Expert Rewind and Repair Services for Industrial Brake Motors and Coils
Reliable braking systems are essential for safety, precision, and efficiency in industrial machinery, powering everything from overhead cranes and conveyors to specialized lifting equipment. When a brake motor or its critical component, the brake coil, fails, rapid and expert service is required to minimize downtime. Professional repair and rewinding services offer a sustainable and cost-effective alternative to full component replacement, restoring your equipment to optimal operational standards.
We specialize in the meticulous diagnosis, repair, and rewinding of all makes and models of AC and DC industrial brake motors and coils.
Key Stages in Professional Brake Motor and Coil Overhaul
The following procedural steps ensure longevity and peak performance following a repair or rewinding service:
| Stage |
Process Description |
| I. Comprehensive Diagnostics and Pre-Repair Assessment |
- Initial Inspection: Thorough visual and mechanical inspection to identify physical damage, excessive wear, or heat stress on the brake motor housing, rotor, and brake assembly.
- Root Cause Analysis: Utilizing advanced electrical testing equipment (including surge testing and insulation resistance checks) to determine the precise nature of the electrical fault impacting the brake coil or motor windings.
- Tolerance Measurement: Verification that critical dimensions and air gaps within the brake assembly meet OEM specifications to ensure proper engagement and release.
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| II. Specialized Brake Coil Rewind and Repair |
- Coil Stripping and Cleaning: Careful stripping of the failed copper windings and subsequent cleaning of the coil former to remove contaminants, burnt insulation, and residue.
- Rewind Brake Coil: Precision winding using high-grade copper wire and Class F or H insulating materials, ensuring robust thermal stability and electrical integrity suitable for demanding industrial environments.
- Vacuum Pressure Impregnation (VPI): Application of specialized resin under vacuum to fill all voids and pores within the coil structure. This significantly improves thermal dissipation, resistance to moisture and chemicals, and overall mechanical rigidity.
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| III. Motor and Assembly Refurbishment |
- Mechanical Component Restoration: Replacement of worn mechanical parts, including bearings, seals, friction discs, and pressure plates, to eliminate slippage and ensure smooth operation.
- Dynamic Balancing: The motor’s rotor is dynamically balanced to mitigate vibration, reduce operational noise, and prolong bearing life.
- Surface Preparation: Cleaning and application of protective coatings to the motor framework to guard against corrosion in challenging operating conditions.
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| IV. Rigorous Performance Testing and Quality Control |
- Electrical Testing (Static): Post-rewind and assembly testing, including megohmmeter (megger) and hi-pot testing, to confirm insulation can safely withstand voltage spikes.
- Functional Testing (Dynamic): Connecting the repaired brake motor to a load bank to simulate real-world operation, verifying correct brake torque, timing, and thermal performance.
- Final Documentation: Detailed reports outlining all repairs, materials, and test results for traceability and quality assurance.
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Frequently Asked Questions
Brake motors should be inspected every 6–12 months depending on load conditions and environment. Early signs of wear or heat damage should be addressed immediately to prevent full system failure.
VPI enhances dielectric strength, heat resistance, and moisture protection. It fills microscopic voids within the winding structure, improving durability and extending the motor’s operational lifespan under demanding conditions.
After rewinding and reassembly, motors undergo electrical, mechanical, and load simulation tests. These confirm proper insulation strength, braking torque, and operational performance consistent with OEM design.
