Electric Motor Rewinding

Electric Motor Rewinding is a delicate and technical procedure that requires extreme accuracy, experience, and expertise to perform efficiently. At Universal Rewind, we have years of experience and knowledgeable staff to guarantee a high level of workmanship. Our team of specialists uses state-of-the-art equipment and tools to rewind motors quickly and precisely.

The Electric Motor Rewind Process

The electric motor rewind process involves replacing old windings with new ones to restore the motor’s optimal efficiency. Our technicians ensure the insulation can handle temperatures up to 200 degrees Celsius. We use only the best quality insulation materials to guarantee optimal performance.

We do not overlook any detail when rewinding a motor. Our technicians inspect the motor to detect any damage or wear and tear that could impair its performance. They also ensure that they tightly wind the new windings to prevent vibration or movement that could cause early motor failure.

We understand that turnaround times are very important, so we keep a large inventory of replacement parts to minimize downtime. We are a trusted motor rewinding shop in Alberta, committed to meeting the manufacturer’s specifications.

Before we get started on a rewind, we would first inspect the motor to determine what type of repair is required.

Your Motor May Need a Rewind if…

1. Signs of Excess Wear or Deterioration

Your motor may need a rewind if you notice signs of deterioration, like burns, broken parts, or contamination from moisture or rust. Electric motors typically have a long lifespan, but wear and tear can still take its toll over time.

Rewinding can be a more affordable alternative to buying a new motor, as it can cost up to 40% less. This is especially true if you own larger motors, which can be costly to replace. During an inspection, a technician may suggest rewinding if the laminations inside the motor remain undamaged.

Rewinding your motor can be a great option if you want to save money or don’t have the resources to buy a new one. It’s also the way to go if you have larger motors that can be pricey to replace. Plus, if the laminations within the motor aren’t damaged, rewinding is an ideal choice.

However, you should be aware of the signs that your motor needs rewinding. These include burns, broken parts, and contamination from moisture or rust. Electric motors tend to be long-lasting, but they’re still susceptible to gradual wear and tear.

Rewinding your motor is more cost-effective than replacing it, as it can cost up to 40% less. Plus, it’s a great way to restore your motor if the laminations remain in good condition. Before rewinding, make sure to look out for any signs of deterioration, such as burns, broken parts, or contamination.

2. Poor Winding resistance

If an electric motor isn’t performing as it should, a motor shop or electrician would typically measure its winding resistance. This test helps detect if shorted coils are causing issues. The recommended winding resistance levels are usually stated on the motor’s nameplate or in the manufacturer’s documentation. If the numbers don’t match up to the measurements taken, a rewind could be necessary.

Replacing the motor is an option, however, rewinding would be more cost-effective and environmentally friendly. Core materials are reused, resulting in a much lower carbon footprint than creating a new motor. Plus, it’s a great way to recycle and make use of what’s already available.

3. Problems with Insulation Resistance

Electric motors are vulnerable to winding faults, which can be a huge problem. Heat has a serious impact on the components inside a motor, and when the insulation resistance is low, it can lead to reduced lubrication, damaged parts, and other issues. That’s why it’s so important to be aware of how insulation resistance can affect an electric motor. Taking the necessary steps to ensure the insulation resistance is high enough can save you a lot of trouble.

Insulation resistance can drop over time, due to contamination, vibration, and power surges. Rewinding an electric motor is a great way to improve the insulation resistance and the efficiency of your motor.

Taking your motor to an experienced motor shop for the rewinding process is recommended. With the use of advanced techniques, along with top-notch resins and insulating tapes, the efficiency of an electric motor can be significantly improved. Finding the right team with the proper experience is the key to a successful and cost-efficient motor rewind.

These questions will help you make the right decision regarding your motor. Consider these points carefully and make a wise decision – one that will save you money in the long run.

To Rewind or Replace

Motor Repair or Replace Flow Chart

The choice of whether to rewind or replace your motor can be a difficult decision. EASA (The Electrical Apparatus Service Association, Inc.) has developed an easy-to-follow Flow Chart that helps identify each situation with the corresponding outcome.

The factors we typically weigh are; cost comparison, rewind benefits (when an option), and motor lead time/availability. There are other, more complicated, questions that we go through. Read more on these specific questions here.

While the cost of replacement is usually higher, the cost of rewind may exceed that of a brand-new motor.

Generally, we’d recommend a new motor if the cost to repair is 60-70% of a new motor. This is usually the case for anything under 75/100HP. It is always recommended to understand and weigh your options in every unique situation.

If your motor is only a few years old, and in relatively good condition, then a rewind would help improve its performance and efficiency (especially if upgrading to a higher-efficiency motor), and save you money. Repairing or rewinding motors also prevents a premature land-fill donation.

Naturally, understanding the availability of your specific motor is key. If the wait times don’t work for you, you have no choice but to rewind/repair, regardless of other factors.

Overall, determining if your motor needs rewinding can be difficult on your own. An experienced motor shop, like Universal Rewind, can diagnose issues and provide you with a rewind quote and replacement cost quote to help you make your decision.

Regardless of the decision to repair or replace, it is paramount that you determine the cause of the motor failure in order to prevent reoccurrence.

Source: https://universalrewind.com/wp-content/uploads/2023/07/EASA_RepairReplace_SalesTool_0821.pdf

What does it cost for an electric motor rewind?

This will vary depending on the size and HP of the motor. Having your motor rewound can be anywhere from 40% to 70% of the price of a brand-new motor. In addition to saving money, choosing to rewind your motor can also help the environment. The rewinding process has a very minimal environmental impact when compared to the carbon costs of creating a brand-new motor and disposing of the old motor.

Benefits of rewinding your electric motor

When your electric motor is not performing as expected, you often must make a critical decision about it: Rewind it or replace it. There are some instances where rewinding a motor simply is not a practical solution, but many times using a motor rewind service is a better, lower-cost, option. Here are the benefits of using a motor rewind service:

Saves energy

If an electrical motor is running inefficiently, it’s wasting a lot of energy. A motor rewind can help to restore it to peak efficiency, which will reduce energy costs. Rewinding a motor is a great way to give it a new lease on life, without having to create unnecessary waste by manufacturing a brand-new motor when the old one could still do the job.

Improves electric motor efficiency

If you use a professional motor rewinding service such as Universal Rewind you can expect to bring back efficiency similar to that of when the motor was originally manufactured. We follow the original winding configuration or, in some cases, wind it in a different way to improve the motor’s original efficiency.

Saves money

Rewinding your electric motor is can definitely be cheaper than replacing a motor, especially if you can get another 5+ years use out of that motor.

Saves time

Most motor rewind jobs can be turned out in under 1-2 weeks, in an emergency we may be able to complete the job quicker. Wait times for new motors can exceed 8-10 MONTHS! Though we often have common motors in stock, it can be significantly quicker to rewind a motor than wait for a new one.

Often times the customer will opt to order a new motor (when readily available) to get their equipment back up and running and then use the newly repaired motor as a spare.

For a comprehensive overview of Repair or Replace, download the EASA presentation.