September 21, 2023

Decoding Motors: Differences Between Servo and DC Motors 

Servo Motors and DC motors are highly used machinery assets for different applications within the manufacturing industry. The distinctive difference between the two types of motors is control, precision, and application. 

Servo Motors are commonly used in CNC machines, robotics, and industrial automation. Strong precision makes a servo the go to motor for automation. Torque control is a key benefit, providing control at high and low speed, for machining applications cutting through tough materials or applying significant force during the operation. 

DC Motors are commonly used in Electric Vehicles, HVAC systems and Conveyor systems. The build of the motor is simple, which contributes to the reliability of the motor, ease of maintenance and durability. Providing high-efficiency levels, a DC motor converts electrical energy into mechanical energy with minimal loss. This is a benefit for businesses to reduce operating costs, also helping to become sustainable and reducing environmental impact as a business by a reduction in energy usage. This is crucial to maintain ISO 14001 standards, Environmental Management System regulations.   

Key differences between a Servo Motor and a DC Motor 

Servo and DC motors have different characteristics, as they are each suitable for different applications within the industry. The key differences are:   

Control Mechanism:  

Servo motors are designed for precision and positioning when running. Built with a feedback system, such as an encoder, to provide information on speed, direction and position when machining. This type of motor is controlled using a closed-loop control system.  

DC Motors are controlled by a signal that determines speed and direction, but not position, using an open-loop control system. 

Torque Output (Torque is the force within a motor): 

Servo’s higher torque capability allows them to control heavier loads to high precision.  

DC motors have varying torque depending on the specific type of motors, brushed or brushless. This type of motor cannot guarantee the same torque output as a Servo.  

Speed Control:  

Servos have the capability to consistently maintain a set speed as a result of the closed-loop system, and can quickly change their speed to the requirement.  

A DC motor can control the speed, however the accuracy can be affected if changes to the speed are continually altered. A DC motor will run better when set at one speed.  

Choosing your Motor 

It is crucial to investigate the specifications of the application in order to determine the appropriate motor for machining purposes. This will enhance the accuracy and effectiveness of your equipment. Neutronic suggests researching the following before investing in a Servo or DC Motor: 

Precision Requirements – If you require machining at high precision, a servo motor will meet this demand and offer accurate speed and precision when machining. A DC motor is suitable when precision control is not as critical, and simplicity and cost are key focuses.  

Compatibility Requirements – Consider the implementation of the equipment into existing systems, such as communication, compatibility with controllers and programming tools.  

Cost Consideration – DC motors are considered to be more cost-effective than Servo’s, due to their build simplicity. However, consider the application requirements to make sure the investment meets the performance requirements to produce a successful ROI on the asset investment.  

Investing in a Motor? 

Our account managers at Neutronic can offer outstanding advice, if you are unsure about which motor is best suited to your manufacturing needs. Neutronic can source motors from a range of major manufacturers such as SEW-Eurodrive, WEG and ABB with reduced lead times and outstanding prices.  

Contact our team on 0845 180 0483 to discuss this further, or take a look at our supply page! 

Industry Application  

As discussed throughout the blog, different industries will require different motors to meet the manufacturing requirements. An example of an industry application is a Servo Motor being used within a CNC machine.  

A CNC machine requires high precision, this is crucial within CNC machining as they machine complex part with a high-quality surface finish. Servos offer control of speed and acceleration making it easy to adjust the speed of machining throughout the programme.  

The closed-loop control used within the Servo is what contributes to the accurate positioning when machining, which is why improved performance is offered, in comparison to a DC motor for this specific industry application.  

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Megan Birch0 commentDC Motor Repairs, Electro-Mechanical Repairs, Servo Motors
September 21, 2023

Reasons for Servo Motor Failure

There are numerous reasons why Servo Motor failures happen. It’s crucial to understand the preventative maintenance measures you can implement to minimise the likelihood of unforeseen motor failures. A Servo Motor can be affected by Electrical, Mechanical, or Environmental factors, which can hinder its operation. 

Run Testing a Servo Motor

Most manufacturers estimate a machining lifespan of 20,000 to 30,000 working hours for servo motors, although this can fluctuate based on the application and maintenance performed on the servo. 

This blog will explore 5 potential causes of Servo motor failures and suggest methods to optimize the efficiency of the Servo Motor. 

