In this article, our team offers you some insights into the common causes of electric motor failure to assist you in preventing this issue. These are five things you need to know about the common electric motor failure causes.

The Status of the Average Electric Motor in the United States

Electric motors used in industrial settings are crucial to many businesses in the United States. When motors fail, it is often due to bearings, external causes, windings, shafting/coupling, and other unknown causes.

5 of the Most Common Electric Motor Failure Causes

These are the five most common electric motor failure causes. They include:

• Excessive current flow can lead to electrical overload
• Low resistance is the most common cause of electric motor failure
• Overheating leads to 55 percent of insulating failures with electric motors
• Dust, chemicals, and dirt can lead to electric motor contamination
• Vibrations are another common cause of issues with electric motors

Some Key Lessons Learned from Electric Motor Failure

One of the most important lessons to learn from electric motor failure is the importance of performing routine checks. The good news is that you do not have to feel like you are alone in these efforts. You can count on the Tekwell Services team to be there for all your service needs.

Get a Motor Maintenance and Repair Service Consultation

You can rely on the Tekwell Services team when it comes to industrial motor service in Knoxville. Contact us today to find out more about what we can offer you regarding motor maintenance and repair services. We look forward to making a difference for you and your crucial electric motors. Our team can be reached online or by giving us a call at 1-888-984-4668.

The post 5 Things You Need to Know About the Common Causes of Electric Motor Failure first appeared on Tekwell.

Vibration analysis for electric motors is a powerful tool that can be used to save time and money on repairs. It’s a way of monitoring the condition of your motor on a regular basis, which can lead to timely maintenance and repair when necessary. At Tekwell Services, we are the industry leader in motor vibration analysis in Knoxville. The following is the latest information about electric motors and the process of vibrational analysis.

An Introduction to the Topic of Vibrational Analysis for Electric Motors

When it comes to the basics of vibration analysis of an electric motor, essential factors to focus on include intensity, amplitude, and frequency. These various vibrations can link to different phenomena that occur with the engine. This is how the vibration analysis data can help provide insight into whether the electric motor is currently in a good state of repair.

Vibration analysis of an electric motor is done in order to access the health of the motor. Vibration is typically measured in G’s, or millimeter per second squared, units for use by engineers.

The Basics of Vibration Analysis

Vibrational analysis for electric motors is important as it can help to keep them running smoothly and at their best performance. The purpose of vibrational analysis is to identify and eliminate sources of vibration that could lead to degradation in motor performance, lifespan, and efficiency.

One of the basic uses for this analysis is that when an electric motor is in operation, its bearings are subjected to high levels of friction. This friction will cause heat buildup which in turn causes metal parts to expand and contract. The uneven expansion and contraction displace the metal parts from their original position, causing vibrations at both high and low speeds.

What Can Vibration Analysis Measure?

Vibration measurement is a way to identify and monitor machinery faults. It is used in different industries such as the Aerospace, Automotive, Manufacturing, and Service industries.

Examples of problems vibration analysis can detect include:

• Rotating equipment errors
• Misalignments
• Loads that are unbalanced
• Faults in rolling element bearings
• Resonance conditions

The Best Way to Use Vibration for Your Electric Motors

Vibration is an often-overlooked factor of electric motors. The vibrations can cause a variety of issues such as decreased lifespan and unfavorable output. Using vibrational analysis for electric motors is promising. It can help to reduce the downtime of your equipment and can also extend the equipment’s lifespan. This will lead to lower repair and replacement costs.

Use vibration analysis for electric motors to gain the following benefits:

• Reduced maintenance costs
• Reduced equipment downtime
• Increase the electric motors’ lifetime of use
• Keep repair costs low

Contact Us for Electric Motor Vibration Analysis

Contact the Tekwell Services team today to find out more about motor vibration analysis Knoxville. Our friendly and knowledgeable staff members are standing by and ready to offer you a consultation for the motor repair and maintenance services. We look forward to taking your call and answering your questions. You can reach us through our quick solution form or you can give us a call at 1-800-829-7454. You can also contact us by email at info@tekwellservices.com.

