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MOTOR REWINDING AND EFFECT ON EFFICIENCY

Conference Paper · November 2012

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Sanja Antic Miroslav Bjekić

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 ‘
12 INTERNATIONAL SCIENTIFIC CONFERENCE
16 – 17 November 2012, GABROVO

MOTOR REWINDING AND EFFECT ON EFFICIENCY

Sanja Antic, Miroslav Bjekic, Milos Bozic, Marko Rosic
Technical Faculty, Čačak, University of Kragujevac, Serbia

Abstract
The paper unifies previous experiences related to the motor rewinding. It discusses factors that influence the repair-
replacement decision, provides overview of the motor losses, analyzes the factors that determine the efficiency of the
motor and describes process of motor rewinding using traditional and alternative methods. Also the importance of
strictly following "Good Practice Guide to Maintain Motor Efficiency" during motor rewinding is highlighted.
Particular emphasis refers to the goal one should strive for: achieving maximum efficiency in the actual working point
of the motor. "Round robin test" and "Repeatability test", used to check the spread in efficiency figures, confirm the
importance of testing the efficiency of the motor in the same place and with the same equipment.

Keywords: efficiency, rewinding, motor losses.

INTRODUCTION should be done for a particular operating point

It has long been thought the motor repairs
inevitably cause efficiency reduce and performance
deterioration. In the literature, some motor
rewinding studies suggest that, this reduction
is less than 1% [1], 1% [2], 2% [3], or up to
6% [4]. Even it was thought that, any rewinding
causes a reduction in efficiency of about 1%.
There are also opposite opinions that rewinding
brings small or negligible loss [5-8], or on the
contrary improves efficiency [9, 10]. These
contradictory conclusions are due to testing on
different groups of motors and also different
approaches to the process of rewinding and
testing. All the results are in fact the proof of
different qualities of individual rewinding
workshops.
However, researches carried out for EASA
and AMT (Electrical Apparatuses Service
Association and Association of Electrical and
Mechanical Trades) show a very small impact
of rewinding and repeated rewinding on the
losses and efficiency of the motor, if Good
Practice Guide to Maintain Motor Efficiency is
strictly implemented [11].
It should be noted that the obtained motors
efficiency results, in most of the researches
concerning rated load. Most motors are minimum
at least 30% under loaded [12], and one-third
of the motors operate below 50% of rated load
[13]. So the analysis of the achieved efficiencies
of a rewinding motor. The goal of rewinding
should then be focused on achieving the
maximum efficiency at the working point of
the specific motor [10].
FACTORS AFFECTING REPAIR -
REWIND DECISION
When the motor fails, if the downtime is
not critical, the user is faced with options that
can be generally classified into the following
groups: to rewind it back to its original
efficiency, to rewind it to a higher efficiency,
to replace it with the same efficiency motor or
to replace it with higher efficiency motor. The
fifth possible variant, that can be occurred in
negligence, and that certainly is not desirable,
is to rewind the motor to a lower efficiency.
This, for example, will happen if in the process
of the coil removal the core is damaged.
Nevertheless, in most cases, the decision is
more complex. Possible options when the
motor fails are shown in Figure 1 [11].
To make the proper decision, one must take
into account numerous factors such as initial
price, age of the motor and its condition,
history of operation and rewinding, motor type
and application, the urgency of restoring the
motor to work, potential energy savings [14,
15]. Often putting the motor back into the
work that i.e. reducing downtime, is of highest

