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A convenient incoming inspection report for basic DC motor conditions and test values.
There are times when a DC motor or generator experiences a catastrophic failure and the customer wants to know why it happened. One type of failure that seems to stimulate lively conversation is when the failure involves dramatic damage to the brushholders and commutator. The term "flashover" describes the appearance of the failure; the very name conveys an accurate mental image of the failure. The questions that arise next are predictable: "What caused this?" and "What can be done to prevent a recurrence?" Or, if the motor was recently repaired: "What did you do to my motor to cause this?!" The purpose of this article is to help you answer those questions.
When servicing DC motors, one of the many tests we do to determine the condition of the commutator is to check it for loose bars. We check for loose bars by lightly tapping the face of the commutator with a very small hammer. Then we check for suspicious sounds and movement or vibration of the bars as they're struck. A loose bar will have a dull thud while tight bars will have more of a crisp "peck." You should not feel any movement of the bar with respect to adjacent bars. If the commutator is molded or riveted,it is not repairable and it should be replaced. However, V-ring commutators can be repaired.
One of the least understood parts of a DC motor is the commutator. With a little understanding and some helpful tips, commutator life can be maximized.
This 40-page booklet provides great advice for obtaining the longest, most efficient and cost-effective operation from general and definite purpose electric motors.
This booklet covers topics such as:
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The Effect of Repair/Rewinding on Premium Efficiency/IE3 Motors
Tests prove Premium Efficiency/IE3 Motors can be rewound without degrading efficiency.
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Recommended Practice for the Repair of Rotating Electrical Apparatus
This is a must-have guide to the repair of rotating electrical machines. Its purpose is to establish recommended practices in each step of the rotating electrical apparatus rewinding and rebuilding processes.
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Revised May 2021
The EASA Technical Manual is the association's definitive and most complete publication. It's available FREE to members in an online format. Members can also download PDFs of the entire manual or individual sections.
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