The post Put Your Electric Motors to the Test with Vibrational Analysis first appeared on Tekwell.

All types of ultrasonic cleaners use cavitation bubbles—bubbles created by rapid changes of pressure in a liquid–to clean parts with lots of crevices and complex shapes within them.

Why Ultrasonic Cleaners Are Popular

Ultrasonic cleaners are popular for a couple of reasons:

1. They are less destructive than other methods for cleaning electric motor parts. Pumps, sprayers, and agitators may be damaging to delicate parts.
2. Faster–Because high-frequency sound waves create the cavitation pressure by soaking the part in a cavitation-friendly cleaner, the contaminants on the parts get stripped away far quicker than using any other method.
3. More Efficient–Pumps, sprayers, and agitators consume a lot more water and energy because an ultrasonic cleaner can do the same work with the cleaning solution in the tank alone and doesn’t require any labor-intensive scrubbing and rinsing. It saves a lot of water and energy.

Generating the Cavitation Bubbles

The ultrasonic cleaner uses high-frequency sound waves (up to 40,000 pulses per second) to create millions of microscopic cavitation bubbles, bombard contaminants such as grease, dirt, and rust, old paint, grease, and much more attached to the part and strip them away.

An ultrasonic generating transducer generates the ultrasonic waves that produce the cavitation bubbles, either built into the ultrasonic cleaning unit’s chamber or as a stand-alone unit that can be lowered into the cleaning solution.

Ultrasonic Cleaning Solution

Because the ultrasonic cleaner requires cavitation to clean the parts, water is not an option. It has too high surface tension to produce cavitation well. As a result, special additives are added to the cleaning solution to reduce the liquid’s surface tension, and any number of detergents, wetting agents, and other chemicals as needed by the type of part being cleaned. Typically, the cleaning solution is between 122- and 149-degrees Fahrenheit to clean the parts effectively.

The Ultrasonic Cleaning Process

Once you have the ultrasonic cleaner set up, the cleaning solution is poured into the tank, and the process is quite simple, immerse the parts in the solution. Depending on the cleaning unit’s size, you may be able to clean many parts at one time, which again saves a lot of time and energy. The operation is simple; once the parts are in the solution, you start the system, let it run for 20 to 30 minutes, and do the job.

Tekwell Services Offers Ultrasonic Part Cleaning Services

Our ultrasonic cleaner at Tekwell Services is large and able to clean parts up to 10 feet long, 4 feet wide, and 3 feet deep. This size also allows us to clean multiple smaller parts at the same time. For more information about our ultrasonic cleaning services, give us a call at 1-888-984-4668 or fill out our quick solution form today.

The post How Does an Ultrasonic Cleaner Work? first appeared on Tekwell.

1 – Power Needed

One of the most important factors to consider is the amount of power needed to run the applications this motor has been selected for. Get a motor that is too small, it gets overworked and the stress this creates decreases the motor lifespan overall. On the flip-side, if you buy a motor that is much too big for the application, it starts and stops frequently. This start/stop process also creates a lot of wear and tear on the electric motor decreases its lifespan.

2 – Motor Lifespan

How long do you hope the motor will last? Because a new electric motor can be such a large investment, it is important to consider this factor. Knowing what and how the motor will be put to use helps determine which type of motor fits the need best.

3 – Enclosure Rating

This is also critical to the smooth operation and lifespan of an electric motor. The enclosure rating (AKA an Ingress Protection Rating) is an indicator of the type of environment where the electric motor will work. Some electric motors need to be protected against water, or excess dust, others simply need to be protected well enough that someone cannot accidentally insert a finger into the motor while it is in operation. Knowing the enclosure rating you need for your operating environment is essential for prolonging the electric motor’s overall lifespan.

4 – Maintenance

What is the electric motor brand’s reputation for reliability and ease of service and repair? Is it easy to gain access to the key components of the motor to make repairs and perform routine preventive maintenance? Easy accessibility is also very important for extending the life cycle of the motor.