Международна научна конференция “УНИТЕХ’12” – Габрово I-43

priority and the decision must be quickly
taken. Although the process of making decision
is complex and depends on the specific case,
general decision- making algorithm can be
represented as in Figure 2 [11].
Fig. 1. Possible options when the motor fails
Fig. 2. The decision- making algorithm when
a motor fails
I-44 Международна научна конференция “УНИТЕХ’12” – Габрово
The most common causes of motor failures
are shown in Figure 3. Thus, for example,
since 50% of motor failures come from the
bearings, the investment in bearing temperature
detectors of vibration or vibration probes is
logical choice in many situations. Also investment
in motor rewinding provides an opportunity to
improve motor performance and reliability,
and thus to increase its efficiency. This is
achieved by changing the windings configuration,
increasing the copper content in them and also
increasing the slot fill. High quality rewinding
also achieves increase resistance to moisture,
due to better varnish steadfast a motor becomes
more resistant to variations in voltage, the
starting and ambient conditions.
Fig. 3. The causes of motor failures
OVERVIEW OF POSSIBLE MOTOR
LOSSES
Overview of possible motor losses is shown
in the table 1.
According to the EASA/AEMT study, the
distribution of losses in the motor can be
graphically represented as in Figure 4.
Fig. 4. The distribution of losses in the motor
according to the EASA/AEMT study
Table 1. The losses in a motor and the degree depends on the squares of the load current.
of their presence according to EASA/AEMT Maximum efficiency is usually achieved
study below full-load point.
Losses Losses causing factors % of
distribution
Core Energy required to 5-20%,
losses magnetize the stator core constant
Friction Friction in the bearings,
and and air friction against 10-25%,
windage the rotating rotor and constant
losses cooling fan
Stator Current flowing through
25-35%, vary
I2R the stator winding
with load
losses conductors
Current flowing through
Rotor I2R 15-20%, vary
the rotor bars and end
losses with load
rings
Fig. 5. Efficiency versus load
The remaining losses in
Stray the motor - the primary
10-15%, vary
load result of harmonic
with load
losses reactance flux leakage
induced by load current

MOTOR EFFICIENCY
The efficiency of any motor depends on its
original design (construction quality or
rewinding), motor load and power supply
quality [16].
Efficiency dependence on the motor design
is determined by: type ("U frame" motor is
generally more effective than the "original
NEMA" and smaller "T frame" designs),
power (high power motors are more efficient
than low power motors) speed (for example,
1800 r/min rated speed motors are mostly
more efficient than 1200 r/min and 3600 r/min
designs) (table 2), enclosure (totally enclosed
motors are more efficient than standard
efficiency design motors) and the value of the
rated motor voltage (with the same slot fill
configuration, low voltage motors are more
efficient than the higher voltage designs)[17].
Table 2. The efficiency dependence on motor
speed and power
Power (hp) 3600 r/min 1800 r/min 1200 r/min
71/2 84.0% 84.0% 84.0%
50 90.2 91.7 91.7
100 91.7 92.4 92.4
An example of efficiency dependence on
motor load is shown in Figure 5. Maximum
efficiency occurs where fixed-no load loss is
equal to variable-load loss that actually
Fig. 6. Supply voltage unbalance dependence
on the motor efficiency
The supply voltage unbalance has a
significant impact on the efficiency of the
motor, figure 6.
MOTOR REWINDING
Motor rewinding methods can be divided
into three steps: coil removal, winding new
coils and varnishing the stator.
Based on the applied techniques these
methods can be classified into two groups:
traditional and alternative.
Traditional techniques generally last long,
figure 7. To start the next phase one must wait
for the end of the previous, which can take
several hours. Traditional techniques require
higher operating temperatures and thus higher
insulation class rating. Higher operating
temperatures also increases pressure on the
mechanical components (such as bearings)
shortening their lifetime [18]. The alternative

