5 Causes of Motor Failure and How to

Prevent Them
All electric motors have their predetermined life span, typically ranging from 30,000 to
40,000 hours. However, this is dependant on proper maintenance - without which they
are likely to break down much quicker. Understanding the top five cuases of motor
failure, as well as the steps that can be taken to reduce the risk of these failures
occurring will give your motor the best chance of achieving its maximum possible
service life.

1. Electrical Overload
Electrical overload or over-current is caused by an excessive current flow within the
motor windings, exceeding the design current which the motor is able to carry efficiently
and safely. This can be caused by a low supply voltage, resulting in the motor drawing
in more current in an attempt to maintain its torque. It can also be a result of short
circuited conductors, or an excessive voltage supply.
Possible solution: Electrical overload can be prevented by installing effective over-
current protection which will detect overcurrent and interrupt supply.

2. Low Resistance
The most common cause of motor failure, and arguably the most difficult to overcome,
is low resistance. Low resistance is caused by the degradation of the insulation of the
windings due to conditions such as overheating, corrosion, or physical damage. This
leads to insufficient isolation between the conductors or motor windings, which can
cause leakages and short circuits, and eventually motor failure.
Possible solution: The insulation should be regularly inspected for signs of wear, and
replaced before low resistance is able to cause failure.

3. Over-Heating
Around 55% of insulating failures in motors occur due to overheating. Overheating can
be caused by poor power quality, or a high temperature operating environment. For
every 10oc that the temperature of a motor rises, the insulation life reduced by 50%.
Possible solution: It is critical that the motor is kept as cool as possible, ensuring the
operating environment is kept cool if possible will help prevent breakdowns.
4. Contamination
Contamination from dust, dirt and chemicals is one of the leading causes of motor
failure. Foreign bodies which find their way inside the motor can dent bearing raceways
and balls, leading to high levels of vibration and wear. It can also block the cooling fan,
limiting the motor’s ability to regulate its temperature, and increasing the likelihood of
overheating.
Possible solution: Preventing contamination is relatively easy. Keep work areas, tools
and fixtures as clean as possible to help eliminate the chance of contamination entering
the motor. Also, when laying out the workspace, try to position motors away from
grinding machines which produce large amounts of contaminants.

5. Vibration
Vibration can lead to many issues with the motor, and can eventually cause the motor to
fail prematurely. Vibration is often caused by the motor being positioned on an uneven
or unstable surface. However, vibration can also be a result of an underlying issue with
the motor, such as loose bearings, misalignment, or corrosion.
Possible Solution: Motors should be checked regularly for vibration, using a motor
analysing tool such as the SKF EXP4000 Dynamic Motor Analyser. In order to reduce
vibration, ensure that the motor is positioned on a flat, stable surface. If vibration still
occurs, check for signs of wear, as well as loose bearings or misalignment. Consider
contacting a specialist if the source of vibration cannot be identified.