5 – Physical Footprint

How much space does the new electric motor take up in your shop? It is important to know how much space is available at your workplace in order assure that it fits in the space provided with enough room to access the key components of the unit, as well as provide adequate ventilation for the motor.

6 – Noise

Where is this motor being used? In some shops, noise isn’t a big deal, but in some settings such as retail areas, hospitals, and other public spaces, the noise generated by the unit should be minimal.

7 – Altitude

One often-overlooked factor that has a significant impact on the electric motor’s performance is the altitude where it has been installed. Thinner air, such as that at altitudes higher than 5000 feet, changes the performance of the motor and it needs to be adjusted accordingly to get the best performance possible.

Are You Looking for a New Electric Motor?

Tekwell Services is an authorized reseller of the best electric motor brands such as Yaskawa, WEG, and GE. We also have many electric motors already in inventory which can be pulled and installed at your site in a matter of hours. For more information, give us a call (toll-free) at 1-888-984-4668 or fill out our quick solution form to speak to one of our electric motor sales experts today.

The post 7 Often Overlooked Factors to Consider Before Purchasing a New Electric Motor first appeared on Tekwell.

What is EASA?

EASA stands for Electrical Apparatus Service Association, Inc. According to the EASA website, EASA is:

“an international trade organization of more than 1,800 electromechanical sales and service firms in nearly 70 countries. Through our many engineering and educational programs, EASA provides members with a means of keeping up to date on materials, equipment, and state-of-the-art technology.”

They are recognized internationally as the leader in the electrical and mechanical apparatus sales, service, and repair industry, who serve companies that repair or perform regular service or maintenance on electric motors, pumps, drives, controls, gearboxes, or other rotating machinery.

What Does EASA Do?

EASA provides a robust support network for anyone who works with electric motors and related equipment. They provide resources and extensive training on the repair of electric motors. This has led to the establishment of an international accreditation program for service centers to assure exceptional service and repair work on all electric motors. They have worked with service centers all over the world to establish best practices for all electrical and mechanical repair procedures and electric motor rewinding. This reduces the number of errors and repeat work on your equipment and improves its efficiency and reliability.

Why is EASA Accreditation Good for Your Electric Motor?

Becoming an EASA-accredited service center is not an easy process. It includes an in-depth assessment of the electric motor repair shop’s equipment, processes, and procedures, and must pass an accreditation assessment from independent third-party auditors to assure that the shop follows all best practices and procedures for electrical and mechanical repairs for all three-phase, squirrel-cage motors including electric motor rewinding.

This accreditation is based on these industry resources: ANSI/EASA AR100: Recommended Practice for the Repair of Rotating Electrical Apparatus and the Good Practice Guide of the 2003 study The Effect of Repair/Rewinding on Motor Efficiency, by EASA and the Association of Electrical and Mechanical Trades (AEMT). This ensures that these repair processes are thoroughly covered, including:

• Instrument calibration
• Mechanical measurements
• Core testing and rewinding
• Bearing replacement and lubrication
• Bearing fit rebuilding
• Electrical testing

Although EASA accreditation cannot guarantee perfect repairs every time, it can ensure that you receive better customer service, improved reliability for your electric motors, and less downtime.

Tekwell Services is an EASA Accredited Member

Find out for yourself why Tekwell Services earned its EASA accreditation. Give us a call at 1-888-984-4668 or fill out our quick solution form to speak to one of our electric motor specialists today.

The post Why You Should Work with an EASA Accredited Electric Motor Repair Shop first appeared on Tekwell.

Roller Bearing Loading Test Device

Tekwell Services, partnered with SKF, has developed a one-of-a-kind apparatus to help test roller bearings properly. Most roller bearings require a load during testing to avoid damaging the bearing when running the motor, but because there are no simple, reliable, and safe devices to accurately measure and display the bearing load, most shops ignore the loading of roller bearings during testing under the misguided belief that the test run doesn’t really damage the bearing. SKF has proven that testing roller bearings without proper loading damages them–especially in high-speed applications.