Continual operation of a servo motor at high temperatures, or without adequate cooling intervals can lead to overheating. Persistent overheating can eventually lead to motor failure, as it damages the internal insulation and diminishes the motor’s efficiency. 

To avoid overheating in the Servo, it is advisable to improve the regulation of heat distribution within the servo. Regular upkeep of the servo can help detect worn-out parts; replacing these parts can minimize the heat generated during rotation. Allowing extended cooling periods will assist the motor in resetting its temperature before it starts operating again. 

Degraded Bearings 

Continuous spinning inside the Servo can degrade specific parts, with bearings being a prime example. When a bearing deteriorates, it can cause the motor to become loud or even stall. Bearings play a crucial role in a servo, as their degradation can affect the accuracy during machining. 

Increased friction is produced when bearings are worn out. This friction can elevate the temperature while the motor is in operation, and potentially lead to the motor overheating, which is an adverse effect. 

Environmental Consequences 

The environment in which the Servo motor operates can influence its effectiveness, especially if it’s not an appropriate setting. Environments that are corrosive, hot, or humid can heighten the risk of motor breakdowns and diminish the dependability of the Servo Motor. This factor should be considered when choosing the motor for a specific task, ensuring it can endure the environmental conditions. 

Intrusion of dust or liquids can negatively affect the motor and its internal parts. Monitoring the dust accumulation within the servo is crucial, as excessive dust can pose a fire hazard within the motor. 

Servo Motor Maintenance Obligations 

Maintaining machinery is crucial for detecting and fixing issues before they inflict internal damage to other parts. Regular inspections of lubrication levels, cleanliness, and motor balance are essential aspects to be examined when the motor is frequently in operation. 

Servo Motor Vibration Issues 

Vibration in the motor can lead to misalignment, as the motor’s movement can displace internal components. If your servo is vibrating, this is an indication that it needs to be inspected and rebalanced to reduce the vibration. At our Neutronic workshop, we utilize our CEMB 2000 or ZB20/TCN/GV balancing machines, essential tools for motor repairs. Every motor that exits our workshop is rebalanced to G1.0, enhancing its efficiency and lifespan. 

Our servo motor specialists at Neutronic possess the skills to detect, correct, and test the servo motor to ensure it operates at OEM specifications. Email Neutronic today to schedule your Servo Motor repair today! 

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Megan Birch0 commentElectro-Mechanical Repairs, Servo Motors
September 21, 2023

Investment in Another CEMB Balancing Machine

We are proud to announce we have recently invested in another CEMB balancing machine. This is a smaller balancing machine, in comparison to our ZB2000. Investing in this equipment will allow us to balance smaller rotors easily and more accurately.

The ZB20/TCN/GV CEMB balancing machine implemented in our Electro-mechanical workshop has the capability to re-balance rotors up to 20KG. Built to provide precision and outstanding balancing capabilities, this machinery asset can feel any vibration within the rotor, due to being compact. This allows Neutronic to provide re-balancing to all small-sized motors.

What Machinery Assets Can be Rebalanced?

Rotors within a motor can be rebalanced on this machine. As part of the Electro-Mechanical repair Neutronic service, we rebalance every motor repair which is sent to our workshop. We understand this is a critical part of the repair to prolong the longevity of the motor, and minimise the need for replacements.

Benefits of Rebalancing Rotors

There are many benefits to why rebalancing rotors is important and a critical part of the repair, as stated below:

1) Reduction in Noise and Vibration. Noise and vibrations are both signs of a fault within machinery. Vibration within a rotor can be generated from loose connections, misalignment or internal damage. It is crucial for an engineer to take a look if your motor is vibration or making a noise.

2) Increase Reliability. If a motor is regularly balanced, this can improve the reliability of the asset, and unexpected breakdowns are less likely. It helps reduce long-term internal damage.

3) Improved Efficiency. Bearings and internal components will become damaged, if weight is uneven on a motors shaft. A correctly balanced motor allows the load to be evenly distributed and run efficiently.

4) Reduction in Maintenance Costs. If a motor is regularly re-balanced, it is likely to experience fewer mechanical breakdowns and will require less maintenance cost.

