servo motor repairs

ServoMotorrepairsGET IT RIGHT THE FIRST TIMEwww.fletchermoorland.co.uk

K E E P I N G I N D U S T R Y R U N N I N G

Don’t take a risk– call the experts

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REFURBISHED MOTORSARE AS GOOD AS NEW

SOLUTIONTO KEEPPRESSESROLLING

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SPECIALIST ENGINEERSREADY TO RESPOND 24/7

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RELIABILITY and confidence are keyfactors in the business of servomotor repairs – and at Fletcher

Moorland we are proud to say we havethese attributes in abundance. Nobodywants to take risks with the repair andmaintenance of their factory’s servomotors – the consequence of productiondown time is too costly.

We have a long-standing track record inproviding quality repairs – and over thepast five years we have built on thatreputation by investing more than£300,000 on hi-tech testing equipment.This means that after we have completedthe repairs we can test a motor at fullpower to make sure every part of itsoperation is 100 per cent right.

Of course, it is not just a question ofhaving state-of-the-art equipment, we

also have the highest levels of specialistexpertise. Repairing servo motors requiresa combination of electronic, electrical andmechanical know-how and at FletcherMoorland our engineers have thenecessary breadth of skills. We continue todevelop and invest in this expertise toensure we stay at the cutting edge ofmodern servo motor technology.

Added to this know-how is anotherimportant asset we put great store on –an ethic of excellent customer service. Ourservo repair workshop in the heart of theUK at Stoke-on-Trent operates 24 hours aday, 365 days a year – and our customersknow we will respond immediately totheir calls with our own fleet of vehiclesready to go out to factories anywhere inthe country, whatever the time of day ornight.

When a repair is an emergency wepromise to turn it around as quickly aspossible – but without compromising thethorough and comprehensive nature ofthe repair. This is why we are confident ingiving industry-leading guarantees – aminimum of 12 months.

We carry out around 2,500 servo motorrepairs a year for a wide-range ofindustries in the UK, mainland Europe andNorth America – and we are also a repairand service centre for a number ofleading servo motor manufacturers. Wewelcome people to come to view ourpremises to see at first hand the standardsof work and thoroughness of our testing.

You will see why, when a repair is doneby Fletcher Moorland, you can count on itbeing done properly. Why take a risk onanything less than the best?

Servo Motor repairs2Fletcher Moorland 24 hours a day hotline – 01782 411021

By Matt FletcherMANAGING DIRECTOR

Don’t take a risk with yourrepairs – choose the experts

We have a long-standing track recordin providing quality repairs – and overthe past five years we have built onthat reputation by investing morethan £300,000 on hi-tech testing equipment.

“”

�Managing Director MattFletcher tests the operation ofa Heidenhain EnDat encoder.

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Servo Motor repairs 3www.fletchermoorland.co.uk

WHETHER it is maintenance and testing or a full strip-down repair, Fletcher Moorland’s dedicated ServoDepartment brings a wealth of experience and

specialist training to each job they work on.Servo Motors Manager Alan Palmer and his team of

engineers combine all-encompassing mechanical,electronic and electrical skills and training to make surethe sophisticated motors return to customers as good as– if not – better than the day they rolled off theproduction line.

Alan, who has trained all members of his teampersonally, also has several decades working inproduction engineering, so appreciates what customers want.

He said: “I know from experience that if equipmentgoes down it can be costly to a company and, in termsof some customers we work with, very costly. Forexample we have one client who loses tens of thousandof pounds per hour if a servo-controlled robot or machineis down. That is why the customers rely on us to providefirst class maintenance. However, if one of their servosbreaks down they need to know we can turn a repair aroundasap – and in some cases that can be a matter of hours.”

He added: “Our aim is to send the servo motors back tocustomers as good as or better than they were when they werefirst manufactured and we always go the extra mile to carry outmodifications and extensive testing that will ensure this.”

To guarantee Fletcher Moorland stays at the cutting edge, in oneyear alone more than £250,000 was injected into the company,which included a complete refurbishment of the servo motorworkshop and new servo test equipment development.

Alan added: “The sophistication and complexity of servo motorsis changing all the time that is why we need to continually upgradeequipment and train our people so we can excel at what we do.”

