Our skilled winders have the ability equipment to rewind any kind of industrial motor including AC, DC, Servo, pump motors, magnetic  chucks etc.

Dual enamel coated wires are used for winding to provide extra winding strength. Dual coated wines have the dielectric strength to with stand harmonics injected by VFDA.

All our motors are varnished with f50 varnish and baked in the oven. A layer of epoxy gel coat I applied on the windings to provide an additional lager of protection.

Motor windings then undergo high voltage (3 kv-5kv) test to reassure the insolation strength.
 

A large percentage of motor failures occur due to bearing failures. Bearings serve to reduce friction and allow smoother rotation. since bearings bear much of the mechanical load in a motor. They must withstand in a huge amount of friction and perform under tremendous force. Because these bearings are under immense stresses, they tend to wear out more quickly than other motor Components.
In order to maintain the original performance of a bearing for as long as possible, proper maintenance and inspection should be performed
It is a standard protocol for us to on every repair we perform.

Reasons for bearing failures:

Lubrication Failure

Contaminations

Improper Mounting

Misalignment

Corrosion

Pitting

Fatigue

Overheating

Excessive Loads

Improper storage and handling

If the induction rotor suspected to be faulty, first a through visual inspection is performed and checked for any damages in the rotor bars or end rings.

The rator is then tested on a growler to confirm for broken or damaged rotor conductors.

If found faulty one aluminium die cast is then dissolved and replaced with Copper bars and shorted on either side using copper end rings.

This process of rotor rectification using copper is extreamly robust and reliable.
 

We have the expertise to machine almost any kind of motor shaft or perform a repair on a worn out shaft.
We understand the importance of producing high quality and closely toleranced parts with our in-house machining facilities we can respond quickly when needed and manufacture on an urgent.

All our shaft are machined in-hase and finally inspected by our own engineers to ensure compliance with the required specification.
 

For dry rotating apparatus, such as an induction rotor,  slip ring rotor, alternator main field, DC armature or blower fan, it is extremely important that it is perfectly balanced on all sides. If there is more weight on one side of the rotating element, it will wobble as it rotates, causing failures due to vibration and instability. These problems get exponentially worse the higher speed the motor runs.

The most common failures due to imbalances in the rotor are,

• Premature Bearing failures
• Broken body or mounting due to excessive vibration.
• Destruction to the driven equipment or adjecent machine failures.
• Overheating of the motor causing winding failure.
   

Atmost care is taken to dynamically balance every single rotor on our very own inhouse 5 ton dynamic balancing machines.

At Certain times during winding failures flashes occur and damage the core stack. These damages can be severe enough to cause hot spots to occur at the points where the winding has flashed.

The inter-laminar insulation at these hot spots is completely deteriorated. If the damage is small and heat is not produced during a core test  it is left as it is. But during a core test if a hot spot is found to producing an abnormal amount of heat it indicates that it needs to be rectified. If left unrectified these hot spots might cause the winding insulation to breakdown prematurely and result in winding failure.

During the core fest the location of the hot spots are identified. The stampings dismantled and then restacked randomly distributing the damaged areas throughout the core.

Core restacking is very effective solving the issues that might occur due to a damaged core.

We are the authorised service partners for various reputed manufactures like ..

Kirloskar cropmton jyoti weg nidec these manufactures. We also have a robust network of suppliers and vendors to supply you any motor spare regardless of the brand.

After the machines are rewind and assembled they are subjected to a series of tests to ensure reliable performance under full load conditions.

Here are some of the tests:

1. Insulation resistance test
2. Winding resistance test
3. High-Voltage (HV) test (5 Kv- 5Kv)
4. Vibration and noise analysis 
5. Temperature rise test
6. Surge test

The overhauling process includes the following steps

1. Inspection and testing:

• The bearings are first tested for wear by running a vibration and noise analysis test
• The rotor and shaft is inspected for cracks, bends, corrosion or wears at bearing seatings
• The windings are inspected for insulation damage, discoloration or short circuits. (eg: surge tests, high voltage test etc.)
•  The covers are inspected for bearing fit tolerance in the bearing housing

2. Repiars and replacement:

• The motor is rewound is winding condition is fund to be bad
• If not the windings are revarnished and cured in the oven to change winding insulation and durability
• Damaged shafts are replaced or rectified
• The rotor is dynamically balanced.
• Other components such as worn sealf, gaskets, fasteners, terminal boxes, connectors and fans and replaced is needed.  

3. Testing after overhaul:

The motor is subjected to as series of test to ensure reliable performance under full load conditions. Here are some of the tests:

• Insulation resistance tests
• Winding resistance tests
• High-voltage (HV) test (3kv - 5kv)
• No-load run test
• Vibration and noise analysis
• Temperature rise test
• Surge test

4. Benefits of overhauling:

• Extends the motors service life
• Enhances performance and efficiency
• Reduces the likelihood of unexpected failures
• Saves cost compared to replacing the motors
• Minimize downtime

Our team of engineers will be at your site within a short notice to provide with any technical support or service your motor on-site if required.

Ουr engineers have the expertise to perform a failure analysis on your machine give a comprehensive feedback as to why the failure might have occured. This can enable you to take measures to prevent any further faults.