Международна научна конференция “УНИТЕХ’12” – Габрово I-45

methods are of a shorter duration but require
additional more expensive equipment.
However, some targets such as a better slot
filling and reduction of the end turns for I2R
stator losses decrease can easier be made by
manually rewind (traditional way) rather than
mechanical rewind (alternative) method [17].
Also, the cold coils removal process
(alternative method) while eliminating the risk
of core damage due to high temperature during
burning out (traditional method) does not
eliminate the possibility of increased motor
losses. Some types of epoxy varnishes may
require a very strong force to remove the coil,
which increases the risk of the core mechanical
damage [17]. This generally preferred traditional
burnout process in the oven with controlled
burnout temperature over cold coils removal
(cold stripping).
Fig. 7. Traditional and Alternative time (in
hours) during the rewinding process
Coil removal
Coil removal is traditionally made by
burning out in the oven.
EASE recommendation that it is realized at
maximum temperature 360 C (AEMT earlier
work suggested a maximum temperature 350 C
[19]) for the organic coreplate, i.e. 400 C for
inorganic coreplate [7, 11]. Burning out below
360 C is not recommended because it may
lead to incomplete burning out of coils which
greatly complicates their mechanical removal,
and can cause damage to the teeth at the ends
of the stator core, which significantly increases
the stray load losses. In the contrary, higher
temperatures can cause damage to the organic
interlaminar insulation and contribute to a
I-46 Международна научна конференция “УНИТЕХ’12” – Габрово
dramatic increase in losses due to eddy
currents [7, 18].
Practical experience shows that mentioned
temperature values recommended by EASA
are only sufficient to burn out winding
insulation but the process of mechanical coil
removal remain difficult, which may increase
the risk of damage. It is therefore reasonable to
increase the temperature about 10 C above
the values recommended by EASA, which
provides easier coil removal (stripping the old
windings) and the cleaner core [10].
The burnout process takes about 10 hours
until the winding insulation turns to ashes. The
stator is then removed from the oven and leave
to cool down. Then the coils are pulled out and
the slots are cleaned. The force required to
remove old windings depends on the burnout
temperature - Figure 8.
Fig. 8. Force required to remove winding after
3 h in oven
By slots cleaning the residual insulation
from the slots is removed. It can be done in
several ways: using the precise removal of
sharp blade, by high pressure washing,
brushing with a brush for medium-soft wire
brush, burn out using an oxy-propane lance…
[19].
Alternatively coil removal can be done
mechanically [18]. This method uses low
temperatures and rapid removal of coils. When
the temperature is about 10° C above the
insulation class of varnish coil insulation,
stator is placed to the stripping machine for
coil removal. On a rotating table with special
clamps and using hydraulic cylinder, ends the
process of removing coils. The windings are
removed with all their isolation, which
significantly shortens the slots cleaning time.
Coil winding
Traditionally and mostly coil winding is
done by hand on a coil winding machine. The
tension of wire is controlled manually and the
number of turns per coil is monitored by
mechanical counter. Length of each coil may
be different because wire tension is manual
controlled, causing unbalanced impedance
values. This greatly contributes to temperature
increase of the windings. Also if he turns are
not layered correctly, chances of damaging the
wire insulation during insertion increase.
Alternatively coil winding is done running
automatic winding machine that automatically
counts the number of turns per coil and keeps
constant wire tension. This ensures the
maintenance of the impedance balance. While
the machine is winding, the technician can
insult the slots and prepare stator for the coil
insertion.
Besides the advantages of automatic
winding, a manual method, however, can
achieve better slot filling which reduce I2R
losses in the stator and is generally favoured
by repairers.
Varnishing the stator
Traditionally varnishing the stator is done
by dipping the stator into an epoxy varnish and
then baking it into an oven, approximately at
temperature 150° C. Over time, the varnish
coating on the stator is wasted, and can act as a
thermal insulator increasing I2R losses in the
stator and may clog cooling paths through the
core. This procedure proved inefficient due to
the gaps that occur in isolation winding during
its application. This creates space for humidity
pass especially in the stator slots.