Specialist team hasA WEALTH OFEXPERIENCE

� Servo Motors Manager Alan Palmer pictured in theFletcher Moorland servo motorsworkshop at Stoke-on-Trent.

�MechanicalEngineer Alex Bluntprecision balances aservo motor rotor.

� A selection of servo motorswhich are awaiting repair andrefurbishment.


SERVO motors are complex pieces ofprecision equipment, combiningaspects of electrical, electronic and

mechanical engineering.Repairing them requires an in-depth

understanding of each of these engineeringdisciplines – an expertise which has servedFletcher Moorland and its customers well for decades.

Managing Director Matt Fletcher said:“Theservo motors we see for repairs presentthemselves with a variety of different faults –

such as coolant ingress into the windingsof a CNC motor, frame

corrosion on a foodprocessing

motor,

brake damage on an automotive robotmotor, shaft damage on a saw motor andencoder errors on a conveyor system motor.

“Having an understanding of the correctrepair and refurbishment procedures is vitalin being able to offer the full servo motorrepair service.

“We can repair and replace motor shafts;repair keyways; manufacture end shields;balance the rotors; refurbish and fully testthe brakes; rewind the motors; repairencoders, resolvers and electronictachogenerators; align the feedback devices; and read and reprogram theencoder memory.”

The Fletcher Moorland workshop has themost advanced equipment to diagnose

faults – be it electrical, mechanical orelectronic feedback related. The servo motorgoes through a full refurbishment, bringing itback to the condition it was when new.

The company also has one of the mostthorough facilities in Europe for servo motortesting.“We test each and every servo motorto full power throughout its speed range –this ensures it will work right first time whenfitted to a machine,” said Matt.

“We have invested to ensure we maintainour position at the forefront of the industry’stechnology and we have the equipment totest and verify the most modern encodertypes on the market – those withprogramable encoder data and nameplatesuch as EnDat and DriveCliq encoders.”


Full refurbishment makes a motorAS GOOD AS NEW

● Shaft Repair

● Keyway Repair

● Dynamic Balancing to G1.0

● Precision Bearing Replacement

● Full Mechanical Refurbishment

● Repair & Test Incremental Encoders

● Repair & Test Absolute Encoders

● Repair & Test Serial Encoders

● Align Encoders

● Test & Align Resolvers

● Repair & Test Commutation Sensors

● Align Commutation Sensors

● Reset Encoder Memory

● Winding Integrity Check

● Baker Surge Testing

● Superior Rewinds to Class ‘H’

● Two Year Winding Guarantee

● Brake Overhaul

● Bed-in New Brakes

● Check Holding Torque

● Check Breakaway Torque

● Perform Run Tests

● Perform Dynamic Load Tests to 60Nm

● Perform Vibration Analysis Checks

● Produce a Load Test Certificate

ARE YOU GETTING ALL THIS FROM YOUR CURRENT SERVO MOTOR REPAIR COMPANY?If not, contact Fletcher Moorland for a comprehensive repairservice at a competitive price – and the peace of mind knowingyou can have confidence in your servo motors’ reliability.


Keepingdisruption to minimumat distribution centre

A fullSiemens motorrefurbishment

A fault on a Rexroth MKD090B-047-GG0-KNservo motor caused disruption to asupermarket distribution centre when a beltfeed sorter motor failed. We received themotor early one morning and our servo motordiagnostic team knew from their experiencewith the motors that certain discretecomponents on the feedback PCB had blown.

The motor was stripped down and thefeedback PCB was repaired by our electronicsdepartment. The servo motor was fullyoverhauled and assembled. The resolver wasfitted and aligned and the memory on thefeedback was re-programed. A full test wascarried out and the motor was shipped backto the distribution centre.

A well known manufacturer of constructionequipment had a servo motor fail that requiredthe full range of skills at Fletcher Moorland. ASiemens 1FT6108-8AC71 servo motor failed inservice. Once we received it at our works we knewby the smell it was going to be a major repair.

Servo motor engineers stripped the motor andfound one of the bearings had collapsed, debrisfrom the bearing had penetrated the motorwindings, the shaft was bent and we found theencoder was giving error counts.

Our winding department stripped andrewound the stator, our mechanical departmentreclaimed the bearing housings and straightenedthe shaft. The electronics department repairedand tested the encoder and, finally, servoengineers rebuilt the motor and fully tested it,ensuring it met nameplate specifications.

