Our workshop is equipped with a winding facility where we address the stator winding issues of servo motors brought in for repair and maintenance purposes. In our dedicated winding workshop, we are capable of successfully and efficiently handling the winding (rewinding) of various types of electric motors, including servo motors, spindle motors, asynchronous motors, DC motors, high-voltage motors, and more, without any power or voltage limitations. For the winding of servo motors and other motors, we utilize high-quality materials such as H-class enamel copper wire, F-class insulation papers, and other premium winding components. These materials, combined with skilled craftsmanship, allow us to effectively solve our valued customers' problems. Furthermore, after the winding process, all motors undergo insulation and surge tests using state-of-the-art testing equipment to ensure the quality of the performed work. As a testament to our confidence in the quality of our services, we provide a one-year warranty for all our servo motor repair, maintenance, and rewinding services.

One of the important tests that determine the quality of servo motor repair and maintenance is the measurement of the insulation quality of the stator windings with respect to ground and between each other. All servo motors that come to our workshop for repair and maintenance undergo pre- and post-repair coil insulation tests to measure and record the insulation quality. The measurement of insulation quality in stator windings is crucial for the following reasons: To determine whether the enamel coating on the conductive copper wire has been burnt due to the heat generated during motor operation. To assess whether the insulation papers, which protect the phases from each other, have retained their insulation properties over time. To detect any damage caused by dust, dirt, oil, or other contaminants that accumulate on the coil windings. During the assessment of the insulation quality of servo motor windings, it is not sufficient to conduct a basic insulation test using an ordinary insulation testing device against ground and between coil terminals. It is essential to perform a surge test, which examines for any leakage or short circuits between the windings. This is particularly important because servo motors are generally small in size, and their windings are connected in a star configuration with three power terminals. In such cases, it is not possible to conduct inter-winding insulation tests. Our company utilizes a Baker brand HIPOT SURGE test device, which is one of the most important testing equipment in our technical infrastructure, to perform all the necessary coil tests and measurements on servo motors with high quality and reliability.

The majority of servo motor failures are caused by mechanical problems. Statistics worldwide indicate that 65% of electric motor failures are due to mechanical issues. Due to the production pressure on the machines where servo motors operate, regular and periodic maintenance is often neglected. This leads to serious mechanical problems and subsequent motor failures. If these mechanical issues are not detected in a timely manner, they can result in: Damage to the bearing housings in the front and rear motor covers Damage to the motor bearings Damage to the front and rear bearing housings of the rotor shaft Damage to the keyway in the rotor shaft Damage to the coupling and pulley location on the rotor shaft These issues significantly prolong the repair and maintenance processes, making them more time-consuming and costly. Our company has an advanced technical infrastructure that enables us to address all mechanical problems quickly and efficiently. Additionally, our in-house lathe workshop and Castolin Thermal Spray technology allow us to coat and process the rotor shaft bearing housings, as well as the motor cover bearing housings. These processes are carried out by our skilled technical personnel, enabling us to provide fast and reliable services to our customers, while also offering cost-effective solutions.

One of the most common problems encountered during servo motor repair and maintenance is the loss of torque, excessive current, and overload errors, which are primarily caused by power loss in the magnets of the servo motor rotors due to the heat they are exposed to over time. In servo motors undergoing Back EMF testing, the rotor magnets are also measured using a gauss meter after they are mounted to make a definitive judgment about the condition of the magnets when there is a suspicion of problems. Furthermore, not only the rotor magnets of faulty motors are measured, but also the rotor magnets of motors where no issues are detected during the Back EMF test are measured to determine the required values for the magnets. These reference magnet values are recorded for future comparisons. The aim is to make a precise diagnosis of a rotor when another motor with similar specifications comes to our workshop for repair, enabling an accurate determination of the fault

We subject all serviced, maintained, and repaired servo motors to a dynamic drive test by operating them with original or equivalent servo drives after the assembly process. The purpose of this test is to measure the accuracy and quality of the mechanical and electrical interventions performed during the repair and maintenance stages. It is a critical step following the completion of servo motor repairs, including the adjustment of encoders and resolvers to ensure their proper functioning, measurement of current and voltage values to assess coil quality, verification of correct stator winding if performed, measurement of thermistor values to monitor sudden changes in coil temperature and ensure accurate readings, and analysis of various details to assess the accuracy of electrical interventions. Additionally, vibration measurements of the servo motors are conducted during this stage to evaluate the performance of replaced bearings and the quality of mechanical interventions on the motor. These tests and measurements are recorded in video format and shared with the customer. Motors that successfully pass the drive test are shipped to our customers, ensuring their seamless operation upon arrival.

Back EMF Test in Servo Motor Repair and Maintenance The Back EMF test is performed to detect potential power losses that may occur in the rotor magnets of long-running synchronous servo motors due to the heat they are exposed to. The power losses occur in the magnets of the rotor of synchronous servo motors as a result of the heat they are exposed to, which is dependent on the current they draw. This situation leads to power (torque) loss in the motors. The servo motor draws more current to perform its work, resulting in more heat generation, and over time, the magnets lose more power and become unable to function properly. In response to this issue, customers often report power loss, torque loss, thermistor errors, and overheating complaints. As part of the repair and maintenance process, all synchronous servo motors that come to our workshop undergo a Back EMF test to identify potential magnet problems.