How to protect the motor to be burnt

1, Core preventive measures

1.Maintain cleanliness and ventilation

There should be no dust, water stains or debris within 3 meters around the motor air inlet to avoid short circuits or insulation damage caused by inhalation, and to ensure that the heat dissipation channel is unobstructed.

2.Operate at rated current

Avoid overloading (such as overloading, jamming, low voltage), otherwise the current will rise sharply, causing temperature rise to exceed the limit, accelerating insulation aging, and even burning the winding

Three phase current balance (for three-phase motors)

The difference between the current of any phase and the average value of the other two phases shall not exceed 10%, otherwise it is prone to local overheating

Real time monitoring of temperature

Regularly check the temperature of bearings, stators, and casings; If there is no automatic protection device, manual inspection is particularly important. If the temperature is abnormal, the machine should be stopped immediately.

3.Observe abnormal phenomena

Vibration, abnormal noise, burnt smell, etc. are all precursors of faults, and it is necessary to stop the machine in a timely manner for troubleshooting.

4.Maintain startup equipment

Contactors, thermal relays and other starting components need to be cleaned and fastened regularly to prevent burning caused by phase loss, arcing or poor contact.

 

 

2, Technological Upgrade and Intelligent Protection

1.Install protective devices

Overload protector: Set the current to the rated value of the motor for faster and more reliable response.

Integrated protector: integrates multiple protections such as overcurrent, phase loss, locked rotor, temperature, etc

2.Intelligent monitoring: For example, Wheatstone explosion-proof motors are equipped with PT100 temperature sensors and vibration monitoring, which can achieve predictive maintenance

Optimize operation mode

Reduce frequent start stop (especially avoid starting in hot conditions)

Adopting soft start or star delta start to reduce the impact of starting current

3.Regular insulation testing

Motors that have been out of service for over a month must have their insulation resistance measured before starting to prevent moisture damage and breakdown.

3, Special scenario precautions

1.In high-risk environments such as pyrotechnic devices, motors must meet intrinsic safety requirements:

2.Adopting explosion-proof (Ex d) or dust explosion-proof (Ex tb) enclosures to prevent electric sparks and surface high temperatures.

Using brushless electronic commutation technology to completely eliminate carbon brush sparks

Control surface temperature ≤ 135 ℃ (T4 group) to adapt to the limit of self ignition point of chemicals.

Tip: If the motor is equipped with overheating protection (such as electric vehicle motors), overheating shutdown is a self-protection mechanism and cannot be forcibly reused. The cause of overload should be identified and dealt with.

 

 

The direction of how to protect motor

1, Short circuit protection: "safety airbag" for the motor

The motor is most afraid of sudden short circuits, just like a car hitting a wall. The short-circuit protection of small and medium-sized asynchronous motors is like installing a safety airbag on the motor. When there is an abnormally high current in the circuit, the protection device can cut off the power supply within 0.1 seconds. The common short-circuit protection device is a fuse, which is like a "fuse". When the current exceeds the rated value, the fuse will quickly melt and cut off the circuit. There is also an air switch that can automatically trip in case of a short circuit, preventing the motor from being burned out. These two devices are like the "personal bodyguards" of the motor, always guarding the safety of the motor.

2, Overload protection: the "intelligent manager" of motors

The motor running under overload for a long time is like a person working under overload for a long time, which will be "exhausted". The overload protection device is the "intelligent manager" of the motor, which can monitor the current and temperature of the motor in real time. When the motor is overloaded, the current will increase and the temperature will rise. The overload protection device will act in a timely manner to cut off the power or reduce the motor speed, preventing the motor from being damaged due to overheating. A common overload protection device is a thermal relay, which cuts off the circuit by bending a bimetallic strip under heat, just like installing an "intelligent thermometer" on a motor to constantly monitor its "body temperature".

3, Phase loss protection: "anti leg breaking device" for motors

Running a three-phase motor without a phase is like losing a leg, which can cause a person to limp or even fall. The phase loss protection device is the "anti break leg device" of the motor, which can monitor the three-phase voltage of the motor in real time. When a certain phase voltage disappears, the phase loss protection device will immediately cut off the power supply to prevent the motor from burning out due to phase loss operation. Common phase loss protection devices include phase loss protection relays, which cut off the circuit by detecting the imbalance of three-phase voltage, just like installing an "intelligent balance meter" on a motor to constantly monitor whether the motor's "pace" is stable.

 

 

The reasons to cause the motors to be burnt and the maintain the motors

1, The Three Hidden Killers Who Burn Out Electric Motors

The sudden strike of the motor is often related to these three "behind the scenes black hands":

Cooling system strike: Dust wraps around the cooling fins like a cotton quilt, the fan bearings get stuck and cannot rotate, the internal temperature of the motor soars above 100 ℃, and the insulation material is directly "burnt".

Voltage fluctuation shock: If the grid voltage suddenly rises by 5%, the current will surge by 25%! Frequent overvoltage shocks can cause the motor coil to lose its elasticity like a spring baked by fire.

Overload operation overdraft: Making a 5kW motor do 10kW work is like making elementary school students carry adult luggage. Continuous overload can cause copper wires to overheat and melt, and insulation paint to carbonize and short-circuit.

2, Five tips to double the lifespan of motors

These maintenance techniques can keep the motor "alive" for 5-8 more years:

Monthly deep cleaning: Use compressed air to blow away dust from the gaps of the heat sink, paying special attention to whether the air inlet and outlet are unobstructed.

Quarterly lubrication inspection: Remove the bearing cover, inject special lubricating grease with a syringe, rotate the shaft core to evenly distribute the grease, and avoid high temperature caused by dry grinding.

Installing a voltage protector: Like buying "insurance" for a motor, it automatically shuts off when the voltage is abnormal, preventing hidden damage caused by overvoltage/undervoltage.

Load matching should be precise: leave a 20% margin when selecting, for example, if a 7kW power is needed, choose a 9kW motor to avoid long-term full load operation.

Optimization of operating environment: Maintain good ventilation, ambient temperature not exceeding 40 ℃, humidity below 80%, and avoid use in corrosive gas environments.

3, These details determine the life and death of the motor

90% of users are unaware of fatal details:

Start frequency: Start no more than 6 times per hour. Frequent start stop cycles will double the number of current surges and accelerate coil aging.

Loose wiring: Check the wiring terminals every six months. A contact gap of 0.1mm can cause local overheating, leading to arc burning.

Abnormal vibration: If the motor shakes, stop immediately for inspection. The unbalanced rotor generates hundreds of small impacts every revolution.

Cooling water flow rate: The water-cooled motor should ensure that the water flow rate is ≥ 0.5m/s and the water temperature does not exceed 35 ℃, otherwise the heat dissipation efficiency will decrease by 60%.

 

 

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