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I N D U S T R Y
R U N N I N G
Servo Motor
repairs GET IT RIGHT THE FIRST TIME
www.fletchermoorland.co.uk
Don’t take a risk – call the experts PAGE 2
SPECIALIST ENGINEERS READY TO RESPOND 24/7 PAGE 3
REFURBISHED MOTORS ARE AS GOOD AS NEW PAGE 5
SOLUTION TO KEEP PRESSES ROLLING PAGES 6/7
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Don’t take a risk with your repairs – choose the experts By Matt Fletcher MANAGING DIRECTOR ELIABILITY and confidence are key factors in the business of servo motor repairs – and at Fletcher Moorland we are proud to say we have these attributes in abundance. Nobody wants to take risks with the repair and maintenance of their factory’s servo motors – the consequence of production down time is too costly. We have a long-standing track record in providing quality repairs – and over the past five years we have built on that reputation by investing more than £300,000 on hi-tech testing equipment. This means that after we have completed the repairs we can test a motor at full power to make sure every part of its operation is 100 per cent right. Of course, it is not just a question of having state-of-the-art equipment, we
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also have the highest levels of specialist expertise. Repairing servo motors requires a combination of electronic, electrical and mechanical know-how and at Fletcher Moorland our engineers have the necessary breadth of skills. We continue to develop and invest in this expertise to ensure we stay at the cutting edge of modern servo motor technology. Added to this know-how is another important asset we put great store on – an ethic of excellent customer service. Our servo repair workshop in the heart of the UK at Stoke-on-Trent operates 24 hours a day, 365 days a year – and our customers know we will respond immediately to their calls with our own fleet of vehicles ready to go out to factories anywhere in the country, whatever the time of day or night.
When a repair is an emergency we promise to turn it around as quickly as possible – but without compromising the thorough and comprehensive nature of the repair. This is why we are confident in giving industry-leading guarantees – a minimum of 12 months. We carry out around 2,500 servo motor repairs a year for a wide-range of industries in the UK, mainland Europe and North America – and we are also a repair and service centre for a number of leading servo motor manufacturers. We welcome people to come to view our premises to see at first hand the standards of work and thoroughness of our testing. You will see why, when a repair is done by Fletcher Moorland, you can count on it being done properly. Why take a risk on anything less than the best?
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We have a long-standing track record in providing quality repairs – and over the past five years we have built on that reputation by investing more than £300,000 on hi-tech testing equipment.
Managing Director Matt Fletcher tests the operation of a Heidenhain EnDat encoder.
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Servo Motor repairs
Fletcher Moorland 24 hours a day hotline – 01782 411021
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Specialist team has A WEALTH OF EXPERIENCE HETHER it is maintenance and testing or a full strip-down repair, Fletcher Moorland’s dedicated Servo Department 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 sure the sophisticated motors return to customers as good as – if not – better than the day they rolled off the production line. Alan, who has trained all members of his team personally, also has several decades working in production engineering, so appreciates what customers want. He said: “I know from experience that if equipment goes down it can be costly to a company and, in terms of some customers we work with, very costly. For example we have one client who loses tens of thousand of pounds per hour if a servo-controlled robot or machine is down. That is why the customers rely on us to provide first class maintenance. However, if one of their servos breaks down they need to know we can turn a repair around asap – and in some cases that can be a matter of hours.” He added: “Our aim is to send the servo motors back to customers as good as or better than they were when they were first manufactured and we always go the extra mile to carry out modifications and extensive testing that will ensure this.” To guarantee Fletcher Moorland stays at the cutting edge, in one year alone more than £250,000 was injected into the company, which included a complete refurbishment of the servo motor workshop and new servo test equipment development. Alan added: “The sophistication and complexity of servo motors is changing all the time that is why we need to continually upgrade equipment and train our people so we can excel at what we do.”
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Servo Motors Manager Alan Palmer pictured in the Fletcher Moorland servo motors workshop at Stoke-on-Trent.
A selection of servo motors which are awaiting repair and refurbishment.
Mechanical Engineer Alex Blunt precision balances a servo motor rotor.
www.fletchermoorland.co.uk
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Servo Engineer Adam Locastro tests signals output from a Fanuc encoder.