Alternatively varnishing the stator is done
using trickle varnish impregnation technique.
The stator is mounted on a special turntable
that rotates at low speed. Then the current is
applies to the windings until they warm up.
Turntable is then titled at a 35 ° C angle and
the tubes are placed for easy application.
Varnish is trickled onto one coil end and due
to capillary action flows between the wires to
the other coil end. This process achieves better
slot fill and coats only the winding. Advantages
of this procedure are: varnish is little wasted,
the protection against humidity is greater and
cooling the stator is not in question.
Международна научна конференция “УНИТЕХ’12” – Габрово
Bearings lubrication
It is important to have in mind that over-
lubrication of bearings can cause a substantial
increase in friction losses and shorten their
life.
Mixing incompatible greases is not
recommended but only using lubricant
recommended by the manufacturer. Closed
bearings with full contact have higher friction
than closed noncontact bearing and should be
avoided [16]. Practical experience shows that
during bearing replacement the manufacturer's
recommendations should be respected [7, 11].
Fans
Replacing the original fan with some other
type of fan can be a cause of ventilation losses
increase, temperature rise and thus I2R losses
increase [10, 16]. For this reason, replacement
fans should meet the designer original idea
Table 3 presents a systematic review of
techniques that can help reduce losses in the
motor with rewinding process.
Table 3. Possibilities of motor losses reduction
with rewinding process
Losses Reduction possibilities
Core -Controlled burn out temperature
losses -Be careful not to mechanically damage
the core when pulling out the windings
Friction -Appropriate selection of fans
and -Appropriate selection of bearings
windage -Proper installation of bearings
losses -Adequate greasing of the bearings
(neither too much nor too little)
Stator I2R -Increasing the relative slot fill
losses -The use of two-layer lap windings instead
of concentric
-The increase of copper in the windings
-The increase of wire diameter
-Reducing end turns length
-Reducing mean length of turn (MLT)
-Reducing the number of stator turns (be
careful in its application)
Rotor I2R -Be careful not to damage the rotor cage
losses -Reducing the number of stator turns (be
careful in its application)
Stray load -Taking care of all of the above factors,
losses but the factors influencing the windage
and friction losses. (In particular, taking
care not to mechanically damage the
stator lamination teeth during stator core
burnout or winding coil removal, and all
that would affect air gap symmetry)
-Reducing the number of stator turns (be
careful in its application)
I-47
MOTOR EFFICIENCY AND
REWINDING
A typical recorded efficiency curve with
variable and fixed losses is shown in Figure 9
[10].
Fig. 9. Typical maximum efficiency
occurrence
Theoretical analyses show that the point of
maximum efficiency occurs at the load point
where the fixed loss to load (core losses and
friction and windage losses) is equal to
variable loss (I2R losses in the stator and rotor
and stray load losses):
Pj + Pvt = Pcu1 + Pcu 2 + Pdod (1)
For given example the point of maximum
efficiency occurs at the load point 63%. If the
motor operating point is say, at the load point
90%, the task of rewinding process would be
to move the maximum efficiency point
towards that point. Moving the point of
maximum efficiency to higher loads on the
basis of relation (1) was achievable if the
variable loss is decreased and the fixed losses
increased (although this is generally not
recommended).
Thus, by improving the design of stator
winding, I2R stator losses can be reduced.
Since the losses in the core must inevitably be
slightly increased due to rewinding process, on
the basis of relation (1), the objective would be
achievable. Also the goal could be achieved by
reducing the number of stator turns. This
would reduce the losses in the stator and
increased losses in the core [10]. However,
reducing the number of stator turns also causes
I-48 Международна научна конференция “УНИТЕХ’12” – Габрово
an increase of starting current and starting and
maximum torque, which can cause problems
in the system of distribution and protection as
well on the driven machine [17], so one should
be careful in its application.
Figure 10 shows the efficiency curve
shifting due to control of rewinding process
and moving the maximum efficiency point to
the operating load point of 90%, so the desired
goal was achieved [10].
Fig. 10. Change in efficiency due to rewinding
The best known measure of losses in the
motor, efficiency and rewinding quality using
method IEEE 112b, were carried out for
