The Insulation of the Gear Reducer Motor Connection Wires or Sleeves is Damaged

The insulation damage to the connection wires or lead-out sleeves of the gear reducer motor can lead to severe faults, such as phase-to-phase short circuits. Overloading, overvoltage, single-phase operation, poor wire insulation materials, and other issues can also cause inter-turn short circuits in the motor windings.

Causes of Insulation Damage

One common cause of insulation damage is poor impregnation of the motor windings. For example, polyester varnish-coated wires, when not properly impregnated, fail to form a solid bond between the turns, allowing external dust to accumulate between the turns. Under the influence of electromagnetic forces, the wires vibrate and rub against each other. The dust trapped in the gaps acts as an abrasive, gradually wearing down the insulation and leading to turn-to-turn short circuits. Furthermore, phase-to-phase short circuits can occur due to improper insulation dimensions between phases, defects in the insulation pads, or damage to the insulation pads during coil winding.

Repairing Insulation Damage in Motor Connection Wires

When the insulation of the connection wires or bridge wires is damaged, it can lead to short-circuit faults in the motor windings. This can happen if the sleeve is crushed. Or if plastic insulation sleeves soften after drying and no longer provide adequate insulation. In these cases, phase-to-phase short circuits can occur. Here’s what you can do to repair and prevent further damage:

1. Inspect and Repair the Damaged Area

• Stop Using the Motor: Disconnect the power supply to ensure the motor is not energized.
• Inspect the Damage: Use insulation testing tools to locate the damaged section and determine the severity of the damage—whether it is localized or widespread.
• Replace Damaged Parts: If only a small area of the insulation is damaged, it can be repaired with insulating tape or heat shrink tubing. For more extensive damage, you will need to replace the motor connection wires or lead-out wires.
• Check Insulation Materials: If the insulation material (e.g., plastic sleeve) has aged or softened, it should be replaced with higher-quality insulating materials to avoid recurring issues.

2. Prevent Insulation Aging

• Use High-Quality Insulation Materials: Select insulation materials that are resistant to high temperatures and wear. such as silicone rubber sleeves or high-voltage polyurethane materials.
• Ensure Proper Impregnation of Windings: The winding impregnation process should be thorough to ensure a uniform and strong insulating layer. Avoiding any potential weak spots between the turns.
• Prevent Dust Accumulation: Regularly clean the motor’s interior to prevent dust and debris from accumulating, which could lead to insulation wear.

3. Monitor the Motor’s Operating Environment

• Avoid Overloading: Operating the motor beyond its rated load can increase the risk of winding overheating, leading to faster insulation aging. Ensure the motor operates within its rated capacity.
• Prevent Overvoltage: Regularly check the power supply for stable voltage and avoid fluctuations that could damage the motor.
• Avoid Single-Phase Operation: Single-phase operation can lead to severe motor overload. Ensure that the motor operates in a balanced, three-phase system to avoid such issues.

4. Regular Maintenance and Inspection

• Frequent Motor Inspections: Regularly check the motor’s operating parameters, including temperature, current, and insulation resistance, to identify potential issues early.
• Keep the Motor Clean: Prevent the accumulation of oil, dirt, and dust inside the motor. As these can affect the insulation performance.
• Inspect Connection Terminals and Bridge Wires: Pay special attention to the insulation of the connection terminals and bridge wires, as these areas are prone to damage that could result in short circuits.

Conclusion

By following these guidelines, you can effectively repair and prevent insulation damage in the motor’s connection wires and sleeves. Extending the life of the gear reducer motor and minimizing the frequency of downtime and repairs. Regular maintenance, proper material selection, and a stable operating environment are key to ensuring the motor’s optimal performance and reliability.