal that the motor needs to be reconditioned. Unlike restacks or rewinds, reconditioning refers to the replacement of worn bearings in the motor’s rotor.
This process involves removing the old bearings and inspecting the shaft. If the shaft is within the manufacturer’s tolerances, simply install the new bearings and check lubrication levels before testing. Worn bearings can result in binding and excessive heat, which typically leads to catastrophic motor failure.
Why Do Electric Motors Fail?
Most motor failures can be attributed to excessive heat created by extended duty cycles, electrical issues, contamination, and poor ventilation. It’s important to remember that he wiring insulation has a shelf life that begins when the motor is taken off the assembly line.
Most overheating issues can be diagnosed through regular insulation inspections, thermal imaging, and electrical testing procedures.
Electric Motor Repair vs. Replacement
The chart below compares typical repair costs and timelines against purchasing a new replacement motor.
| Factor | Repair | Replacement |
| Cost | 40-70% of new motor cost | 100% of new motor cost |
| Downtime | 3-7 days | Weeks to months depending on available inventory |
| Lifespan Extension | 5-10 years | New motor lifespan |
| Environmental Impact | Low (reuses materials) | High (all new materials) |
And that’s a wrap for our first team video. We hope you find the insights provided by the Hi-Speed team of electric motor experts helpful. If you still have any questions regarding the cost analysis for your electric motors or need help with basic repairs or a complete motor replacement, the Hi-Speed experts can be reached at 800-713-0103. Alternatively, you can send us an email to learn more.
Additional Electric Motor Resources
Based on your interest in repairing or replacing an electric motor, here are some recent blog posts you might find interesting or helpful.
Best Electric Motor Repair Practices
The Essential Guide to Getting Your Electric Motors Serviced or Repaired