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Section 1: Case Study 1: Motor Startup Failure

Release Date:

2024-11-28

During operation, an air compressor manufactured by KIMAIR at a certain factory suddenly failed to start its motor. Despite multiple attempts to restart it, the motor remained inoperative. To resolve the issue, the maintenance team conducted a thorough fault diagnosis. The technicians first inspected the power supply lines and confirmed that the power was stable, with voltage and frequency both within the specified limits. They then examined the motor’s wiring and discovered loose connection terminals, resulting in poor contact. The team tightened the terminals and performed an insulation test to ensure the wiring was safe and reliable. However, the motor still would not start. Further inspection of the motor windings revealed, via a multimeter measurement of winding resistance, that one phase exhibited abnormally high resistance, indicating a possible open circuit in that phase. To verify this finding, the technicians disassembled the motor and confirmed the presence of a broken wire in the winding. In response, the maintenance team decided to replace the damaged winding. They carefully measured the winding’s dimensions and specifications, procured suitable replacement materials, and rewound the coil. After rewinding, the team conducted another insulation test and resistance measurement, confirming that the winding had returned to normal. Following reinstallation of the motor, the technicians performed a no-load test, during which the motor started normally and ran smoothly. To ensure the motor’s long-term stable operation, the team also recommended that the plant conduct regular maintenance, including checking the tightness of the connection terminals and the insulation condition of the windings.

　　During operation, an air compressor manufactured by KIMAIR at a certain factory suddenly failed to start its motor. Despite multiple restart attempts by the operators, the motor still did not function properly. To resolve this issue, the maintenance team conducted a thorough fault diagnosis.

　　The maintenance personnel inspected the power supply lines and confirmed that the power supply was functioning normally, with voltage and frequency both within the specified limits. They then examined the motor wiring and discovered loose terminal connections, which were causing poor contact. The maintenance team re-tightened the wiring terminals and conducted an insulation test to ensure the wiring was safe and reliable.

　　However, the motor still failed to start. The maintenance personnel conducted a more thorough inspection of the motor windings and used a multimeter to measure the winding resistance. They found that the resistance of one phase winding was abnormally high, indicating a possible open circuit in that phase. To verify this conclusion, the technicians disassembled the motor and confirmed the presence of a broken wire in the winding.

　　To address this issue, the maintenance team decided to replace the damaged windings. They carefully measured the dimensions and specifications of the windings, selected appropriate winding materials, and rewound them. Upon completion of the rewinding, the maintenance personnel conducted insulation tests and resistance measurements again to verify that the windings had returned to normal operation.

　　After the motor was reinstalled, the maintenance personnel conducted a no-load test, during which the motor started normally and operated smoothly. To ensure the motor’s long-term stable operation, the maintenance team also recommended that the plant perform regular maintenance and inspections, including checking the tightness of the wiring terminals and the insulation performance of the windings.