Full refurbishment makes a motor AS GOOD AS NEW
A full Siemens motor refurbishment A well known manufacturer of construction equipment had a servo motor fail that required the full range of skills at Fletcher Moorland. A Siemens 1FT6108-8AC71 servo motor failed in service. Once we received it at our works we knew by the smell it was going to be a major repair. Servo motor engineers stripped the motor and found one of the bearings had collapsed, debris from the bearing had penetrated the motor windings, the shaft was bent and we found the encoder was giving error counts. Our winding department stripped and rewound the stator, our mechanical department reclaimed the bearing housings and straightened the shaft. The electronics department repaired and tested the encoder and, finally, servo engineers rebuilt the motor and fully tested it, ensuring it met nameplate specifications.
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Servo Engineer Adrian Chuter tests a Siemens Sinamics servo motor with a DriveCliq encoder.
Keeping disruption to minimum at distribution centre A fault on a Rexroth MKD090B-047-GG0-KN servo motor caused disruption to a supermarket distribution centre when a belt feed sorter motor failed. We received the motor early one morning and our servo motor diagnostic team knew from their experience with the motors that certain discrete components on the feedback PCB had blown. The motor was stripped down and the feedback PCB was repaired by our electronics department. The servo motor was fully overhauled and assembled. The resolver was fitted and aligned and the memory on the feedback was re-programed. A full test was carried out and the motor was shipped back to the distribution centre.
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ERVO motors are complex pieces of precision equipment, combining aspects of electrical, electronic and mechanical engineering. Repairing them requires an in-depth understanding of each of these engineering disciplines – an expertise which has served Fletcher Moorland and its customers well for decades. Managing Director Matt Fletcher said:“The servo motors we see for repairs present themselves with a variety of different faults – such as coolant ingress into the windings of a CNC motor, frame corrosion on a food processing Richard Urwin, motor, Servo Engineer,
brake damage on an automotive robot motor, shaft damage on a saw motor and encoder errors on a conveyor system motor. “Having an understanding of the correct repair and refurbishment procedures is vital in being able to offer the full servo motor repair service. “We can repair and replace motor shafts; repair keyways; manufacture end shields; balance the rotors; refurbish and fully test the brakes; rewind the motors; repair encoders, resolvers and electronic tachogenerators; align the feedback devices; and read and reprogram the encoder memory.” The Fletcher Moorland workshop has the most advanced equipment to diagnose
faults – be it electrical, mechanical or electronic feedback related. The servo motor goes through a full refurbishment, bringing it back to the condition it was when new. The company also has one of the most thorough facilities in Europe for servo motor testing.“We test each and every servo motor to full power throughout its speed range – this ensures it will work right first time when fitted to a machine,” said Matt. “We have invested to ensure we maintain our position at the forefront of the industry’s technology and we have the equipment to test and verify the most modern encoder types on the market – those with programable encoder data and nameplate such as EnDat and DriveCliq encoders.”
prepares to rebuild a Fanuc servo motor. ● Brake Overhaul
● Perform Run Tests
● Bed-in New Brakes
● Perform Dynamic Load Tests to 60Nm
● Check Holding Torque
● Perform Vibration Analysis Checks
● Check Breakaway Torque
● Produce a Load Test Certificate ● Winding Integrity Check ● Baker Surge Testing
Rewind Department Supervisor Ken Dean surge testing a rewound Fanuc servo motor.
● Superior Rewinds to Class ‘H’ ● Two Year Winding Guarantee
Washdown failure
● Repair & Test Incremental Encoders
OFTEN in food manufacturing facilities, over enthusiastic wash-downs cause problems with electrical machines. A dairy foods producer sent an Allen Bradley MPL-B420P-RK22AA motor to us suspecting it had been washed down. This was on a Friday and the customer wanted the motor back for the next day. Our servo motor workshop assessed the motor and it had indeed been washed down. The motor was wet throughout. We cleaned and dried the motor windings before confirming they were OK. The resolver unit tested faulty on our rig. Luckily this is one type we held in stock so a new resolver was fitted to the refurbished motor and aligned before the motor was fully tested and sent back to the customer.
