AC and DC Drive Repairs: Full Load Testing Is a Must
AC and DC drives play a crucial role in controlling motor speed and torque in some of the most important equipment in your factory. These devices are the workhorses of production lines, powering everything from conveyor belts to complex robotic systems. Yet many manufacturers overlook a critical step when it comes to maintenance for AC/DC drives: full load testing.
AC and DC drive repairs
When an AC or DC drive malfunctions, the typical repair process involves these steps:
- Diagnosing of the issue
- Replacing or repairing faulty components
- Basic testing
But this process often falls short of ensuring the drive will perform adequately under real-world conditions once it gets back up and running. This is where full load testing becomes important.
Full load testing involves running the repaired drive at its maximum rated capacity, simulating the actual operating conditions it will face in the production environment. This crucial step goes beyond basic functionality checks, verifying the drive can handle the demands of its specific application.
The process and benefits of full load testing
Full load testing typically involves connecting the drive to a test motor and load bank and then gradually increasing the load to the drive’s full rated capacity. Throughout the test, technicians monitor various parameters such as current, voltage, temperature, and performance stability. This process offers several key advantages:
- It ensures complete functionality under real-world conditions.
- It identifies hidden issues that might not appear during basic testing.
- It prevents unexpected failures after the drive is reinstalled.
- It extends the lifespan of the repaired drive.
The consequences of inadequate testing
Skipping full load testing might seem like a way to save time and money, but it can lead to severe consequences:
- Unexpected equipment failures after reinstallation
- Production downtime due to drive malfunction
- Potential safety hazards from improperly functioning drives
During the summer months, when temperatures and other disruptive catalysts are high, these consequences are more likely to emerge.
Full load testing can uncover issues such as overheating under sustained load, intermittent faults apparent only at high power levels, or inadequate performance at critical operating points.
While full load testing does add to the initial repair cost, it offers significant long-term savings. The cost of unexpected downtime or premature drive replacement far outweighs the investment in thorough testing.
Get full load testing with GES
With demanding production schedules, it’s possible to slip into tunnel vision and see getting equipment back online quickly as the only priority worth tackling. But when it comes to AC and DC drive repairs, full load testing is not a luxury — it’s a necessity. Ensuring repaired drives can handle their intended workload protects your operations from unexpected downtime while enhancing safety and maximizing the return on your repair investment.
Summer slowdowns are a smart time to repair and load test AC/DC drives so they’re in optimal condition to pick up the pace as production schedules ramp up. The investment in thorough, high-quality repairs will pay dividends in improved reliability, reduced downtime, and enhanced productivity when it matters most.
