Electric Motor Repair
Industrial Electric Motor Repair
Optimized and Repaired to boost life cycle performance
At US Gearbox, we don’t believe in off-the-shelf solutions to electric motor repair. That kind of approach might fix a problem now, but won’t prevent it from happening again. And you have better things to do than to chase the same repair problem time and again. So before we start any repair, we ask “Why.” Why did the failure occur? What can be done to keep it from occurring again? Only then will we begin the repair. And our capabilities there are second to none.
Our electric motor repair shop capabilities and services include:
- Rewinds with Vacuum Pressure Impregnation (VPI) to ensure a void-free, cooler-running, longer-lasting electric motor winding
- Quality reconditions that increase motor life and prevent failures
- Computerized diagnostic equipment that provides accurate and complete testing of the electrical components within an electric motor or generator
- Stationary and portable motor repair equipment in order to repair in-house or on-site
- Testing capabilities of up to 13.8kV, 4000kVA, enabling us to apply full voltage to a motor, thereby simulating the full-voltage environment that exists within a given plant
- Computerized vibration spectrum analysis on an isolated test stand that yields true vibration readings on the motor individually, which can then be compared to the motor’s in-plant performance
- Dynamometer testing up to 2,200 ft-lbs that allows us to apply a load to your electric motor, further simulating how the motor will run when it is installed at the plant
- An in-house machine shop to manufacture parts that meet or exceed the original manufacturer’s specifications
- Large Electric Motor Repair: Lathe machining capabilities up to 79″ swing, 20′ long, at 64,000 lbs, so we can repair the largest of rotating components within an electric motor or generator
- Demagnetizing and degaussing equipment that allows us to remove residual magnetism from electric motor shafts, journals, bearing housings, etc.
Reliable electric motor Repair
US Gearbox services and maintains a wide range of electric motors. Using quality materials and thorough testing procedures, our experienced electric motor repair professionals can provide 24/7 service and support. Our electric motor and industrial maintenance services include inspection, testing and documentation, motor rewind and reconditioning, repair and removal services as well as pick-up and delivery of serviced parts.
All Types
- AC & DC Electric Motors
- Brake Motors
- Dynamometers
- Eddy Current Clutches
- Explosion Proof Motors
- Gear Motors
- Generators
- High Frequency Alternators
- Hoist Motors
- Metric Motors
- Miscellaneous Apparatus
- Permanent Magnet Motors
- Railroad Motors and Generators
- Small & Large Motors up to 10,000 h.p.
- Special Purpose Motors
- Spindle Motors
- Synchronous Motors
- Vertical Hollow Shaft Motors
The Electric Motor Experts
Dedicated small motor repair
US Gearbox has dedicated small electric motor repair shops (a shop within a shop) at many of our regional service centers. These cells typically focus on low-voltage units up to 690 VAC for common industrial applications and manufacturing facilities. Dedicated repair technicians run these small motor cells, instead of moving back and forth between large and small motors. They make fast repair-or-replace decisions, using standardized work procedures and processes engineered to reduce crane, work truck and cart interchange.Redesigning Electric Motors
US Gearbox has performed hundreds of successful redesigns for improved and longer lasting motor windings. Original motor designs (manufactured from 1950 to 1980) allow for modifications that can make repairs to your existing electric motor a better choice than buying a replacement. The newer motor designs have improved insulation but typically run much hotter than the older original units do. This higher heat factor is directly related to the smaller motor sizes used today (to replace existing older motors). The main concern is that the newer motor designs might not have the same lifespan as the original units, which makes it worth considering the redesign option.
Range of capabilities
- AC & DC Horizontal & Vertical NEMA Motors
- AC & DC Horizontal & Vertical Above NEMA Motors
- Synchronous Horizontal & Vertical Motors & Generators
- Wound Rotor Horizontal & Vertical Motors & Generators
- AC & DC Generators and Exciters
- Fan-Cooled, Weather-Protected, Non-Vented, & Drip-Proof Motors & Generators
- Explosion-Proof UL Motors
- Eddy Current Clutch and Press Drives
Industrial Electric Motor and Generator Rewinding & Repair
When it comes to industrial electric motors and generators, it is important to make an informed decision on whether or not to repair, rewind, or replace. The choice can mean the difference on production uptime, energy consumption, and total cost of ownership, which ultimately affects your company’s bottom line. At US Gearbox, we are able to analyze your motor or generator and offer solutions as needed.
US Gearbox has been focused on precision rewinding of industrial motors and generators for over 30 years. Throughout that time, we have strategically invested in our facility equipment and knowledgeable team of technicians to service apparatus small and large. We also provide all ancillary services in-house. Customers who choose US Gearbox as their electric motor repair shop recognize this competitive advantage and appreciate our commitment to first-class service in a one-stop-shop environment.
Our Core Iron Reclamation Process
When a stator or rotor requires a rewind, we make every effort to preserve the mechanical and metallurgical integrity of the core iron. We also work to remove the old conductor in an efficient and economic manner. We have three temperature-controlled ovens equipped with chart recorders and sophisticated controls that limit the core to no higher than 700 degrees Fahrenheit to ensure proper reclamation.
We conduct core loss inspections on all laminations. This process is done using a computerized core loss tester that excites the cores to predetermined parameters for the size and type of iron. Detailed thermographic inspection of the iron reveals the hot spots, and an infrared picture is taken for documentation. In many cases, a core iron can be repaired by a “scramble restack.” However, in situations where a new core iron is needed, we use the latest in laser cut or precision punched C-5 or C-7 lamination material.