At Neutronic, we understand Reliability, Efficiency and Time is important to all of our customers which is why we quote re-balancing as part of each repair. This will allow you to have confidence that your machinery asset is correctly aligned it machining at maximum efficiency and low likelihood of unexpected breakdowns. Contact Neutronic today to book in your asset for re-balancing, Email now!

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Megan Birch0 commentElectric Motors, Electro-Mechanical Repairs, Equipment
September 21, 2023

Applications of Servo Motors in Manufacturing 

Servo motors are widely used in manufacturing, for their strong precision and accuracy. They are applied in different industries for various machining tasks, such as CNC machining, textiles and paper manufacturing.  

Image Source

How Do Servo Motors Work? 

Typically consisting of a DC motor, gearbox, control circuit and a feedback system, these parts work together to provide precision when machining. The DC motor provides the primary rotational force, working alongside the gearbox which reduces the speed, and increases the torque output to meet the running requirements.  

The control circuit signals determine the motors desired position, from the information that is received from the external device or controller. The feedback mechanism provides information about the motors current position. 

How Does a Servo Motor Brake Work? 

The brake within a servo consists of two parts, an electromagnet, and a brake armature. When the brake is engaged, the electromagnet generates a magnetic field that attracts, holds the armature, and stops the motor shaft from rotating. 

The brake is released when the electrical current to the electromagnet is interrupted. By stopping the current flow, the magnetic field diminishes and pushes the armature away from the electromagnet. Once the armature is pushed away, the motor shaft can rotate freely. 

How does a servo Motor know its required position? 

A servo usually has a feedback device, such as an encoder, which provides signals to correspond with the motors current position. Encoders produce precise digital signals. There are two types of encoders: 

Incremental Encoder  

This type of encoder generates pulses as the motor shaft rotates, which indicates the movement and direction of rotation within the motor. The pulses allow the control system to know the position of the motor, in relation to the starting point. 

Absolute Encoder  

An Absolute encoder has a unique digital code for every position of the motor shaft, instead of using pulses from a known starting point. This type of encoder provides precise and immediate position information, enabling accurate control and feedback. 

Servo Motors Holding the Required Position 

Servo motors rely on a feedback device to provide information about the motors current position, in order to hold the required position. If the control system identifies a potential error, which is the difference between the desired and actual position, the control system will adjust the signals which are sent to the motor to meet the needed position.  

Torque is generated within the motor to counteract external forces which could cause the motor to move away from the desired position. Torque is continuously adjusted to protect the motor from moving out of position, as a result of external forces. This is important to provide accuracy and precision for the motor, whilst it is running.  

Servo Motors in Industry 

Where precision is needed in industry, servo motors are the go-to. The features make them highly used across a number of industries, common application examples are: 

Robotics – As controlled movements are required by robots, servos power the limbs and joints of the robot. The different types of robots such as, cobots and humanoid robots, will all use servos for movement power. 

Industrial Automation – For production lines such as textile machinery, printing and conveyors where high speed is required, servos are the chosen motor type to provide the speed control capability. 

HVAC Systems – Servo motors regulate airflows, temperature and pressure control within the HVAC systems. 

The Future of Servo Motors  

Servo motors are highly used within industrial automation, a market which is expected to double in size by 2028. This presents a positive future for servo motors, being a motor which will be in high demand as a result of the use of robots and automation within the industry. Neutronic is excited to support the manufacturing industry with servo repairs.  

Neutronic is proud to support customers with Servo Motor repairs, we have invested in the latest technology and diagnostics systems to test and align feedback devices to OEM specifications. We understand as the use of servos in the industry grows, it is important to continually invest in the department to meet the demand. Our emergency 24/7 repair service allows us to support customers in critical situations and help get production lines back up and running.  

Take a look at Servo Motor repairs at Neutronic Technologies here.  

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Megan Birch0 commentElectro-Mechanical Repairs, Servo Motors
June 19, 2023

Choosing Your Electric Motor Repair Partner

Estimated reading time: 3 minutes

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Not all motor repair facilities are equal, in fact the difference between a motor repair company and a quality motor repair provider could mean a huge difference for the longevity and efficiency of your repaired motor.

Unfortunately, the industry has no legislation to enforce the quality of the repairs that are carried out, so it falls to the person in need of the repair to do their due diligence, and ensure that they are procuring a high level of quality when choosing a repairer.