EASA and AEMT, USA and the United
Kingdom Association for motor repair. Testing
included 23 motors ranging 5.5 to 225 kW,
50Hz (IEC) and 60Hz (NEMA) motors, low
and medium voltage motors, 2-pole and 4-
pole. 18 of 23 motors underwent a complete
rewinding cycle, 3 motors were stripped and
rewound three times, and the remaining 2 were
burn out five times and rewound once;
Measurements carried out in 23 motors
have shown that if during motor rewinding
"Good Practice Guide" is strictly followed,
improving the design of the stator windings
(reduction of losses in the stator), careful
bearing lubrication and the proper choice of
the fan, generally motor efficiency after
rewinding may increase, [10 ]. This also refers
to multiple rewinds which in that case do not
visibly influence the change in efficiency.
There was also no significant reduction in core
losses which were considered sensitive due to
the burnout process during rewinding.
In parallel with these measurements tests
for determining spread in efficiency figures
were carried out: at a 30 kW 4-pole motor so-
called "Round robin test" and the 75kW 4-pole
motor so-called "repeatability test"
"Round robin test" was performed at five
different test sites prior to the rewind tests with
different personnel and equipment. Test results
on all five sites were different (Fig.11, Fig.12)
[10]. Graphs are plotted as a function of
remaining loss (which actually represent stray
load losses, if there is no measurement error)
against load. The registered values of
efficiency are related to full load. Variation of
efficiency varied in the range 0.7% for 50Hz
1.2 % for 60 Hz operations. The test show how
hard it correctly estimated and measured
efficiency of a motor, although IEEE 112b
standard is strictly implemented.
Fig. 11. Round robin test (50Hz operation)
Fig. 12. Round robin test (60Hz operation)
Международна научна конференция “УНИТЕХ’12” – Габрово
These two tests have shown that it is
important to test the efficiency of the motor
(before and after rewinding) in one place and
with the same equipment.
CONCLUSION
It has long been thought the process of
rewinding inevitably reduce the efficiency of
the motor. This was the case when it was done
without control of the process and therefore
the losses that occur in the motor. However,
the motor efficiency after rewinding can be
increased. This is achieved by strictly following
the "Good Practice Guide" in the rewinding
procedure improving the winding design and
bearing lubrication. This also refers to multiple
rewinds which then do not appreciable cause
the change in efficiency [10].
Efficiency tables used for comparison
purposes are referred to full load values.
However, motors are almost always operating
at loads that are less than rated. After
rewinding process, the maximum efficiency
point changes and also the shape of the
efficiency curve. This is inevitable because the
core losses must slightly increase due to the
rewinding. The real goal during rewinding
would be to move the maximum efficiency
point to the real operating load point of the
motor. Changing the relationship between
fixed and variable loss this could be feasible.
If a rewinding company has necessary skills,
for example it is possible to change the
number of stator turns to achieve desired
objective. Unfortunately, most rewind firms
just copy the manufacturer. So an opportunity
for improving energy efficiency is being
wasted.
Also, undertaken so called "Round robin
test" and "Repeatability test" tests prove that
the efficiency of a motor before and after
rewinding should be made in one place and
with the same equipment.
ACKNOWLEDGMENT
These results are part of a project financed
by the Ministry of Science and Technological
Development, Republic of Serbia. (TR33016).
REFERENCE
[1] EASA, “Maintaining efficiency during
electric motor repair”
I-49
 [2] EASA, “Motor repair”, Drive power
[3] Penrose H W, Bauer B, “Time savings and
energy efficiency through alternate electric
motor rewind methods”, Electrical Electronics
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[4] Hirzel JC, “Impact of rewinding on motor
efficiency”, Pulp and Paper Industry Technical
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[8] Penrose H W, “Repair specification for low
voltage polyphase induction motors intended
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[10] Wenping Cao, K J Bradley, Assessing the
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NG7 2RD, England
I-50 Международна научна конференция “УНИТЕХ’12” – Габрово
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[11] EASA/AEMT, “The Effect of
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[19] Francesco Parasiliti, Paolo Bertoldi, (2003)
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