Industrial Electrical Services: The Essence of Rewinding an Electrical Motor

01 June 2023

In industrial electrical services, rewinding an electrical motor refers to the process of replacing the wire windings on the motor’s stator or rotor. This procedure is performed when the motor’s original windings become damaged, worn out, or when a different voltage or frequency is required.

Rewinding an electrical motor involves the replacement of copper wire coils, which can help the motor function optimally, last longer, and many more.

Industrial plants maximise a wide range of tools and equipment pieces to carry out their daily operations. Some things they utilise are fans, compressors, pumps, conveyors, mixers, machine tools, cranes, screens, feeders, and generators.

While these things function differently, they all feature a component that should be checked and maintained regularly. This component is the electrical motor.

An electrical motor works by converting electrical energy into mechanical energy. It works by creating a magnetic field that interacts with the one found on a stationary component called the stator. The interaction between the two magnetic fields generates a rotating force, causing the motor shaft to rotate and give power to the machine or tool that utilises the said motor.

The Significance of Copper Wire Coils

One crucial component of an electrical motor is the copper wire coils. These coils, as their name implies, are made from a high-quality copper wire tightly wound around a core. The wire is insulated to deter electrical current from leaking out of the coil, which may only cause the motor to malfunction or fall.

The coils found on motors are responsible for creating the electromagnetic field that drives and powers them up. Once an electrical current is passed through the wire, it generates a magnetic field around the coil. The motor’s rotor will then rotate as the said magnetic field interacts with the former’s magnetic field.

An electrical motor’s performance can be determined by the size and configuration of the wire coils. Over time, however, the copper wire in the coils can become damaged or worn out due to high temperatures, exposure to moisture or chemicals, or normal wear and tear.

Rewinding Electrical Motors are Vital

To restore the performance and extend the service life of an electrical motor, it should be rewound. Rewinding an electrical motor involves the replacement of the copper wire coils in the motor with new ones. It should be done once existing coils have become damaged, worn out, or have failed due to various reasons. Once done, one can expect their motor to last longer and work more effectively.

Rewinding an electrical motor begins by disassembling it and removing the existing coils. Disassembling it should be done carefully so that parts like shaft, bearings, or housing will remain intact. Once the coils have been removed, they must be measured to determine the gauge and length of the wire needed to create the new coils.

Afterwards, the technician would have to wind the new coils. The wire must be wound tightly and evenly around the coil without gaps or overlaps. They should also control the number of turns and the direction of the windings to ensure the compatibility of the new coils with the motor. The next step in the process is to place back the new coils into the motor and connect them to the appropriate terminals.

Ultimately, the motor must be reassembled and tested to ensure it is functioning properly.

Benefits of Rewinding Electrical Motors

Rewinding an electrical motor can bring tons of benefits. For one, it can ensure that the motor will not fail again due to electrical issues. This process can also extend the service life of the motor as well as prevent the need for a complete replacement that tends to be costly. Finally, rewinding an electrical motor can help maintain a safe and efficient operation.

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