Repairers vary from independent 1 man operations working from tiny premises, to multinational businesses operating in various places around the globe. So when choosing your repairer, does big mean better? And does being affiliated with a trade body such as the AEMT guarantee a high standard of repair? The answer is no to both of those questions.

Motor being repaired in the Neutronic Technologies Workshop

When choosing your repairer, you need to ensure they have the appropriate equipment to carry out the repair properly and if the repairer has multiple sites. Make sure they have the equipment needed at the branch you are using. You would be amazed at how many companies I have come across over the years who are poorly equipped or even lack basic essential repair equipment.

What to ask your Electric Motor repairer to demonstrate?

Surge Tester:- Without a surge tester the repairer has no real way of performing electrical tests on the stator. A multi-meter and megger test is simply not capable of testing electric motors sufficiently. In our repair shop we use the Electrom Instruments iTIG III Winding analyser.

Pyrolysis Oven:- One of the major processes of rewinding a motor is to remove the old windings, varnish and insulation. It’s not an easy process unless you have one of these Ovens which you must not mistake for a curing oven, they are very different. It’s surprising how many rewind shops don’t have this equipment but without it you cannot guarantee the ongoing efficiency of the motor after the repair.

Dynamic Balancing:- Another large and expensive piece of repair equipment that is essential to a high quality repair. The balancing machine ensures the rotor assembly is finely tuned and balanced for all speeds of rotation. Remember a slight imbalance on a rotor can quickly degrade bearing life and cause damage to other areas of the machine the motor is connected to.

There are lots of other pieces of equipment that we use in the repair process such as sand blasters, wash tanks, curing ovens, rotor removal equipment, bearing heaters, cranes, mechanical measurement devices and countless other tools, but in my opinion the 3 listed above are by far the most important for any rewind shop to effect a quality and reliable repair.

Book in your Repair with Neutronic Technologies:

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    admin0 commentElectric Motors, Electro-Mechanical Repairs, Equipment
    June 19, 2023

    Repair It, Rather Than Replace It…

    Estimated reading time: 3 minutes

    Table of content

    In the event of a breakdown, your first thought may be to replace the HMI, Power supply or machinery asset. This could be due to production pressures or an obsolete part. However, it may be more expensive to replace the existing one, than to repair it!

    Motor Gearbox Repair

    In most scenarios, repairing faulty parts is most likely the best financial option, until the cost exceeds the economic repair costs. Another benefit for companies is the repaired part can be easily reinstalled into situ, rather than installing a new part. Research conducted by the AEMT and EASA associations reveals that electric motors can be rewound multiple times. This process can maintain, or even improve, the motor’s electrical efficiency without needing to be replaced.

    Repairing Obsolete Parts

    As technology advances, there will be an increase in obsolete repairs due to capabilities and automation developments. A part becomes obsolete because it is no longer produced by manufacturers or has been discontinued.

    At Neutronic, we understand the need to continue using obsolete parts. We support our customers with our in-house equipment and skills to complete obsolete repairs. Our testing facilities can run test obsolete parts to ensure they are operating at peak efficiency.

    An obsolete part we regularly have sent to Neutronic is a Mitsubishi E1012 HMI, commonly used by Food and Beverage manufacturers. These are widely used in the industry, however, are no longer manufactured by Mitsubishi. Our engineers can repair and run test the obsolete E1012 HMI back to working order with our in-house facilities.

    How can I reduce breakdowns?

    Regular asset maintenance will help reduce unexpected breakdowns, ensuring the machinery meets OEM specifications to keep running at peak efficiency.

    Implementing a Condition Monitoring system into your workshop will help you to monitor the equipment’s efficiency. Indications of concerning changes that could lead to breakdowns in the future will be outlined. Preventative maintenance allows you to schedule the repair, suiting your production schedule, minimising unexpected downtime.

    Asset management helps to monitor the operation of your parts. Research recommends that Motors should be serviced every 6 months. Performing routine preventative and predictive tasks can extend a motor’s life and improve its efficiency.

    Keeping a Spare on the shelf?

    Storing spares helps you quickly get your production lines back up and running in the event of an unexpected breakdown.

    Financial costs can be reduced by storing replacement equipment onsite. This will help reduce downtime. Exchange the faulty part for a working part to start production again. The failed part will then be sent in for repair.

