SERVO MOTOR REPAIR & REWIND SERVICES

 Our goal is to provide the Best Servo Motor Repair Solution and not to just fix the     problem, but to treat the motor as a whole, as it is our intent is to let you know how 

 to prevent the failure from happening again. Our Shop produces an efficient and   high quality repair for a longer and more reliable operation of your servo motors.

 Servo motor repair is highly specialized and requires a motor repair shop that has the resources   necessary to diagnose and rebuild. We employ servo trained technicians, full documentation,

 state of the art test equipment, cabling, and the expertise to repair complex sophisticated motors.

WE HAVE SPECIALITY SERVO REPAIR AND TESTING EQUIPMENT !

Most electric motor shops are not set up to repair and test servo motors. We have invested in the necessary equipment and training to repair servo motors fast and accurately. We are a premiere repair center for industrial electric motors and other rotating equipment. Our repairs are completed and tested by technicians with more than 40 years of field experience. With In-House machining and winding centers, our team of experts examines the motor and looks for dynamic or static parts that do not meet factory specifications.

Our Servo motor repair shop performs a thorough appraisal of the motor’s condition, as received, to determine what specific repairs are needed as well as to find unsuspected trouble, perhaps unrelated to the obvious defect. Our technicians diagnose cause and effect to help prevent a recurrence. The servo motor must be inspected visually for parts that maybe missing and/or damaged. any defects or anomalies. Additional tests from rotation to more advanced information, including

the number of poles and commutation are recorded for each motor.

2.0 Initial Motor Test Run and Feedback Check

Prior to an incoming run test, we perform the following and record information where appropriate: Servo motor will be mechanically inspected to determine if shaft turns freely, test the brake, if applicable, verify that bearings are lubricated, Insulation resistance tests are performed. As well as , the continuity of stator windings, condition and installation of brushes, Surge test (where appropriate). If conditions permit, feedback alignment and full encoder analytics will be performed. The motor will be run at reduced voltage initially and the motor will be run up to 100% of rated speed.

3.0 Dismantle & Inspection

A thorough appraisal of the servo motor’s condition, as received, is to be performed, to determine what specific repairs are needed as well as to find unsuspected trouble, perhaps unrelated to the obvious defect. Our technicians diagnose cause and effect to help prevent a recurrence. Our appraisal will include a complete review of the following conditions of each part of the motor: General cleanliness, Cracked or broken welds or castings, Missing hardware, Wear or rub marks, including fretting, discoloration, charring, or other evidence of overheating, Looseness at mating fits, Corrosion, moisture, or oil inside the machine. 

4.0 Test Stator Windings

A full test of the winding condition shall be carried out with the motor disassembled. Windings are tested to ensure that there are no grounds, short circuits, open circuits, incorrect connections or high resistance connections. The condition of the windings and the extent of repairs should be determined by inspection and, as necessary, by tests. The Baker AWA 2.2 Advanced Winding Analyzer/Surge Test unit is to be used to carry out the following tests:  2.4.1.1 Winding Resistance and Inductance (Per IEEE 1415)

5.0 Mechanical Inspection

All mechanical parts are to be thoroughly cleaned and inspected for defects, cracks or damage. Visually check rotating components for excessive heating and other abnormalities, as well as an Inspection of condition of rotor, stator windings, baffles etc. Furthermore, measure and record dimensions of the following: Shaft extension, Journal and bearing fits, measure and record bracket fits for housings and bearings, the condition of ball or roller bearing housings. Any damage appraisal of motor components is divided into two categories, electrical and mechanical. 

6.0 Stator Rewinding

Rewind the stator to a full Class “H” insulation specification. Ensure full slot wedges and full phase separation is included. Slot liners are installed for all motors. Coils are formed from continuous lengths of properly sized and insulated magnet wire              (to match nameplate criteria). Insertion of coils in slots is done with extreme care to avoid damage to the insulation or magnet wire. Crossings of magnet wire within the slots should be held to a minimum on random-wound coils.

7.0 Balance Rotor

EMX Shop Balancing Systems are designed to perform measurements of vibrations and calculations in horizontal shop balancing machines and in the field. The servo motor rotor shall be dynamically balanced in a balance stand before assembly of the motor. Rotors are supported at the bearing position. Ref EASA AR 100 Dynamic balancing of the rotating element should be to the level specified by the customer. In the absence of a requested level, dynamic balancing to balance quality grade G1.0 (ISO 1940/1) should enable the machine to meet final vibration limits.

