Motor overload is a common industrial fault, easily causing motor overheating, insulation aging or burnout, and even affecting the power grid and other equipment. Mastering its common causes and quick troubleshooting methods is key to improving efficiency and reducing maintenance costs.
Common Causes of Motor Overload
1. Excessive Load on Driven Equipment: The primary cause, including material accumulation, pipeline blockage, or mismatched motor power (insufficient power for high-load devices).
2. Mechanical Jamming: Occurs when the motor rotor is stuck, bearings are worn/seized, or transmission components (couplings, gears) fail, requiring extra torque and causing overload.
3. Abnormal Power Supply: Unstable voltage (too high/low), three-phase voltage imbalance, or phase loss can all lead to motor overload, even burnout in severe cases.
4. Improper Installation/Adjustment: Issues like overly tight belt drives, incorrect starter settings, or faulty protection components can cause or fail to prevent overload.
Quick Troubleshooting Methods for Motor Overload
1. Check Driven Equipment Load: Stop the motor, disconnect it from the driven equipment and idle. Normal idling indicates the problem is with the driven equipment; continued overload points to the motor or power supply.
2. Inspect the Motor: Check for overheating, odor or abnormal noise; measure winding insulation resistance and bearing condition; verify the functionality of starting and protection devices.
3. Verify Power Supply Parameters: Use tools to detect voltage stability, three-phase balance and phase loss. Address power grid issues promptly or install a voltage stabilizer if needed.
4. Recheck Installation/Adjustment: Ensure proper belt tension and coupling alignment; verify starter settings; check motor power matching with actual load.
Experts remind that quick positioning and timely handling are key to addressing motor overload. Regular daily inspections help reduce faults; online monitoring devices are recommended for key equipment to realize early warning and ensure stable operation.
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Post time: Dec-29-2025