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Abstract
The paper unifies previous experiences related to the motor rewinding. It discusses factors that influence the repair-
replacement decision, provides overview of the motor losses, analyzes the factors that determine the efficiency of the
motor and describes process of motor rewinding using traditional and alternative methods. Also the importance of
strictly following "Good Practice Guide to Maintain Motor Efficiency" during motor rewinding is highlighted.
Particular emphasis refers to the goal one should strive for: achieving maximum efficiency in the actual working point
of the motor. "Round robin test" and "Repeatability test", used to check the spread in efficiency figures, confirm the
importance of testing the efficiency of the motor in the same place and with the same equipment.
Fig. 2. The decision- making algorithm when Fig. 4. The distribution of losses in the motor
a motor fails according to the EASA/AEMT study
I-44 Международна научна конференция “УНИТЕХ’12” – Габрово
Table 1. The losses in a motor and the degree depends on the squares of the load current.
of their presence according to EASA/AEMT Maximum efficiency is usually achieved
study below full-load point.
Losses Losses causing factors % of
distribution
Core Energy required to 5-20%,
losses magnetize the stator core constant
Friction Friction in the bearings,
and and air friction against 10-25%,
windage the rotating rotor and constant
losses cooling fan
Stator Current flowing through
25-35%, vary
I2R the stator winding
with load
losses conductors
Current flowing through
Rotor I2R 15-20%, vary
the rotor bars and end
losses with load
rings
Fig. 5. Efficiency versus load
The remaining losses in
Stray the motor - the primary
10-15%, vary
load result of harmonic
with load
losses reactance flux leakage
induced by load current
MOTOR EFFICIENCY
The efficiency of any motor depends on its
original design (construction quality or
rewinding), motor load and power supply
quality [16].
Efficiency dependence on the motor design
is determined by: type ("U frame" motor is
generally more effective than the "original
NEMA" and smaller "T frame" designs), Fig. 6. Supply voltage unbalance dependence
power (high power motors are more efficient on the motor efficiency
than low power motors) speed (for example,
1800 r/min rated speed motors are mostly The supply voltage unbalance has a
more efficient than 1200 r/min and 3600 r/min significant impact on the efficiency of the
designs) (table 2), enclosure (totally enclosed motor, figure 6.
motors are more efficient than standard
efficiency design motors) and the value of the MOTOR REWINDING
rated motor voltage (with the same slot fill Motor rewinding methods can be divided
configuration, low voltage motors are more into three steps: coil removal, winding new
efficient than the higher voltage designs)[17]. coils and varnishing the stator.
Based on the applied techniques these
Table 2. The efficiency dependence on motor methods can be classified into two groups:
speed and power traditional and alternative.
Power (hp) 3600 r/min 1800 r/min 1200 r/min Traditional techniques generally last long,
71/2 84.0% 84.0% 84.0% figure 7. To start the next phase one must wait
50 90.2 91.7 91.7 for the end of the previous, which can take
100 91.7 92.4 92.4
several hours. Traditional techniques require
higher operating temperatures and thus higher
An example of efficiency dependence on insulation class rating. Higher operating
motor load is shown in Figure 5. Maximum temperatures also increases pressure on the
efficiency occurs where fixed-no load loss is mechanical components (such as bearings)
equal to variable-load loss that actually shortening their lifetime [18]. The alternative
ACKNOWLEDGMENT
These results are part of a project financed
by the Ministry of Science and Technological
Development, Republic of Serbia. (TR33016).
REFERENCE
[1] EASA, “Maintaining efficiency during
Fig. 12. Round robin test (60Hz operation) electric motor repair”