8.0 Assemble Servo Motor

All Servo Electric Motor assemblies are made in accordance with the equipment technical manual and good machine shop practices. All mechanical repairs on shafts, bearing journals, end bells, and other equipment are handled in-house by experienced machinists. Servo motors will be assembled in a manner that will ensure proper fit and alignment. The assembly of the motor is the reverse of the disassembly process and all match marks shall line up. All assembled components will be checked to ensure secure fits. Bearings packed with BMG Gen 2 Polyurea Motor Grease. 

9.0 Feedback Alignment and Final Test

After the insulation tests, the motor shall be run at no load at rated nameplate voltage, frequency and speed. Record the current drawn on all phases and check motor speed. Feedback alignment will be performed using the Linea X3 by Octava Engineering with its digital-first alignment for improved diagnostic capabilities and to guarantee the sought-after and often elusive 0° position for perfect operability. Followed by a full encoder analytics and individual waveforms can be viewed for deeper analysis.

10.0 Paint & Protection

At the completion of the test, the motor shall be painted, unless otherwise requested by the customer, with two coats of EM Machinery Black paint or Customer preferred paint color or type, application-specific paint, such as Food grade epoxy, IP67 epoxy Marine epoxy. Servo motor products are cleaned and free of any dirt, oil or grease on the primed surface prior to finish painting. Film thickness: 2 to 4 mils. The shaft shall be protected by either a rust and corrosion preventing coating or mechanical impact cover, and prepared for shipment.

EMX technicians use the Linea X3 Encoder Tester by Octava Engineering with its digital-first alignment to guarantee the sought-after and often elusive 0° position for perfect operability.

Each type requires different alignment and test equipment specific for each manufacturer.

Every servo device is tested both statically and dynamically to insure proper operation.

Encoders, resolvers and tachometers are adjusted to the correct timing, waveform shape, offset position, voltage level, etc.

The data output from encoders can be in a variety of forms, from simple “A&B” quadrature outputs or parallel outputs to bi-directional serial communications in binary, hexadecimal, grey or an OEM specific code. This data needs to be checked and verified to ensure the feedback device is working properly and is correctly aligned relative to the rotors magnetic field.

With feedback data in a specialized communication form we have the test equipment to read

the data and run the motor at working speed to renew your equipment to peak performance.

1. Mechanical Structure Problems

Loose Motor Installation

Defective Shaft

Malfunction of the Transmission Device, Pulley, Belt or Coupling

Poor Gear Meshing

Bearing Lubrication and Wear

Unbalanced Rotating Parts

The rotor, shaft and any connected parts must be properly balanced to allow the motor to rotate smoothly. Unbalanced rotating parts can cause vibration at the motor's inherent frequency. Electromechanex motor repair shop is equipped with state of the art Balancing Systems which are designed to perform measurements of vibrations and calculations within horizontal shop balancing machines as well as, in the field.

The balance application measures the running speed

(1X) filtered vibration amplitude and relative phase with

a reference mark in the rotor to allow full balancing correction.

Repair, Remanufacturing, and Rebuild

Electromechanex. LLC specializes in Electric Motor Repair, including CNC Spindle Motor repair. With the ability to repair your spindle motors from any Turning Center, HMC, VMC, Grinding Machine, or any other application. Today’s machining centers are run by complicated spindle motors. These spindles utilize a variety of sensors, proximity switches and encoders that allow them to communicate with one another. We repair all makes and types of spindles, with our specialization in precision machining, it’s only fitting that our CNC spindle motor repair service is among the best as well. Because of the high speeds of spindle applications, eventually mechanical Imbalances within the rotating apparatus will cause unwanted problems to develop sooner, every spindle rotor is balanced to very tight specifications. Many spindle motor repairs will involve correcting mechanical damage in some form or another, all machine work done is performed using precision methods and with absolute mechanical attention.

TYPES OF SPINDLES REPAIRED

• Motorized Spindles
• Grinding Spindles
• High-Speed Spindles
• Machine Tool Spindles
• Machine Tool Spindle Repairs
• Milling Spindles
  

SPINDLES REPAIR SERVICES

• Analyze Service Recondition
• Onsite Spindle Repairs
• Precision Spindle Bearings
• Predictive Maintenance Services
• Remanufactured Spindles
• Spindle Service Information