Electric motors are the backbone of industrial and residential applications. However, they can fail prematurely if not properly selected, installed, or maintained. Understanding common causes of motor failure and implementing preventive measures ensures reliability, efficiency, and long service life.

1. Overheating

Excessive heat is responsible for nearly 50% of motor failures. Causes include overloading, poor ventilation, high ambient temperature, and frequent starts/stops.

• Prevention: Maintain clean ventilation paths, use motors with correct duty cycle (S1, S2), add external cooling if required, and avoid overloading.

2. Bearing Failures

Bearings carry the motor’s rotating load and are prone to wear from misalignment, poor lubrication, vibration, or stray currents.

• Prevention: Use correct alignment during installation, follow lubrication schedules, monitor vibration, and consider insulated bearings in VFD applications.

3. Electrical Insulation Breakdown

Voltage spikes, harmonics, moisture, and thermal stress can weaken winding insulation, leading to short circuits or ground faults.

• Prevention: Install surge protection, use VFDs with filters, maintain insulation resistance through periodic testing, and choose motors with Class F/H insulation where needed.

4. Shaft Misalignment

Poor coupling alignment leads to vibration, bearing wear, and premature shaft damage.

• Prevention: Align shafts with laser alignment tools, check foundation rigidity, and perform routine alignment checks after maintenance.

5. Contamination (Dust, Moisture, Chemicals)

Ingress of dust, moisture, or corrosive agents can damage windings, bearings, and cooling systems.

• Prevention: Use correct IP-rated motors (IP55, IP66), ensure seals are intact, and install motors in clean, ventilated areas or with protective enclosures.

6. Improper Voltage & Supply Issues

Undervoltage, overvoltage, unbalance, or single-phasing leads to overheating and winding damage.

• Prevention: Monitor supply with protection relays, ensure balanced loads, and use motors designed for wide voltage bands (like CG Power motors rated 180–260V).

7. Frequent Starts and Stops

Repeated cycling causes thermal stress, excess current draw, and mechanical wear.

• Prevention: Use motors with suitable duty rating, employ soft starters or VFDs, and avoid unnecessary frequent starts.

Final Thoughts

Motor failures are preventable with correct selection, installation, and preventive maintenance practices. By using high-quality CG Power motors and following best practices, industries can reduce downtime and extend motor lifespan. Bombay Engineering Syndicate supports customers with technical expertise, genuine motors, and after-sales guidance.

Contact us today for motor maintenance advice and reliable CG Power motor solutions.

By: Manish Chandrani; +919825014977