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Should I rewind a failed electric motor?

We’ve been rewinding electric motors for almost half a century, and if there’s one question we hear more often than any other, it’s “Should I rewind a failed electric motor?”

There’s no definitive answer to this question, as there are many factors to consider, including:

What size is the motor?

Manufacturing costs for smaller motors are relatively low, meaning that, as a general rule, buying new is more cost-effective than a rewind. For larger motors, the opposite is true; as frame size goes up, the cheaper it is to opt for a rewind. In fact, the cost difference can be as much as 40 per cent for larger frame sizes.

Is the motor custom built?

Motors built to specification – for example, those with an unusual shaft size – are far more economical to rewind rather than replace. This is because having a replica built can take several months and will be very expensive, whereas a rewind can be carried out in a matter of days.

Are you sure the motor is suitable for its application?

A motor incorrectly sized for the process it is running will only fail again after it is rewound, so the problem should be dealt with at its source by replacing the equipment.

Has severe damage or catastrophic failure occurred?

In cases of serious damage requiring the replacement of many components, possibly as a result of overcurrent, the cost of repair or overhaul usually far outweighs that of replacement.

Still unsure whether you need a motor rewind or replacement? Give Gibbons a call on 01621 868138 or email and one of our friendly engineers will be happy to help find the most economical solution for you.

Electric Motors


  • Date: 26 July 2016 David Varley
    You might think reputable (say ISES) repairers would always perform a stator core pack integrity check. But unless you know the motor's history AND can clearly see the damage is in the overhang and not the slots then always specify and police the test.

    If it is worth rewinding it is worth doing the check and do not, from experience, rely on your repairer to 1) do it themselves. 2) do it without checking even when specified. For Marine motors also consult Class and obtain "repair approved by Class" confirmation.

    A question. If I were specifying again I would be tempted to specify the use of standard efficiency motors. I don't know about ageing but it is said that rewinding will never restore the same efficiency of a high efficiency design and so my real load may 'grow' for this reason. I would prefer to start of with a plant that remained 'matched'. Am I too old fashioned?

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