Electric motors play a critical role in nearly every industry—driving machinery, conveyors, pumps, compressors, and more. Whether in manufacturing, HVAC systems, automotive applications, or utilities, these motors are essential for operational continuity. Over time, motors can suffer from insulation breakdown, overheating, voltage spikes, or contamination, leading to coil failure or electrical short circuits.

• Motor rewinding is a precise and cost-effective process that restores electric motors to optimal condition by replacing the copper windings and insulation system. When done professionally, motor rewinding can extend the motor’s life, reduce energy consumption, and restore it to original or even enhanced efficiency.

• Winding Burnout: Caused by overcurrent, overheating, or insulation failure. Burned windings lead to shorts, loss of torque, and eventual motor failure.

• Insulation Degradation: Age, vibration, or exposure to moisture/chemicals can degrade insulation, causing voltage leaks or arcing.

• Electrical Shorts or Grounds: Conductive dust, oil ingress, or damaged insulation can lead to shorts between windings or to the motor frame.

• Thermal Overload: Motors that run above their rated temperature lose efficiency and damage windings over time.

• Bearing Failure: Though not directly a rewinding issue, faulty bearings can cause rotor imbalance, leading to winding damage from vibration.

• Diagnosis: Every rewind starts with a comprehensive evaluation. This includes insulation resistance testing, surge comparison, and visual inspection to determine if rewinding is needed.

• Disassembly: The motor is carefully disassembled, and all components (rotor, stator, windings) are removed to access the failed windings.

• Core Testing and Cleaning: The stator core is thoroughly cleaned and tested (e.g., core loss test) to ensure no damage exists before rewinding.

• Coil Removal & Slot Preparation: Old windings are stripped out, and the slots are cleaned and prepared for new coils.

• Coil Manufacturing: New coils are manufactured using high-quality magnet wire and insulation materials, following OEM specs or improved thermal ratings if applicable.

• Rewinding & Lacing: Coils are inserted into the stator slots, properly spaced, and laced to hold position securely.

• VPI (Vacuum Pressure Impregnation): The entire stator is dipped in resin and placed under vacuum and pressure, ensuring deep insulation penetration and durability.

• Baking & Curing: The impregnated windings are baked in an oven to cure the resin, improving thermal and mechanical strength.

• Reassembly & Testing: The motor is reassembled, dynamically balanced, and tested using high-pot and surge test methods to ensure insulation integrity and performance.

• Professional Expertise: Motor rewinding requires precision, deep electrical knowledge, and specialized tools. All work at Accu Electric Motors is performed by trained technicians in a controlled environment.

• Efficiency Preservation: Modern rewinding methods, like properly sized wire and advanced insulation, ensure that motor efficiency is maintained or even improved after rewinding.

• Safety Standards: All procedures follow CSA, EASA, and IEEE standards to ensure electrical and mechanical safety.

• Preventive Maintenance: A well-executed rewind is just one part of motor longevity. Regular maintenance, alignment checks, and bearing lubrication help prevent future damage.

• Root Cause Analysis: Before any rewind, we determine why the winding failed—whether due to environmental issues, poor voltage conditions, or mechanical misalignment—to ensure it doesn’t happen again.