Because of this, Tekwell Services designed and manufactured a load roller bearing testing device (with Patent Pending) to be mounted to a standard T plate to apply a load vertically or horizontally. The load is then applied by a single-threaded rod attached to a load cell with a digital readout. The load cell and display can also be calibrated annually to meet the strict quality control requirements of the SKF Certified Rebuilder program.

“This device is a game-changer,” says Mark McKinney, Vice President at Tekwell Services. “We worked with SKF to bring a test for roller bearings that is safe, easy to use, accurate, and easy to remove and store.”

Dry Ice Cleaning

Some motors are just too large to bring into the Tekwell Services shop for proper cleaning. For these situations, Tekwell now offers dry ice blasting cleaning services.

Dry ice is excellent for cleaning motors because of its versatility. By using dry ice pellets about the size of a grain of rice, loading them into a hopper which is connected to a high-velocity air compressor that then “blasts” the dry ice into every gap and crevasse in the motor. Then the ice simply evaporates away leaving no residue behind. This gentle cleaning method can be used in a number of ways including for switchgear, busbars on cranes, and even the inside of a building.

Pump Testing System

Tekwell has developed a unique way to load test industrial pumps for diagnostic purposes or to load test them after a repair has been completed.

Tekwell has engineered a 6’ by 6’ by 8’ closed-loop water tank to measure the pump’s flow efficiency as well as test it for leaks before returning the pump to the worksite for reinstallation. The ability to test pumps without having to install them back into a production environment to see if they have been completely repaired is game-changing because it saves considerable time and rework.

This tank uses a ball valve to regulate flow pressure over a load curve which is carefully measured within the tank to verify that the pump is working, moving water at the proper rate. This is a unique testing method that is only available at Tekwell Services in the East Tennessee area.

“This new equipment is just one of the ways we continue meeting, and exceeding, our customers’ expectations,” says Jamey Steffner, CEO at Tekwell Services. “We believe that investing in new diagnostic and repair equipment for electric motors, as well as our knowledgeable staff, is the key to our growth and continued success.”

Looking for Industrial Motor Controls for Your Electric Motor?

At Tekwell Services, we continuously reinvest in our business to provide state-of-the-art equipment for our electric motor diagnostic and repair services. Our new panel shop provides us with the tools and materials to put together suitable machine automated controls for your electric motor or industrial pump. Give us a call (toll-free) at 1-888-984-4668 or fill out our quick solution form to reach out to one of our automated control experts today.

The post Tekwell Services Invests in New Industrial Electric Motor Service Equipment first appeared on Tekwell.

Marshall Harvey – Chief Financial Officer (CFO). Marshall has been a CPA for over 30 years. He has extensive experience in financial services, financial institutions, healthcare, and manufacturing industries. Marshall comes to us from Elliott Davis where he served as the assurance shareholder in the Financial Services Group, serving private investment companies and employee benefit plans. Marshall is active in the Chattanooga community, serving in leadership roles for many civic organizations such as the Chattanooga Kiwanis Club and Signal Centers.

Brandon Jones – Shop Superintendent, Cartersville Shop. With close to 15 years of electric motor service experience working for Tampa Armature Works (TAW) in Augusta, Georgia, Brandon brings his years of total shop experience that includes supervising and managing the repair of large motors and many other types of equipment to our Cartersville Shop.

Joe Cowgill – Outside Sales Representative, Knoxville Shop. Cowgill comes to us from Flanders, a large motor repair and service company, where he was responsible for over 100 accounts that included Disney and Universal Studios. He brings over 20 years of industrial business experience to Tekwell.

Patrick Stone – Outside Sales Representative, Cartersville Shop. Patrick also comes to us from TAW where he served as an outside sales rep. There he established new accounts, revived old ones, and maintained business relationships. Patrick is a retired Lieutenant Firefighter who served the City of Warner Robins for over 25 years.

Denver Stonecheck – Sales Engineer/Territory Manager, Cartersville Shop. Denver has a degree in Electrical Engineering from the University of North Florida and has served in the US Navy as a mechanic on a nuclear submarine. He brings over 15 years of electric motor experience to Tekwell, including stints with Siemens and GE. He specializes in delivering engineering solutions to complex challenges for our customers.

