Common Causes of Industrial Electric Motor Failures and How to Avoid Them

Industrial electrical motors are the backbone of many operations, from manufacturing plants to heavy machinery. However, even the most reliable motors can face unexpected issues, leading to downtime and expensive repairs. Understanding the common causes of electric motor failure and knowing how to prevent them can save time and money.

Our team at BCB Sales & Service explore these failures and practical tips to keep your motors running smoothly.

What Causes Electrical Motor Failures?

Electric motors don’t just stop working without reason. A combination of factors can contribute to their failure, and it's crucial to identify these issues early on.

1. Electrical Overload

Electrical overload, often referred to as overcurrent, occurs when a motor draws more current than it is designed to handle. This is usually due to low supply voltage or excessive demand on the motor. The extra current can cause the motor windings to overheat, damaging the insulation and shortening the motor’s life.

How to Prevent Electrical Overload:

• Install Protection Devices: Use circuit breakers or overload relays that detect and interrupt excessive currents.
• Check Motor Sizing: Ensure the motor is appropriately sized for its load.
• Monitor Voltage Levels: Regularly check that the voltage supply stays within the motor’s recommended range to avoid overloading.

2. Overheating

Overheating is one of the most common causes of electrical motor failures. This problem can stem from poor ventilation, high ambient temperatures, or the motor working beyond its rated capacity. Overheating damages the winding insulation, which can lead to motor burnout—meaning the motor stops functioning altogether.

How to Keep Motors Cool:

• Ensure Proper Ventilation: Keep cooling fans and vents clean and unobstructed to maintain airflow.
• Install Temperature Sensors: Use sensors that alert you when the motor reaches unsafe temperatures.
• Maintain Ambient Conditions: Use air conditioning or cooling systems in high-temperature environments to reduce heat buildup around the motor.

3. Contamination

Contaminants such as dust, dirt, and chemicals are silent killers for electric motors. These particles can find their way into the motor, damaging bearings, blocking cooling paths, and causing electrical faults.

Ways to Keep Contaminants Out:

• Clean Work Areas: Regularly clean your workspace, tools, and equipment to minimise dust and debris.
• Use Protective Covers: Install seals or covers on motors to keep out harmful contaminants.
• Position Wisely: Place motors away from equipment that generates dust or particles, like grinders or sanders.

4. Vibration

Vibration can result from loose mounts, misalignment, or worn bearings. This constant movement stresses the motor components, leading to premature wear and eventual failure.

How to Minimise Vibration:

• Regular Alignment Checks: Use alignment tools to properly align the motor and load.
• Tighten Mounts: Make sure all bolts and mounts are secure to prevent excessive movement.
• Inspect Bearings: Check bearings for signs of wear or damage and replace them as needed.

5. Low Resistance

Low resistance typically occurs when the insulation within the motor windings degrades due to factors like heat, corrosion, or mechanical damage. This results in electrical leaks, short circuits, and motor failure.

How to Prevent Low Resistance Issues:

• Inspect Insulation Regularly: Look for signs of wear or damage to the winding insulation.
• Use Quality Insulation Materials: Invest in high-grade insulation that withstands harsh operating conditions.
• Monitor Operating Environment: Keep the motor’s operating area cool and dry to prevent insulation breakdown.

6. Improper Lubrication

Lubrication is essential for motor bearings to operate smoothly. Too much or too little lubrication can lead to overheating, increased friction, and motor failure.

Tips for Proper Lubrication:

• Follow Manufacturer Guidelines: Stick to the recommended lubrication schedules and amounts.
• Use the Correct Type of Lubricant: Ensure the lubricant is compatible with your motor’s specific requirements.
• Avoid Over-Greasing: Over-greasing can cause heat buildup, so add lubricant slowly and carefully.

7. Motor Burnout

Motor burnout refers to the failure of the motor windings due to excessive heat, poor insulation, or mechanical stress. This condition often results in the motor seizing up or completely stopping.

How to Prevent Motor Burnout:

• Install Overload Protection: Use devices that cut off power when the motor starts drawing excessive current.
• Keep Motors Clean and Cool: Regularly remove dust and debris around the motor and ensure adequate ventilation.
• Inspect Motor Windings: Periodically check the windings for signs of wear, heat damage, or electrical shorts.

8. Moisture Damage

Moisture can seep into the motor windings, especially in humid environments, leading to corrosion, insulation breakdown, and electrical faults. This is a significant concern for industrial electrical motors operating in wet or damp areas.

Ways to Protect Motors from Moisture:

• Control Humidity: Use dehumidifiers or climate control systems to keep moisture levels low in the motor’s environment.
• Seal the Motor Properly: Use waterproof seals and coatings to protect the motor from moisture ingress.
• Store Motors Properly: Keep inactive motors in warm, dry conditions to prevent condensation.

Find the Perfect Electric Motor Solution at BCB Sales & Service

Are you looking to avoid motor failures or upgrade your equipment? BCB Sales & Service has an extensive selection of top-quality electric motors and components designed for reliability and performance. We offer solutions for all industrial and commercial applications, from blower motors to vacuum motors and motor starting capacitors.

Explore our full range of motors online or visit us in-store today. Our knowledgeable team is ready to help you find the perfect fit for your needs.