    Neutronic supplies major manufacturing brands such as WEG, SEW-Eurodrive and Control Techniques. We are an official distributor of WEG products, providing high-quality products to our customer base. Contact our team for advice on which product will best fit your machining needs.

    Neutronic has the expertise to repair most obsolete repairs. If you have an obsolete part which you are looking to get repaired, contact us on 0845 180 0483.

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    Megan Birch0 commentElectric Motors, Electro-Mechanical Repairs, Obsolete Repairs
    June 19, 2023

    Common Faults in a Motor Gearbox

    Estimated reading time: 4 minutes

    Motor gearboxes are used in a variety of applications. Used to transmit mechanical power from an electric motor to a driven component or load. A gearbox is implemented in the motor to determine the required output speed and torque needed for the specific application.

    Gearboxes are often a critical part of machinery in the production line, that keep the line moving. Breakdowns of the gearbox can cause catastrophic failures, stopping production and financially impacting businesses. It is important to prevent unexpected failures, a solution is a preventative maintenance system to regularly monitor your asset efficiency.

    5 Common Faults in a Motor Gearbox:

    A piece of equipment used heavily in manufacturing, motor gearbox failures are common, some failures more common than others:

    1.      Overheating Motor. Excessive heat within the gearbox can further damage internal components such as bearings and gears. Gearboxes can overheat due to misalignment, operating at too high a speed or insufficient lubrication.

    2.      Vibration. An imbalance of the gearbox can cause excessive vibration and damage to internal components such as bearings or gears. Noise from the gearbox can be a sign of misalignment, in such case the gearbox should be booked in for repair.

    3.      Gear Damage. Damage within the gearbox can be caused by overloading, misalignment, or insufficient lubrication. This fault can lead to noise coming from the gearbox or even a breakdown of the machinery.

    4.      Lubrication Problems. It is important to monitor the lubricant level. If lubricant levels are too low, it can cause overheating and damage to the gearbox.

    5.      Electrical Failure. Causing damage to the motor gearbox, electrical faults can be caused by a variety of factors such as overloading.

    How can I Minimise Faults Occurring?

    Regular overhauls and maintenance can minimise the risk of unexpected faults. Necessary checks to the machine’s running efficiency helps to prevent damage to internal components.

    Lubrication is critical in the operation of a motor gearbox. For the motor gearbox to operate at maximum efficiency, the value should be kept at a suitable level. A sufficient lubricant level prevents gear and bearing failures.

    What are 3 indications that my Motor Gearbox is failing?

    There are many indications which can present failures occurring within the motor. It is important to manage your assets and when issues are noticed, are investigated for safety reasons. 3 indications of a failing motor Gearbox are:

    1. Excessive vibration within the motor is often a sign of misalignment or worn-out bearings. Neutronic have an in-house CEMB ZB2000 balancing machine, to rebalance rotors, pumps, fans, and impellors, this reduces repair turnaround time.
    2. Oil Leaks can indicate a potential seal failure, which can lead to a reduction in lubrication and damage to internal components.
    3. Reduction in power output can impact the overall performance of the motor including reduction in torque, power output, or speed.

    These 3 indications are just some which should be monitored. If any of these are identified, they should be looked at by a professional engineer.

    How can Preventative Maintenance Reduce Breakdowns?

    The main goal is to minimise unplanned downtime when running machinery. Efficient ways to reduce unplanned downtime is by implementing a Condition Monitoring system.

    Preventative maintenance and scheduled repairs can reduce unplanned downtime costs. This can be done by identifying faults and acting quickly. Monitoring your assets is crucial to reduce unexpected downtime.

    Vibration analysis, Thermal imaging and Laser Shaft Alignment are all ways to gather data on how efficiently your assets are running. Anomalies in the data may point to a potential fault, identifying these faults quickly can help you plan repairs during scheduled downtime.

    Establishing a Motor Gearbox Repair Partner?

    Neutronic engineers are exceptional at repairing motor gearboxes, SEW-Eurodrive is a popular manufacturing brand which we repair. We have an in-house test rig at our Warrington workshop. This rig is purpose-built to test run all SEW Eurodrive Movimot Inverters after they have been repaired. This provides our customers with a quick repair turnaround.

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    Megan Birch0 commentElectro-Mechanical Repairs, Motor Gearbox