James Mongiat – Field Service Technician, Knoxville Shop. James has signed on at Tekwell after working many years as an aircraft mechanic diagnosing and repairing aircraft for Pinnacle Airlines (Delta). There he handled various routine inspections and repairs on a wide variety of regional jets. As a current member of the U.S. Army National Guard, he serves our country with his aircraft maintenance skills.

Caleb Shiflett – Field Service Technician, Knoxville Shop. Caleb is an experienced electrician working with industrial and commercial customers in the Dalton, Georgia, area. He has recently relocated to Knoxville. We are happy to have him as a member of our Knoxville Tekwell team, where he will serve as an integral member of our Field Service Group.

“We are very excited to have these guys join the Tekwell team,” says Jamey Steffner. “Hiring these individuals is the best decision we could make to support our growth for 2020 and the years beyond.”

Get Best-in-Class Electric Motor Repair Services from Tekwell Services

Our people are what make Tekwell Services a great electric motor repair shop. Many of our employees have work for us for 10–some of them longer than 20–years.  Their skills, experience and dedication makes the difference when looking for superior electric motor specialists.  Give us a call (toll-free) at 1-888-984-4668 or fill out our quick solution form to find out for yourself.

The post Tekwell Services Hires Additional Staff to Support Strong Growth in 2020 first appeared on Tekwell.

1 – Knowledgeable Staff

WEG offers a variety of drives, electric motors, and other equipment across a broad scope of industries including energy, farming, water and wastewater, steel production and manufacturing, paper, and many more. An excellent WEG distributor has the proper sales literature on-hand and has a general understanding about all WEG products, and how to get more information about them if necessary. They also have knowledge about what equipment works best in specific industries and details about those industries that help them match up the right WEG equipment with the industry-specific tasks for it.

2 – Trained Service Technicians

Buying a new WEG electric motor, gearbox, or drive is only half of the process. The equipment needs to be installed, adapted to the new work environment, and then maintained and serviced. An excellent WEG distributor backs its equipment sales with comprehensive predictive and preventive maintenance services for the equipment, and fast-responding repair services when necessary. This requires an experienced and well-trained group of service technicians to support these services.

3 – Dedication to Superior Customer Service

Again, selling equipment is one thing. Anyone can sell a WEG electric motor, but providing fast courteous service, the availability and willingness to answer questions, and a dedication to doing things right the first time all contribute to a positive sales and brand experience. Electric motors and equipment are a lynchpin in the operations for many companies, so it is important to be responsive when problems arise.

4 – Certifications

Most WEG authorized distributors maintain high levels of training and hold many certifications that show dedication to the electric motor trade. Certifications and accreditations such as the SKF Certified Rebuilder certification, EISA accreditation, AEGIS trained installations, and much more.

5 – Large Inventory of WEG Electric Motors On-Hand

An excellent authorized WEG distributor has a healthy inventory of WEG electric motors on-hand that can be pulled from the warehouse and installed at a customer site to respond to a customer’s needs quickly. Carrying a good stock of WEG electric motors ensures that you can get them to your customers fast when they are needed urgently.

Tekwell Services is Your Premier WEG Authorized Distributor in the SE United States

At Tekwell Services, we have the knowledge, the experience–with the certifications and accreditations to back it up–along with a healthy inventory of WEG electric motors and drives available for your electric motor power generation needs. Give us a call at 1-888-984-4668 or fill out our quick solution form to speak to a WEG electric motor specialist today.

The post 5 Things to Look for in an Excellent WEG Electric Motor Distributor first appeared on Tekwell.

What Are Industrial Motor Controls Used for?