OFTEN in food manufacturing facilities, overenthusiastic wash-downs cause problems withelectrical machines. A dairy foods producer sentan Allen Bradley MPL-B420P-RK22AA motor to ussuspecting it had been washed down.

This was on a Friday and the customer wantedthe motor back for the next day. Our servo motorworkshop assessed the motor and it had indeedbeen washed down.

The motor was wet throughout. We cleanedand dried the motor windings before confirmingthey were OK. The resolver unit tested faulty onour rig. Luckily this is one type we held in stock soa new resolver was fitted to the refurbished motorand aligned before the motor was fully tested andsent back to the customer.

Washdown failure

� Servo EngineerAdrian Chuter testsa Siemens Sinamicsservo motor with aDriveCliq encoder.

�Mechanical Fitter James Kelly checks the mechanical dimensionsof a servo motor rotor using a Co-ordinate Measuring Machine.

� Richard Urwin,Servo Engineer,prepares torebuild a Fanucservo motor.

ServoEngineer

Adam Locastrotests signals output

from a Fanucencoder.

� Rewind DepartmentSupervisor Ken Dean surgetesting a rewound Fanucservo motor.



FLETCHER Moorland Ltd wasable to deliver some goodnews to the company that

prints North Staffordshire’s dailypaper The Sentinel.

The two presses at the Etruria,Stoke-on-Trent publishing centre willcontinue to roll for many years tocome, thanks to a carefully plannedprogramme of refurbishment for thelarge specialist servo motors that are avital component of the printingprocess.

One of the presses is powered by 17Indramat motors while 34 more areused on the other press and until twoyears ago the motors were serviced bythe manufacturer.

However The Sentinel were told bythe manufacturer that the motors hadexceeded their normal operational life– substantially increasing the cost ofrepairs and servicing.

That’s when Technical Manager JeffHilditch contacted Fletcher Moorland’sManaging Director Matt Fletcher andfound a very local solution to theirproblem.

Fletcher Moorland drew up a planto completely re-build all the motorsat a fraction of what it would have

cost to purchase new ones. Thecomponents are being refurbishedone at a time and it takes around twoweeks to restore each one to mintcondition.

Meanwhile The Sentinel keep anumber of Indramat motors onstand-by in case of a breakdown toensure the presses – which print up to60,000 copies of The Sentinel a day fivedays a week and 300,000 copies ofThe Daily Mail and Mail on Sundayseven nights a week – are notinterrupted by servo motor failure.

Jeff said: “We have embarked on along term project of motorrefurbishment which will take aboutfive years. Fletcher Moorland came upwith a rebuilding programme that isextremely cost effective and meetsour needs perfectly.”

The Sentinel’s Indramat 2AD180Dseries motor is large for aservo/spindle motor, weighing morethan 400 kilograms. It produces peakpower of 95 kilowatts at 6,000 rpm.

When Fletcher Moorland engineersdiagnosed the faults on the motors, itwas found that firstly the windingsand internals were suffering fromheavy contamination.

QUITE often we see servo motors suffering heavycorrosion. One such motor was sent to us from a biscuitmanufacturer. It was a Control Techniques142DSB200CAAAA servo motor.

The endshield frame had corroded at the mountingholes and the shaft was worn from a poor fittingcoupling. Our servo engineers fully diagnosed thefaults and took a new endshield and new rotor fromour extensive stock of spare parts and fully rebuilt themotor to an ‘as new’ condition.

The resolver was aligned to OEM specification andthe motor was returned to production with theminimum of downtime – giving the customer muchmore than a crumb of comfort!

AN automotive customer was having failures on Kawasakirobot motors (model 3MC302G-3DRAE-KJ1). We suggestedthat we carry out a full investigation on the motor. Thistype of motor has a Kawasaki specific serial data encoder,we reverse engineered the encoder and re-engineeredone of our test servo drives to enable full speed and fulltorque operation of the motor after test.

From discussions with our customer, the fault seemed tobe pointing to the brake binding during operation. Thebrake holding and release torque was measured and wasOK, the response time to engage and disengage was OKand within tolerance. After many further trials we foundthere was an issue with one mechanical part in the brakeassembly. This was re-engineered and our customer is nowenjoying long term reliable repairs.

