Servo motors used in industrial production lines are advanced technology equipment that drive CNC machines, axes, and robotic arms worth thousands of Euros. Disassembling and rewinding a faulty servo motor like a standard asynchronous electric motor is not just a waste of time; it is a highly risky mistake that can lead to the explosion of the servo drive panel it is connected to.
As Code Elektronik Makine, we are a fully equipped electronics laboratory providing services to all Organized Industrial Zones (OIZ) in Turkey. Faulty servo motors reaching our facility undergo 3 different engineering phases: mechanical, magnetic, and electronic. After a comprehensive overhaul, the motor is connected to its original brand's (Fanuc, Siemens, Yaskawa, etc.) drive panels and subjected to a dynamic load simulator test.
Our Step-by-Step Guaranteed Servo Motor Repair Process
We apply a transparent, engineering-based repair procedure without confronting our customers with "surprise costs":
Free Evaluation and Insulation Measurement
Before the motor is disassembled in our lab, electrical insulation (Megger 1000V/5000V) tests are performed. The encoder signal quality is read with an oscilloscope. Mechanical clearances and brake coils are measured, and a detailed, transparent damage report and price quote are presented to the customer. We never charge for rejected fault diagnostics.
Stator Rewinding, Baking, and Rotor Magnetization
If the motor is burnt out (short circuit), the rewinding process is performed with pure copper enameled wire conforming to the original thermal class (Class H/F). The stator is baked with high-insulation varnish. The gauss (magnetic field) losses in the rotor magnets are detected and repaired. Worn bearings are replaced with High-Speed SKF/FAG bearings.
Encoder Calibration and Resolver Adjustment
Every servo motor that undergoes mechanical processing will have its encoder reading direction disrupted. When assembling the motor in our lab, the rotor's magnetic field and the encoder's zero point (offset / commutation) are locked together with milli-degree precision using special software and oscilloscopes.
Simulator Load Test and Quality Control
Once the repair and calibration are complete, the motor is connected to a genuine servo drive of its own brand. It is run for hours under heavy load and rapid reversing in our test panels simulating the factory environment. The motor, approved for vibration, current, and heating values, is packed and shipped.
Most Common Faults Reaching Our Lab and Our Solutions
Coolant and Liquid Ingress
Coolants leaking into the motor due to poor insulation or worn seals burn the windings. Stator winding, ultrasonic cleaning, and seal replacement are performed to restore IP65 standards.
Broken / Faulty Encoder
Encoder optical glasses shattered due to impact, blinded sensors, or communication IC failures are resolved with original spare part replacements and oscilloscope calibration.
Brake Failure (Loss of Holding Torque)
The wear of brake pads or the burning of the 24V DC brake coil, especially in Z-axis vertical machining motors, causes the axis to drop. Brake disc renewal and torque tests are performed.
Excessive Noise and Vibration
Shattered bearings and mechanical play in the flange housing cause severe vibration in the motor. Original bearing replacement and mechanical repair (lathe/balance) are applied.