Machine automation controls are used by almost any large industrial function that works with industrial electric motors. Just a few examples of these include:

• Industrial presses (including printing presses)
• Winders and Unwinders
• Precision cutting machines
• Forming machines
• Drawplates

Industrial Motor Control Components

Here are some of the automation control system components used with industrial electric motors:

Power Distribution Components

Probably the single largest function of machine automation controls is managing the power distribution for the equipment in a particular area or at a company. These functions are designed to run various motors and drives to handle basic industrial operations such as running fans to keep equipment cool during operation, or even managing the indoor temperature at the plant. There are many areas and zones within an industrial operation that need to be managed and they are almost always handled using automation controls.

When considering machine automation controls you need to look at what your power requirements are, and what electric motor solution will work best for your situation. There are many different options available such as:

• Manual motor starters
• Motor contactors and starters with overload protection
• Variable Frequency Drives
• Soft starters

Safety Systems

Safety systems are also critical because of how much power is being pumped into these systems. There needs to be both overcurrent (short circuit) and overload protection as well as brown-out protection. But the system must also be designed to safely stop the movement of water (in the case of industrial pump equipment) and the equipment itself from moving to protect both the equipment and the people who use it. These systems are as unique as the equipment they support. Some of these measures include fuses, circuit breakers, ground fault protection, emergency stop systems, motor starters with overload protection devices installed, and much more.

Programmable Controllers

This is what most people think of when they think of machine automation controls. These programmable automation controllers can be anything from a panel on the control system itself to a PC application. These can be customized and configured for your specific needs and location, and be programmed to respond to various situations and conditions. They also need to display operational info in order to keep the plant running smoothly.

Looking for Industrial Motor Controls for Your Electric Motor?

Turn to Tekwell Services. Our new panel shop provides us with the tools and materials to put together suitable machine automated controls for your electric motor or industrial pump.  Give us a call (toll-free) at 1-888-984-4668 or fill out our quick solution form to reach out to one of our automated control experts today.

The post What Are Industrial Motor Controls for Electric Motors? first appeared on Tekwell.

Basic Ball Bearings

Basic ball bearings are used for direct coupled applications. These are commonly seen in non-belted applications in electric motors that are under 150 HP. They can handle both radial and axial loads.

Standard Roller Bearings

These bearings are specifically designed for radial loads because they cannot handle axial loads. These are used for belted applications in motors with at least 150 HP.

Angular Contact Ball Bearings

Angular contact ball bearings are designed to handle high axial loads and operate smoothly at high speeds within electric motors. They can be configured in single or double rows and used in many different cage designs.

Cylindrical Roller Bearings

These roller bearings are what you need when handling extremely high axial loads. They operate efficiently in both medium and high speeds and use several different design configurations. These are used most of the time for belt or gear-driven electric motors.

Deep Groove Ball Bearings

Deep groove ball bearings are some of the most versatile designs for electric motors. With a simple design and a wide range of uses, these bearings are good for high-speed operations with moderate axial and radial loads. These can also be pre-lubricated with seals and shields and are very effective in contaminant-rich environments.

Sealed Bearings

Sealed bearings are a design of bearing that is typically used for smaller motors and designed to limit the bearings’ exposure to contamination. These bearings cannot be re-lubricated with new grease once they have been installed. This means that they have a limited lifespan and should be monitored carefully so that they can be replaced at the first sign of problems.

Shielded Bearings

Shielded bearings are another bearing design used to limit contamination into the rolling elements from the time of installation through the electric motor operation. These can be re-lubricated with packed grease, but if the internal pressure is not relieved, it could lead to forcing the shield against the cage or rolling elements which would create a big problem.

Bearing Design is Important for Electrical Motors

When selecting a motor, one of the factors you must always keep in mind is what type of bearing design works best for the electric motor you are using for this job. If you are not sure what is best for your job in your environment, reach out to an electric motor bearing specialist to figure out which bearing setup and electric motor will work best for you.

At Tekwell Systems, we have experience with many different name brands of electrical motors including WEG, Danfoss, Yaskawa, and many others, so we can help select the right type of electric motor (with the right bearing design) that is right for your application. Give us a call at 1-888-984-4668 or fill out our quick solution form to speak to an electric motor bearing expert today.

The post Different Types of Electric Motor Bearings and What They Are Used For first appeared on Tekwell.