Common DC Motor Failures

When an electric motor fails on your line, you may wonder what caused it or how you can avoid motor failure in the future. The following are some of the most common causes of motor failures, as well as what you can do to avoid them.

1 Overload of Motor Windings

One of the most common causes of motor failure is an electrical short. When the motor windings are overloaded, an electrical short occurs, causing the motor to overheat and eventually fail.

Check that the motor is not overloaded and that the wiring is in good condition to avoid this type of failure. Using an adequate DC supply voltage or adding overcurrent protection is a good solution that can help. This can aid in the prevention of motor overload and electrical shorts.

2 Loose Windings

Loose windings are another common cause of motor failure. Windings that are not properly tightened can come loose and cause the motor to vibrate. Motor failure is inevitable at some point.
To avoid this, make certain that the windings are properly tightened and that there is no excessive vibration. A torque wrench or other similar tool can be used to tighten the windings.

3 Dirty Commutators

Commutators are an important component of DC motors that must be kept clean in order to function properly. Commutators that are dirty can cause the motor to run inefficiently and eventually fail.
To avoid this, clean the commutators on a regular basis with a brush or other cleaning method.

4 Bad Bearings

Another common cause of motor failure is faulty bearings. When the bearings wear out, the motor will vibrate and eventually fail.
To avoid this, make sure to inspect the bearings for wear and tear on a regular basis. If the bearings become worn, they must be replaced.

5 Degraded Winding Insulation Breakdown

Unfortunately, the insulation around the motor windings can degrade and break down over time. This can result in an electrical short, which can lead to motor failure.
The best way to avoid this is to inspect the winding insulation on a regular basis and replace it as needed. Excessive current flow due to winding corrosion is one factor that can cause motor windings to degrade. Debris and moisture combine to create extremely corrosive substances, and heat and physical damage can also cause premature wear. The best way to avoid costly downtime and extend the life of the insulation is to inspect it on a regular basis.

6 Motor Bearing Failure

Another common cause of motor failure is bearing failure. When the bearings fail, the motor can overheat, which eventually leads to failure.
Make sure the bearings are properly lubricated to avoid bearing failure. Improper lubrication or under-lubrication can cause the bearings to fail. In addition, make sure that the bearings are not overloaded and that they are not subject to excessive vibration.

7 Excessive Vibration

Another common cause of motor failure is excessive vibration. Excessive vibration in the motor can cause the bearings to fail or the windings to come loose. The bearing housing can also be damaged, resulting in failure.
To avoid excessive vibration, make sure the motor is properly mounted and listen for rattling noises.

8 Debris and Contamination

The most common causes of failure are debris and contamination. When the motor becomes contaminated with dirt, dust, or other foreign objects, the bearings and windings can fail.
Furthermore, the cooling fan used to cool the motor can become clogged with debris, causing the motor to overheat and eventually fail.
The most effective way to avoid this is to keep the area around the motor clean and clear of debris. Furthermore, ensure that the cooling fan is clean and unobstructed. To avoid problems like this, it's always a good idea to plan for regular maintenance.

9 Improper Installation

Not all motor failures are caused by mechanical issues. In some cases, the failure is the result of incorrect installation.
For example, if the motor is not properly aligned, it can cause excessive vibration, which can lead to bearing failure or winding housing damage.
Furthermore, if the motor is not properly supported, it can result in poor power quality, which can result in motor failure.
Check to ensure that the motor is properly installed and aligned. Also, to avoid power quality issues, ensure that the motor is properly supported.

10 Not Following Manufacturer's Instructions

Another common cause of failure is failure to follow the manufacturer's instructions. When the motor is not used or installed properly, the warranty is voided and the motor fails.
Furthermore, adding stress can result in insufficient torque, causing the motor to overload and eventually fail.
When installing or using the motor, make sure to follow the manufacturer's instructions. In addition, to avoid failure, ensure that the motor is not overloaded.

DC Motor Failures Statistics

While there may appear to be numerous causes of motor failure, statistics show that most failures can be boiled down to five common causes, which can help expound on the list above.

1 Bearings

Faulty bearings cause more than half (51%) of all motor failures. To avoid bearing failure, ensure that the bearings are properly lubricated and not overloaded or subjected to excessive vibration.

2 Windings

Corroded or deteriorated windings account for approximately 16% of all motor failures. Electrical shorts, overheating, and damage are all caused by faulty windings. Never let your windings go without a thorough inspection, and keep an eye out for physical damage.

3 External Causes

External causes of motor failure range from operator error to poor maintenance, weather extremes, and flooding. While some of these events may be beyond your control, the best way to prepare for success is to perform regular maintenance on your DC motors.

4 Other Causes

The remaining 10% of motor failures are due to rotor problems, motor shaft coupling (which is uncommon but can still cause failures), and unknown causes. That doesn't mean you should disregard them during routine maintenance checks.

Regular maintenance is essential for avoiding motor failures, by extension, downtime. By monitoring the health of your DC motor, you can avoid costly repairs and replacements while also ensuring optimal operation.

Conclusion

Did you find this list of the top ten most common DC motor failures useful? Follow the tips provided, such as inspecting your motors and adhering to manufacturer guidelines, to help extend the life of your motors and avoid costly motor repairs. Share this list with your peers in the industry, and check out Assunmotors for our coreless DC motors (brushless, brushed, and servo) today!

Coreless Motor and coreless dc motors - all in FBelec Electronics - professional and trustworthy