● Repair & Test Absolute Encoders
Servo Motor repairs
● Repair & Test Serial Encoders ● Align Encoders
● Shaft Repair
● Test & Align Resolvers
● Keyway Repair
● Repair & Test Commutation Sensors
● Dynamic Balancing to G1.0
● Align Commutation Sensors
● Precision Bearing Replacement
● Reset Encoder Memory
● Full Mechanical Refurbishment
ARE YOU GETTING ALL THIS FROM YOUR CURRENT SERVO MOTOR REPAIR COMPANY? If not, contact Fletcher Moorland for a comprehensive repair service at a competitive price – and the peace of mind knowing you can have confidence in your servo motors’ reliability.
Mechanical Fitter James Kelly checks the mechanical dimensions of a servo motor rotor using a Co-ordinate Measuring Machine.
Fletcher Moorland 24 hours a day hotline – 01782 411021
www.fletchermoorland.co.uk
Servo Motor repairs
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30/10/12
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Servo Engineer Adam Locastro tests signals output from a Fanuc encoder.
Full refurbishment makes a motor AS GOOD AS NEW
A full Siemens motor refurbishment A well known manufacturer of construction equipment had a servo motor fail that required the full range of skills at Fletcher Moorland. A Siemens 1FT6108-8AC71 servo motor failed in service. Once we received it at our works we knew by the smell it was going to be a major repair. Servo motor engineers stripped the motor and found one of the bearings had collapsed, debris from the bearing had penetrated the motor windings, the shaft was bent and we found the encoder was giving error counts. Our winding department stripped and rewound the stator, our mechanical department reclaimed the bearing housings and straightened the shaft. The electronics department repaired and tested the encoder and, finally, servo engineers rebuilt the motor and fully tested it, ensuring it met nameplate specifications.
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Servo Engineer Adrian Chuter tests a Siemens Sinamics servo motor with a DriveCliq encoder.
Keeping disruption to minimum at distribution centre A fault on a Rexroth MKD090B-047-GG0-KN servo motor caused disruption to a supermarket distribution centre when a belt feed sorter motor failed. We received the motor early one morning and our servo motor diagnostic team knew from their experience with the motors that certain discrete components on the feedback PCB had blown. The motor was stripped down and the feedback PCB was repaired by our electronics department. The servo motor was fully overhauled and assembled. The resolver was fitted and aligned and the memory on the feedback was re-programed. A full test was carried out and the motor was shipped back to the distribution centre.
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ERVO motors are complex pieces of precision equipment, combining aspects of electrical, electronic and mechanical engineering. Repairing them requires an in-depth understanding of each of these engineering disciplines – an expertise which has served Fletcher Moorland and its customers well for decades. Managing Director Matt Fletcher said:“The servo motors we see for repairs present themselves with a variety of different faults – such as coolant ingress into the windings of a CNC motor, frame corrosion on a food processing Richard Urwin, motor, Servo Engineer,
brake damage on an automotive robot motor, shaft damage on a saw motor and encoder errors on a conveyor system motor. “Having an understanding of the correct repair and refurbishment procedures is vital in being able to offer the full servo motor repair service. “We can repair and replace motor shafts; repair keyways; manufacture end shields; balance the rotors; refurbish and fully test the brakes; rewind the motors; repair encoders, resolvers and electronic tachogenerators; align the feedback devices; and read and reprogram the encoder memory.” The Fletcher Moorland workshop has the most advanced equipment to diagnose
faults – be it electrical, mechanical or electronic feedback related. The servo motor goes through a full refurbishment, bringing it back to the condition it was when new. The company also has one of the most thorough facilities in Europe for servo motor testing.“We test each and every servo motor to full power throughout its speed range – this ensures it will work right first time when fitted to a machine,” said Matt. “We have invested to ensure we maintain our position at the forefront of the industry’s technology and we have the equipment to test and verify the most modern encoder types on the market – those with programable encoder data and nameplate such as EnDat and DriveCliq encoders.”
prepares to rebuild a Fanuc servo motor. ● Brake Overhaul
● Perform Run Tests
● Bed-in New Brakes
● Perform Dynamic Load Tests to 60Nm
● Check Holding Torque
● Perform Vibration Analysis Checks
● Check Breakaway Torque
● Produce a Load Test Certificate ● Winding Integrity Check ● Baker Surge Testing
Rewind Department Supervisor Ken Dean surge testing a rewound Fanuc servo motor.
