How to Extend the Life of Your Servo and Spindle Motors in Extreme Environments
The lifetime and efficiency of motors can greatly be affected by their environment. In our blog, Electric Motors and Generators Fail from Contamination, we discuss the affects of contamination and how you can prevent downtime. In addition to taking preventative measures discussed in our contamination blog, you may want to consider protecting your windings with Dreisilker’s patented insulation process, Ultra-Sealed Winding™. The process was developed to create total protection against moisture, prevent corrosion, improve heat transfer from the coils to the frame and enhance winding rigidity. The Ultra-Sealed Winding™ procedure involves insulating and sealing the winding through a mechanical and pressure process using a patented resin.
Ultra Sealed Winding (left); Conventional Winding (right)
An Ultra-Sealed Winding™ should not be confused with an encapsulated winding. Encapsulation only involves coating the coil ends, but when Ultra-Sealed, the coils are completely impregnated and sealed within high molecular weight thermoset polymer resin. There are two major advantages over traditional insulation methods. One is total protection against moisture. During in-house tests, windings have been completely submerged in synthetic cutting fluid for as much as 2 months without faulting to ground. The second advantage is more efficient cooling. The high molecular weight thermoset polymer resin is approximately 40 times more efficient at heat transfer than air.
Some common industrial applications for Ultra Sealed Motors include:
- Machine tool CNCs – Servo and Spindle Motors
- Steel Mills: Continuously wet and hot environments that demand reliable 24/7 uptime
- Poultry Processing Facilities
- Irrigation Operations.
- Pulp & Paper Mills
- Mining Operations
- Plastics Injection Molders.
- Petroleum Drilling Operations
- Food Processing
- Foundry Operations
In addition to the Ultra Seal Winding, our Super Seal process can also improve the reliability and uptime of your motors in harsh environments. When a motor operates at a very high output, it can overheat and begin to deform. The Super Seal process reduces motor overheating and flexing in addition from protecting the motor from moisture. Our 7 Step Process includes:
Our 7 Step Super-Seal Process:
- Replace plugs with environmentally sealed plugs, if necessary.
- Stator is stripped to bare metal on the exterior.
- Surface is prepared and masked.
- Motor is powder-coated using polyester materials and baked for two hours.
- Motor is re-assembled with sealed bearings (unshielded).
- End cover is assembled with gasket.
- Oil shield is installed.
The result is a motor that is significantly improved and able to endure adverse conditions at highest performance. Super Seal is commonly found in servo or spindle motor applications.
If you have motors that continue to fail due to their environment, you may want to consider our Ultra Seal and Super Seal processes to improve the lifetime of your motors. To talk with one of our motor experts today about how you can protect your motors, call 1-630-469-7510.
Are you interested in understanding additional reasons why servo motors fail? Read Common Causes of Servo Motor Failures and Preventative Measures to Limit Downtime.