1. Mechanical Wear and Structural Integrity
The first step is to inspect the mechanical components for irreversible wear or damage. Gears should be examined for severe pitting, abrasive wear, or plastic deformation, particularly if metal debris is present in the lubricant or over 50% of the gear teeth show damage. Bearings must be checked for excessive clearance or misalignment, as worn bearings can cause vibration, noise, or shaft instability. Similarly, the shaft and keyways should be evaluated for scoring or gaps exceeding 0.1–0.2 mm, as these issues compromise torque transmission and may to catastrophic failure. If these components exhibit significant wear that cannot be rectified through repairs or part replacements, the entire gear motor assembly may need to be replaced to restore system reliability.
2. Electrical and Operational Performance
Electrical faults are equally critical. The commutator and brushes should be inspected for deep grooves, carbon buildup, or excessive brush wear (below 50% of their original length). If light sanding fails to restore the commutator’s surface or the motor draws abnormally high current (e.g., exceeding 1.5A under load), it often indicates irreversible electrical damage to the armature or windings. Additionally, operational symptoms like persistent overheating (surface temperatures above 93°C), abnormal noise (grinding or rattling), or a noticeable drop in efficiency (e.g., 15% or more) suggest internal issues that may not be cost-effective to repair. In such cases, replacement becomes a safer and more economical long-term solution.
3. Lubrication, Seals, and Environmental Impact
Lubricant quality and environmental factors play a pivotal role in gear motor longevity. Degraded or contaminated lubricant—especially if contaminated with metal particles—accelerates wear and should be replaced according to the manufacturer’s schedule (e.g., every 20,000 hours for hypoid gear motors). Seals and grease must also be monitored for leaks, hardening, or brittleness, particularly in harsh environments with high dust, humidity, or temperature fluctuations. Compromised seals allow contaminants to infiltrate the system, leading to premature failure. If repeated lubrication changes or seal replacements fail to resolve these issues, the motor may require a complete overhaul or replacement to ensure performance.
4. Maintenance History and Safety Considerations
Finally, the gear motor’s maintenance history and safety risks should guide replacement decisions. Motors that have undergone multiple repairs for recurring issues (e.g., bearing failures, gear misalignment) or those operating in high-risk environments (e.g., explosive atmospheres with oil leaks) pose significant operational hazards. Annual disassembly and inspection, aligned with standards like IEC 60072-1, help identify cumulative wear in gears, bearings, or shafts. If critical components consistently exceed tolerance limits despite regular maintenance, replacement is often the safest and cost-effective option.
As a gear motor manufacturer, we understand that assessing whether a gear motor requires replacement involves a comprehensive evaluation of its mechanical integrity, electrical performance, operational behavior, and maintenance history. Gear motors are designed for durability, but prolonged use, harsh environments, or improper maintenance can lead to gradual degradation or sudden failures.
Ningbo Zhongda Leader Intelligent Transmission Co., Ltd. is professional planetary gearbox manufacturers, established in 2006, we have more than 1500 employees, 66666m2 area and we have got 676 million sales on 2019.
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