● Superior Rewinds to Class ‘H’ ● Two Year Winding Guarantee
Washdown failure
● Repair & Test Incremental Encoders
OFTEN in food manufacturing facilities, over enthusiastic wash-downs cause problems with electrical machines. A dairy foods producer sent an Allen Bradley MPL-B420P-RK22AA motor to us suspecting it had been washed down. This was on a Friday and the customer wanted the motor back for the next day. Our servo motor workshop assessed the motor and it had indeed been washed down. The motor was wet throughout. We cleaned and dried the motor windings before confirming they were OK. The resolver unit tested faulty on our rig. Luckily this is one type we held in stock so a new resolver was fitted to the refurbished motor and aligned before the motor was fully tested and sent back to the customer.
● Repair & Test Absolute Encoders
Servo Motor repairs
● Repair & Test Serial Encoders ● Align Encoders
● Shaft Repair
● Test & Align Resolvers
● Keyway Repair
● Repair & Test Commutation Sensors
● Dynamic Balancing to G1.0
● Align Commutation Sensors
● Precision Bearing Replacement
● Reset Encoder Memory
● Full Mechanical Refurbishment
ARE YOU GETTING ALL THIS FROM YOUR CURRENT SERVO MOTOR REPAIR COMPANY? If not, contact Fletcher Moorland for a comprehensive repair service at a competitive price – and the peace of mind knowing you can have confidence in your servo motors’ reliability.
Mechanical Fitter James Kelly checks the mechanical dimensions of a servo motor rotor using a Co-ordinate Measuring Machine.
Fletcher Moorland 24 hours a day hotline – 01782 411021
www.fletchermoorland.co.uk
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Overnight repair of Fanuc motors WE took a call from one of our automotive customers to say they were sending two Fanuc motors (model number A06B-0034-B675) that were required back as soon as possible. Fault information was that they both had snapped shafts. The motors arrived just before 4pm and went straight into our servo motor workshop. The fault information was correct, both shafts had sheared. The motors were stripped down and fully inspected – the windings and encoder were OK, the shafts were pressed out of the magnet pack and our mechanical engineers drew a CAD drawing of the tapered shaft. Overnight our machine shop manufactured two new shafts and, in the meantime, servo motor engineers had cleaned, checked and overhauled the remaining parts. The new shafts were pressed and secured back into the magnet packs and passed back to the servo motor workshop where both motors were fully assembled using new bearings and OEM seals. Once the alignment had been carried out, both motors were load tested ensuring OEM performance was met. They were both despatched back to our delighted customer at 10.45am the following morning.
Delivering GOOD keeping the press
A crumbling motor from a biscuit manufacturer (it really was almost cream crackered!) QUITE often we see servo motors suffering heavy corrosion. One such motor was sent to us from a biscuit manufacturer. It was a Control Techniques 142DSB200CAAAA servo motor. The endshield frame had corroded at the mounting holes and the shaft was worn from a poor fitting coupling. Our servo engineers fully diagnosed the faults and took a new endshield and new rotor from our extensive stock of spare parts and fully rebuilt the motor to an ‘as new’ condition. The resolver was aligned to OEM specification and the motor was returned to production with the minimum of downtime – giving the customer much more than a crumb of comfort!
Kawasaki robot motor faults AN automotive customer was having failures on Kawasaki robot motors (model 3MC302G-3DRAE-KJ1). We suggested that we carry out a full investigation on the motor. This type of motor has a Kawasaki specific serial data encoder, we reverse engineered the encoder and re-engineered one of our test servo drives to enable full speed and full torque operation of the motor after test. From discussions with our customer, the fault seemed to be pointing to the brake binding during operation. The brake holding and release torque was measured and was OK, the response time to engage and disengage was OK and within tolerance. After many further trials we found there was an issue with one mechanical part in the brake assembly. This was re-engineered and our customer is now enjoying long term reliable repairs.
