Maintenance, testing and repair of­ electrical machines

Laser-based alignment measurement technology increases the likelihood of successfully resolving alignment issues. As a direct result of these improved alignments, the efficiency, reliability, and service life of rotating machinery are enhanced. Studies also show that improving alignment by just a few hundredths of a millimeter—which can be easily achieved with a laser alignment system—can save at least 0.5 percent in energy costs.

Laser-Optical Machine Alignment
Fast and accurate machine alignment using lasers replaces the traditional and established method involving a ruler and dial indicator. Instead of merely determining the position of the machine and coupling geometry, the laser is used to measure the rotational axes.

How does laser-optical measurement work?
Laser-optical measuring devices determine the degree of misalignment by measuring the offset of the shafts. The laser/detector unit (transmitter) and the reflector are each mounted on one side of the coupling using continuously adjustable clamping devices. The laser beam from the transmitter passes over the coupling into a glass prism in the reflector, is reflected back there, and strikes a position detector in the receiver.

Our services in detail
- assessment of the machine's condition
- measurement of coupling misalignment, coupling clearance, and machine skew
- screen-guided correction at each individual machine foot.Analysis of the recorded data
- consultation with the customer and joint determination of corrective actions
- implementation of the corrective actions while taking the customer's specific schedule into account
 

1. Safety: Based on sensor data analyzed in real time, a reliable and highly responsive safety system (emergency shutdown) can be implemented. In comparison, previous systems (e.g., vibration sensors) are generally less precise and do not contribute to determining the cause of the failure. Online condition monitoring enables an emergency shutdown based on the collected data—and thus an analysis of the cause of the malfunction.
2. Machine efficiency: Monitoring the condition of machinery is an essential prerequisite for “condition-based maintenance.” This strategy replaces the “preventive” maintenance that was previously the norm. In the latter approach, the machine in question was shut down at fixed intervals to inspect or replace components. This type of machine maintenance often resulted in intact components being replaced, thereby wasting their remaining service life.

This approach places the highest demands on sensor technology, measurement data processing, and system-specific expertise. However, it also offers the greatest potential for cost savings, as the service life of critical machine components can be utilized almost to the fullest, while necessary maintenance work can be scheduled in coordination with the production plan.

Condition-based maintenance, as an interdisciplinary field drawing on mechanics, acoustics, systems theory, electronics, and computer science, is not a fully established branch of science but is undergoing rapid development. However, it can already be highly accurate today, particularly when monitoring individual components. In complex systems, however, its accuracy becomes increasingly limited, as the growing complexity of the system results in an ever-increasing number of signals from a wide variety of sources overlapping. Another shortcoming has often been the lack of suitable sensors capable of detecting signals directly within the wear or damage zones. In the future, microsystem technology may offer a solution here, for example through thin-film sensors that can be mounted directly on the structure being monitored.

The challenges of this strategy lie in
- the search for suitable measurement points and sensors, 
- the identification of meaningful parameters (state variables) for the damage to the components of interest,
- the targeted application of signal analysis and pattern recognition,
- and the enormous volume of data.

Or, to put it simply: What needs to be monitored, when, where, how, and with what?

What condition monitoring cannot do is detect and prevent spontaneous failures, such as a shaft breaking due to fatigue.

We are happy to answer any further questions you may have. Please contact our condition-based maintenance experts.

This is where the method of indirect fault detection comes into play, which involves cyclical measurement of machine vibrations followed by computer-aided analysis—known as vibration analysis. The specific configuration of such measurement systems consists of permanently installed measurement points, a portable transducer, and a PC with specialized software. Vibration analysis detects imbalances, machine misalignments, and bearing damage before failure occurs. Trend monitoring is performed by analyzing high-frequency bearing vibrations using the shock pulse method. The results provide insights into the development of the characteristic condition parameters of the machine bearings.

By regularly recording these parameters, incipient bearing damage can be detected in a timely manner and the condition of the bearing reliably assessed. For example, this makes it possible to determine whether a bearing is sufficiently lubricated or running dry. These advantages, combined with ease of use, have made the impulse method a widely used measurement technique in maintenance. Targeted preventive measures such as alignment, balancing, and bearing replacement eliminate the need for unplanned and uneconomical “first-aid measures.”

The entire system in which the motor is installed must be tested in accordance with DGUV V3.

It always depends on the motor! After a diagnostic check, you’ll receive a transparent quote.

Simple repairs: 1–3 days
- Bearing replacement
- Minor mechanical work

Moderate repairs: 3–8 days
- Winding of small motors
- Mechanical overhaul
- Balancing and alignment

Complex repairs: 2–6 weeks
- Rewinding of large motors
- High-voltage motors
- Explosion-proof motors with ATEX certification

Yes! Blumenbecker specializes in the maintenance and repair of explosion-proof motors in accordance with ATEX directives and Section 14(6) of the German Industrial Safety Regulation.

Our ATEX expertise:
- Certified personnel with official accreditation
- Repairs in accordance with DIN EN 60079-19
- Complete ATEX test report after every repair
- Types of protection: Ex d, Ex e, Ex p, Ex t, Ex nA

Important: Repairing Ex motors without certification is prohibited by law.

Trust in our more than 100 years of experience. 

All major manufacturers, such as ABB, Siemens, SEW, VEM, Nord, and many others. 

It always depends!

We’ll give you honest and transparent advice on which option makes more financial sense. Sometimes we deliberately recommend buying a new one if repairing it wouldn’t be cost-effective.

Yes, absolutely! Explosion-proof motors are subject to specific maintenance and inspection requirements:

Legal requirements:
- Maintenance must be performed only by **qualified personnel** in accordance with §14 of the BetrSichV (6)
- Documentation with ATEX test report
- Markings must remain intact

What we inspect:
- Condition of the type of protection
- Seals and gaps
- Ex markings complete
- Grounding and equipotential bonding
- Temperature class complied with