Why do others have five years of trouble-free motor service, while yours is constantly in need of repair?
It's not because the motor is poor quality; it's likely you've stepped on these "invisible killers"!
Today, we'll uncover the four main culprits of motor shortevity. Learn how to avoid them and reduce maintenance costs by 50%!
Problem Symptoms: Severe motor overheating, loud noise, and frequent tripping
Professional Analysis:
Long-term overload operation accelerates insulation aging and can lead to coil burnout. For example, if a 7.5kW rated motor is forced to drive a 10kW load, its lifespan is reduced by half for every 10°C increase in temperature!
Correct Approach:
Load power must match the load power, leaving a 10%–20% margin.
Install an overload protector and monitor current in real time.
Problem Symptoms: Large starting sparks, contactor sticking, and bearing damage
Professional Analysis:
During a direct start, the current can reach 5–7 times the rated value, severely impacting the windings and mechanical structure. Frequent starting and stopping (e.g., more than 10 times per hour) can significantly accelerate bearing wear.
Correct Approach: Use a soft starter or inverter for smooth starts and stops.
The interval between starts should be at least twice the motor's cooling time.
Problem Symptoms: Reduced insulation resistance, internal short circuits, and increased noise.
Professional Analysis:
Dust clogs heat dissipation holes, increasing temperature rise by 15%; moisture causes rust and insulation failure; and acidic and alkaline gases in chemical environments can directly corrode the coils.
Correct Approach:
Use a motor with an IP54 or higher protection rating (dust and water-resistant).
Regularly clean the air ducts and install a heater for dehumidification in humid environments.
Problem Symptoms: Bearing Seizure, Winding Burnout, and Double Repair Costs.
Professional Analysis:
80% of motor failures are caused by insufficient lubrication. Grease drying increases bearing resistance, power consumption by 30%, and in severe cases, rotor scouring.
Correct Approach:
Replace grease every 2000 hours of operation (half the reduction in high-temperature environments).
Monthly monitor vibration and temperature, and establish trend records for early warning.
Scientific use + proactive maintenance = long-term, stable motor operation.
Avoid these four pitfalls to extend motor life and significantly reduce maintenance costs!