WE took a call from one of our automotive customers tosay they were sending two Fanuc motors (model numberA06B-0034-B675) that were required back as soon aspossible. Fault information was that they both hadsnapped shafts. The motors arrived just before 4pm andwent straight into our servo motor workshop. The faultinformation was correct, both shafts had sheared. Themotors were stripped down and fully inspected – thewindings and encoder were OK, the shafts were pressedout of the magnet pack and our mechanical engineersdrew a CAD drawing of the tapered shaft.

Overnight our machine shop manufactured two newshafts and, in the meantime, servo motor engineers hadcleaned, checked and overhauled the remaining parts.The new shafts were pressed and secured back into themagnet packs and passed back to the servo motorworkshop where both motors were fully assembled usingnew bearings and OEM seals.

Once the alignment had been carried out, both motorswere load tested ensuring OEM performance was met.They were both despatched back to our delightedcustomer at 10.45am the following morning.

A crumblingmotor from a biscuitmanufacturer (it really was

almost cream crackered!)

Kawasakirobot motor faults

Delivering GOODkeeping the press

Overnight repair of Fanuc motors



A number of the motors had windings faultsbecause the contamination had started tocorrode the enamel coating on the windings andthis was evident by a higher than normal earthleakage current.

“Whilst not a cause of failure this would havemeant the motor would have failed at somepoint in service,” explained Fletcher MoorlandManaging Director Matt Fletcher.

“We rewound a number of these machines toan enhanced class ‘H’ insulation system.”

Further investigation into the mechanicaldimension of the bearing housings showed theywere oversize.

“We measure all critical dimensions with aCo-ordinate Measuring Machine which isaccurate to 1,000th of a millimetre,” said Matt.“Itis often overlooked that the bearing fits have anISO tolerance and any part outside of thesetolerances will eventually lead to failure.”

In addition, rotors are balanced to anenhanced G1.0 balance grade and the encoders,which are usually contaminated, are fullyrefurbished – even though they are not faulty.

Final testing of the motors is carried out at6,000 rpm where engineers look to see ifvibration limits are within levels expected of newmotors.

Matt added: “Without our mechanical andelectrical skills, a thorough repair of this type ofmotor would not be possible.”

OD NEWS by sses rolling

Fletcher Moorland came upwith a rebuilding programmethat is extremely cost effectiveand meets our needs perfectly

JEFF HILDITCHTECHNICAL MANAGER

“”

AdrianChuter, Servo

Engineer, with a rotorremoved from a Sentinelmotor for the next stageof precision measuring

and balancing. Inset above, Adrian

removing therotor.

ABB

Allen Bradley

AMK

ASB

Baldor

Baumüller

Bosch

Control Techniques

Elau

Electrocraft

Eurotherm

Fanuc

Indramat

Kawasaki

Kollmorgen

Lenze

Mavilor

Moog

Nachi

NUM

Oemer

Pacific Scientific

Parker

Reliance

Rexroth

Rockwell

Sanyo Denki

SEM

Siemens

Stromag

Vickers

Yaskawa

FletcherMoorlandrepair and service servo motorsmanufactured by a vast range ofcompaniesincluding:


Fletcher Moorland Ltd, Elenora Street,

Stoke on Trent, ST4 1QG, UK

■ Phone: 01782 411021 ■ Fax: 01782 744470

■ Web: www.fletchermoorland.co.uk

● Electronic Drive & Controls Repair

● PCB, PLC & PSU Repair

● Process Pump Repairs

● Electric Motor Repair & Rewind

● Submersible Pump Repairs

● Mechanical Services

● Traction Motor Repairs

● Ex Motor Repairs

● On-Site Services

● Laser Alignment &

Dynamic Balancing

● Preventative Maintenance Services

● Obsolete PCB Redesign

& Manufacture

● Asset Management

Other round-the-clock servicesfrom Fletcher Moorland:

Left, engineers on thenight shift at FletcherMoorland premises inStoke-on-Trent.

Top, night shift LogisticsCo-ordinator Phil Sutchmonitors the company’svehicle tracking systemin order to direct thenearest vehicle to acustomer call out.

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servo motor repairs

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