In this article, we will learn the most common causes reasons for industrial electrical motor failures.
General Reasons for the Electrical Motor Failures
Here is the list of general common failures of electric motor. Later we will explain only main reasons of motor failure.
- Overheating
- Mechanical Wear and Tear
- Electrical Faults
- Motor Bearing Failures
- Stator Winding Failure
- Low Resistance in Windings
- Contamination
- Rotor Bar Failure
- Power Availability
- Insulation Breakdown
- Corrosion
- Overvoltage
- Vibration
- Overload
- Poor Alignment
- Improper Ventilation
- Motor Overload
- Faulty Motor Winding
- High Temperature
- Poor Lubrication
Electrical Motor Failures
Electrical motor failures can occur due to a variety of reasons, such as wear and tear, improper maintenance, overuse, faulty wiring, and overvoltage. The most common causes of electrical motor failure are overheating, mechanical wear and tear, and electrical faults.
Overheating can be caused by a variety of factors, such as improper ventilation, motor overload, or a faulty motor winding. Mechanical wear and tear can be caused by improper lubrication, high levels of vibration, and poor alignment. Electrical faults can include short circuits, open circuits, and incorrect voltage or current. Proper maintenance and monitoring can help reduce the number of motor failures.
Motor Bearings Failure
Motor bearing failures are one of the most common causes of motor failure. This is because motor bearings are subject to a variety of stresses and loads, such as vibration, heat, and pressure.
The most common causes of motor bearing failure are improper lubrication, contamination, and excessive loads. Proper maintenance, such as regularly lubricating the bearings, can help reduce the risk of motor bearing failure. Additionally, if the bearing is overloaded, the motor should be shut down and inspected for any damage or wear.
Stator Winding Failure
Stator winding failure is another common cause of motor failure. This is caused when the insulation between the windings of the stator core breaks down, allowing electrical current to flow between the windings. This can cause damage to the windings, resulting in motor failure.
The most common causes of stator winding failure are high temperature, vibration, electrical faults, and mechanical wear and tear. Proper monitoring and maintenance can help reduce the risk of stator winding failure.
Low Resistance
Low resistance in windings is another common cause of motor failure. This occurs when the resistance in the windings of the motor is too low, allowing too much current to flow through the motor. The most common causes of low resistance in windings are defects in the motor design, poor insulation, and corrosion.
Poor insulation can cause heat to build up in the windings, which can reduce their resistance. Corrosion can also reduce the resistance in the windings. Proper maintenance, such as regularly checking for corrosion and insulation damage, can help reduce the risk of low resistance in windings.
Contamination
Contamination is another common cause of motor failure. Contamination can occur when dirt or other debris enters the motor and disrupts the normal operation of the motor. This can cause damage to the motor’s components, resulting in motor failure.
The most common causes of contamination are improper maintenance, dust and dirt, and fluids. Proper maintenance, such as regularly cleaning the motor, can help reduce the risk of contamination. Additionally, if the motor is exposed to dust or dirt, it should be covered or protected to reduce the risk of contamination.
Rotor Bar
Rotor bar failure is another common cause of motor failure. This occurs when the rotor bars, which connect the rotor to the stator, become damaged or worn. The most common causes of rotor bar failure are mechanical wear and tear, improper maintenance, and overvoltage.
Proper maintenance, such as regularly lubricating the rotor bars, can help reduce the risk of rotor bar failure. Additionally, if the motor is exposed to overvoltage, it should be shut down and inspected for any damage or wear.
Power Availability
Power availability is another common cause of motor failure. This occurs when the power supply to the motor is inadequate or interrupted. The most common causes of power availability issues are voltage fluctuations, power outages, and poor wiring.
Proper maintenance, such as regularly inspecting the wiring and power supply, can help reduce the risk of power availability issues. Additionally, if the motor is exposed to voltage fluctuations, it should be shut down and inspected for any damage or wear.