Electric Motor Repair Case Study Part 2 - Reverse Engineering
After a damaged motor goes through inspection, measurement, and disassembly, it then goes through a reverse engineering process to ensure the laminations that will be manufactured will result in a replacement motor core that exactly matches the original.
Once the core is removed, we remove a few undamaged individual lamination samples to be reverse engineered. Lamination samples from the damaged motor core are taken to a coordinate measuring machine, or CMM, which scans the part and allows us to recreate the geometry of the lamination. Measuring accuracies are rated to a range of .00020". Maximum measuring envelope is 60"x48"x6".
First, the outside diameter is measured, along with assessing key features, such as weld notches. Then, the slot measurement takes place. Once the scan is complete, a DXF file is then exported and given to one of our engineering team members. They will put together the complete drawings for both the individual lamination as well as the stack. After drawings are complete, they are sent to the customer for approval prior to production.
Next, a test lamination sample is created to validate accuracy of the final product. From here, the job will be queued for production, which is the next step of the electric motor repair process.