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Servo Motor repairs
LETCHER Moorland Ltd was able to deliver some good news to the company that prints North Staffordshire’s daily paper The Sentinel. The two presses at the Etruria, Stoke-on-Trent publishing centre will continue to roll for many years to come, thanks to a carefully planned programme of refurbishment for the large specialist servo motors that are a vital component of the printing process. One of the presses is powered by 17 Indramat motors while 34 more are used on the other press and until two years ago the motors were serviced by the manufacturer. However The Sentinel were told by the manufacturer that the motors had exceeded their normal operational life – substantially increasing the cost of repairs and servicing. That’s when Technical Manager Jeff Hilditch contacted Fletcher Moorland’s Managing Director Matt Fletcher and found a very local solution to their problem. Fletcher Moorland drew up a plan to completely re-build all the motors at a fraction of what it would have
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cost to purchase new ones. The components are being refurbished one at a time and it takes around two weeks to restore each one to mint condition. Meanwhile The Sentinel keep a number of Indramat motors on stand-by in case of a breakdown to ensure the presses – which print up to 60,000 copies of The Sentinel a day five days a week and 300,000 copies of The Daily Mail and Mail on Sunday seven nights a week – are not interrupted by servo motor failure. Jeff said: “We have embarked on a long term project of motor refurbishment which will take about five years. Fletcher Moorland came up with a rebuilding programme that is extremely cost effective and meets our needs perfectly.” The Sentinel’s Indramat 2AD180D series motor is large for a servo/spindle motor, weighing more than 400 kilograms. It produces peak power of 95 kilowatts at 6,000 rpm. When Fletcher Moorland engineers diagnosed the faults on the motors, it was found that firstly the windings and internals were suffering from heavy contamination.
Fletcher Moorland 24 hours a day hotline – 01782 411021
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Fletcher Moorland
OD NEWS by
repair and service servo motors manufactured by a vast range of companies including:
sses rolling
ABB Allen Bradley
Adrian Chuter, Servo Engineer, with a rotor removed from a Sentinel motor for the next stage of precision measuring and balancing. Inset above, Adrian removing the rotor.
AMK ASB Baldor Baumüller Bosch Control Techniques Elau Electrocraft Eurotherm Fanuc Indramat Kawasaki Kollmorgen Lenze
A number of the motors had windings faults because the contamination had started to corrode the enamel coating on the windings and this was evident by a higher than normal earth leakage current. “Whilst not a cause of failure this would have meant the motor would have failed at some point in service,” explained Fletcher Moorland Managing Director Matt Fletcher. “We rewound a number of these machines to an enhanced class ‘H’ insulation system.” Further investigation into the mechanical dimension of the bearing housings showed they were oversize. “We measure all critical dimensions with a Co-ordinate Measuring Machine which is accurate to 1,000th of a millimetre,” said Matt.“It is often overlooked that the bearing fits have an ISO tolerance and any part outside of these tolerances will eventually lead to failure.” In addition, rotors are balanced to an enhanced G1.0 balance grade and the encoders, which are usually contaminated, are fully refurbished – even though they are not faulty. Final testing of the motors is carried out at 6,000 rpm where engineers look to see if vibration limits are within levels expected of new motors. Matt added: “Without our mechanical and electrical skills, a thorough repair of this type of motor would not be possible.”
www.fletchermoorland.co.uk
Mavilor Moog Nachi NUM Oemer Pacific Scientific Parker Reliance Rexroth Rockwell
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Fletcher Moorland came up with a rebuilding programme that is extremely cost effective and meets our needs perfectly JEFF HILDITCH TECHNICAL MANAGER
Sanyo Denki SEM Siemens Stromag Vickers Yaskawa Servo Motor repairs
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Other round-the-clock services from Fletcher Moorland: ● 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
Left, engineers on the night shift at Fletcher Moorland premises in Stoke-on-Trent. Top, night shift Logistics Co-ordinator Phil Sutch monitors the company’s vehicle tracking system in order to direct the nearest vehicle to a customer call out.
Fletcher Moorland Ltd, Elenora Street, Stoke on Trent, ST4 1QG, UK ■ Phone: 01782 411021 ■ Fax: 01782 744470 ■ Web: www.fletchermoorland.co.uk