Is the Remanufacturing of the Motor the Same as Refurbishing the Motor?

An old product is processed by a remanufacturing process, and after strict inspection, it reaches the same quality as a new product, and the price is 10%-15% cheaper than the new product. Are you willing to buy such a product? Different consumers may have different answers.

After an old electric motor is finely divided into iron blocks, coils and other parts, it is sent back to the steel mill for refurbishment at the price of scrap copper and rotten iron. This scene is the final destination of most scrapped electric motors. However, in addition to this, the motor can also be remanufactured to regain new vitality.

High-efficiency remanufacturing of motors is to remanufacture low-efficiency motors into high-efficiency motors or system-saving motors suitable for specific loads and working conditions (such as pole-changing motors, variable-frequency motors, permanent magnet motors, etc.)

Due to the lack of publicity on remanufacturing, users often confuse remanufacturing and repair.

Remanufacturing general process

1. Recycling Process

According to the survey, different companies use different ways to recycle electric motors.

For example, Wannan Electric Motor provides different quotations for each recycled motor. Generally, experienced engineers go directly to the recycling site to determine the motor according to the service life of the motor, the degree of wear, the failure rate, and which parts need to be replaced. Whether it meets the requirements for remanufacturing, and then gives a quotation for recycling. For example, in Dongguan, Guangdong, the motor is recycled according to the power of the motor, and the recycling price of motors with different pole numbers is also different. The higher the number of poles, the higher the price.

2. Disassembly and Simple Visual Inspection

Use professional equipment to disassemble the motor, and perform a simple visual inspection first. The main purpose is to determine whether the motor has the possibility of remanufacturing and to simply judge which parts need to be replaced, which can be repaired, and which do not need to be remanufactured. The main components for simple visual inspection include casing and end cover, fan and hood, rotating shaft, etc.

3. Detection

Carry out detailed inspection of the parts of the motor, and inspect the parameters of the motor to provide a basis for formulating a remanufacturing plan.

Various parameters include motor center height, iron core outer diameter, frame size, flange code, frame length, iron core length, power, speed or series, average voltage, average current, active power, reactive power, apparent power , power factor, stator copper loss, rotor aluminum loss, additional loss, temperature rise, etc.

4. Develop a remanufacturing plan and carry out remanufacturing

In the process of high-efficiency remanufacturing of electric motors, there will be targeted measures for different parts according to the inspection results, but generally speaking, part of the stator and rotor needs to be replaced, and the frame (end cover) is generally reserved for use, bearings, fans, etc. , fan cover and junction box all use new components (among which the newly replaced fan and fan cover are new energy-saving and high-efficiency designs).

1. For the stator part

The stator coil and the stator core are cured as a whole by dipping the insulating paint, which is usually difficult to disassemble. In the past motor repair, the method of burning the coil was used to remove the insulating paint, which destroyed the quality of the iron core and caused great environmental pollution (remanufacturing uses special The machine tool cuts the winding end without damage and pollution; after cutting the winding end, hydraulic equipment is used to press out the stator core with coil, and after the core is heated, the stator coil is pulled out; the coil is rewound according to the new plan; after the stator core is cleaned , Carry out the off-line ‘connection and withstand voltage test, enter the VPI dipping tank after passing the paint, and enter the oven to dry after dipping.

2. For the rotor part

Due to the interference fit between the rotor iron core and the rotating shaft, in order not to damage the shaft and the iron core, the intermediate frequency eddy current heating equipment is used for remanufacturing to heat the surface of the motor rotor. According to the different thermal expansion coefficients of the shaft and the rotor iron core, the shaft and the rotor iron core are separated; After the rotating shaft is processed, the intermediate frequency eddy current heater is used to heat the rotor core and press into the new shaft; after the rotor is press-fitted, the dynamic balance test is performed on the dynamic balancing machine, and the bearing heater is used to heat the new bearing and install it on the rotor.

3. For the machine base and end cover, after the machine base and end cover have passed the inspection, use sandblasting equipment to clean the surface and reuse it.

4. For the fan and air hood, the original parts are scrapped and replaced with high-efficiency fans and air hoods.

5. For the junction box, the junction box cover and the junction board are scrapped and replaced with new ones. The junction box seat is cleaned and reused, and the junction box is reassembled

Assemble, test, leave the factory

After the stator, rotor, frame, end cover, fan, hood and junction box are remanufactured, they shall be assembled in accordance with the new motor manufacturing method, and shall be tested at the factory.

Remanufactured objects

So what kind of motor is a motor that can be remanufactured?

In theory, all electric motors in various industries can be remanufactured. In fact, companies often choose to remanufacture motors that require the availability of major components to be more than 50%, because remanufacturing of motors with low utilization rates requires very high costs, low profit margins, and no need for remanufacturing.

At present, most of the users will consider remanufacturing the motor because the energy efficiency of the motor used does not meet the national standard or if they want to replace the high-efficiency motor. After being remanufactured by the enterprise, sell the remanufactured motor to him at a lower price. Motors can be remanufactured in two cases:

One situation is that the motor itself meets the requirements of the national energy efficiency standard. After being scrapped, it is recovered at a low price. Most of the parts can be reused. After remanufacturing, the motor product achieves higher efficiency.

Another situation is that the low-efficiency obsolete electric motor fails to meet the national energy efficiency standard, and reaches the national energy efficiency level through remanufacturing. After taking it back, some parts were used to transform it into a high-efficiency motor and then sell it to him.

About the Warranty Program

Remanufactured motor companies carry out the entire warranty for their remanufactured motors, and the general warranty period is 1 year.

Let the “invisible industry” surface

In our country, the current remanufacturing industry is like a giant whale in deep diving – huge and hidden, it is a stealth industry that is really worth digging into. In fact, in industrially developed countries, remanufacturing has formed an important industry. According to data, the output value of the global remanufacturing industry will exceed US$40 trillion in 2022.

The remanufacturing industry has only gradually developed in recent years. However, this invisible huge market is actually facing a lot of difficulties. One of the embarrassments is the huge dislocation between the high-tech production process and high-level quality performance and the traditional cognition of consumers on remanufacturing, resulting in a continued downturn in the recognition of remanufacturing. Coupled with the lack of unified market access standards, some companies refurbished old parts as remanufactured products, disrupting the remanufacturing market order.

Only by speeding up the regulation of the market and formulating relevant industry standards can the sunrise industry of remanufacturing win a longer-term future from its inception.

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