ac motor repair

Rubber Plant Motor Failure

A 400HP WEG motor on the hydraulic power unit of a plant’s main mixer failed due to a catastrophic drive-end (DE) bearing issue. The bearing failure generated sparks and halted the production of raw rubber critical for automotive products. With the backup mixer already out of service—its old DC motor awaiting replacement in February 2025—production came to a complete standstill. Upon inspection, it was clear the inner race of the failed bearing had welded itself to the motor shaft. The motor was promptly sent to Horner Machining Services (HMS) division for shaft repair. Once disassembled at Washington Street, HMS discovered deep [...]

Rubber Plant Motor Failure2026-04-15T12:07:14-04:00

1000 HP Motor Redesign

Horner Industrial, Springfield OH division, has recently acquired two large customers from one competitor, who fell from grace by not meeting the service expectations of the customers. One of these customers is a large cement processing facility. After firing our competitor, our new customer sent in orders for two 1000 HP motors. One was a large, low speed crusher motor for rebuild and reconditioning. The other order was for a replacement spare fan drive motor that was obsolete and no longer produced. Bill Roper, our salesman in northern OH, located a used motor that was the correct frame and RPM. The [...]

1000 HP Motor Redesign2026-04-14T10:22:39-04:00

Cement Plant Finish Mill Project

The electric motor plays a crucial role in the operation of a cement ball mill. It provides the power necessary to rotate the mill’s cylinder, which contains grinding media such as steel balls. This rotation of the cylinder causes the grinding media to cascade and grind the raw materials or clinker inside the mill into fine powder. The motor’s power and efficiency directly impact the performance and productivity of the cement ball mill. A properly sized motor with sufficient power ensures that the mill can handle the required load and maintain the desired rotation speed. Additionally, the motor’s reliability and durability [...]

Cement Plant Finish Mill Project2025-01-15T13:28:15-05:00

When Buying New Is Too Much – Repair

Horner recently achieved a remarkable success story with a major steel mill. They make specialty metals for the aircraft and aerospace industries including rolled steel, bars, ingots, and wire. Initially poised to purchase two new fan units for their exhaust system in their Finish/Sizing Mill, they hesitated due to concerns over pricing and lead time. Sensing an opportunity for collaboration, I proposed the idea of reconditioning the units instead. Working closely with Horner Fan & Fabrication, we meticulously crafted a competitive quote, addressing the client’s concerns head-on. Despite initial reservations, we assured them of a swift turnaround time of 3 to [...]

When Buying New Is Too Much – Repair2025-01-15T12:21:27-05:00

Horner Electro-Mechanical Diagnostic Group – Coal Fired Power Plant Vertical Motor

At Horner Industrial Group, we take pride in our commitment to excellence and preventative maintenance solutions. Recently, our EMDS department had a significant impact on the operations of a coal-fired power plant, showcasing the vital role of hands-on data collection and analysis in preventing potential disasters. Our client, a coal-fired power plant, relies heavily on rotating equipment to maintain its operations. Every month, our vibration technician Joe Roseberry, performs vibration data collection and analysis on all rotating equipment at the plant. One critical piece of equipment under Joe’s watchful eye is an agitator, which plays a crucial role in an environmental [...]

Horner Electro-Mechanical Diagnostic Group – Coal Fired Power Plant Vertical Motor2025-01-15T11:05:08-05:00

Aggregate Crusher Project

Despite facing challenging weather conditions, our team at Horner recently achieved a remarkable feat at a large Aggregate producer’s facility in Noblesville. Tasked with replacing an underperforming crusher, we seamlessly managed the removal process despite encountering unmarked power and control wiring. Under the leadership of Mark Rosebrock, and with the dedicated support of Kevin Bimrose, Jeff Meshishnik, Gary Anderson, Tyler Wilson, Bob Fisher, and others, we designed and built new control cabinets, laid out power and communication cables, and installed new equipment, all completed a week ahead of schedule. Despite adverse weather, our commitment to excellence prevailed, leaving our client extremely [...]

Aggregate Crusher Project2024-11-15T12:54:48-05:00

Starch Mixing Logs

          An ingredient manufacturer had damaged 20 foot mixing logs that mixed up starch. The customer gave us a tight schedule of 5 days to remove the damaged gears, coupling, bearings, and all bent and broken paddles. Basically receive it Monday and return them Friday! Horner Machining Services worked with Fan and Fabrication to get the job done. Machining straightened the shafts and fixed the gears and bearings. Fan and Fabrication laser cut and installed 64 new stainless steel paddles on the mixing logs. It took both divisions and three shifts through the week to make the [...]

Starch Mixing Logs2024-02-28T10:35:03-05:00

Theme Park Elevator Ride Repair

        An elevator engineering company that is a customer of Horner Industrial manufactured an elevator system for a popular theme park ride known as the Tower of Terror. There are four of these rides across the World: Florida, California, Tokyo, and Paris. Our customer continues to maintain and maintenance these rides. This ride, based on the TV show The Twilight Zone, is described by the theme park's website: “Enter the rickety, elevator-style lift, strap yourself in and prepare to discover what lies beyond the darkest corner of your imagination. Shriek in terror as you’re suddenly propelled up and [...]

Theme Park Elevator Ride Repair2024-02-28T09:45:21-05:00

Horner Springfield: Sulzer Pump Company Repair Center

          There is an old saying that when you mix water and electricity, water will always win. Judging from the amount of submersible work that the Horner Springfield division has been receiving, I would say that the old saying is very true. We have seen a substantial increase in the number of underwater submersible pumps and agitators that have a motor, gearbox and fan. Part of the reason for the increase in this line of repair work is the long lead time for replacement units. Underwater submersible equipment that our division has repaired ranges in size from [...]

Horner Springfield: Sulzer Pump Company Repair Center2024-02-28T09:37:03-05:00

Military Work In Springfield

Our company’s typical clients are heavy industrial-based companies. We are blessed to have such diversity in our customer base – steel, aggregate, plastics, automotive, etc. Since we are in so many sectors of industry, we have increased job security. One sector such as automotive can tank while others may increase, keeping our company workload relatively steady. Another component of this security is our nation’s military who’s mission is to keep America and her people safe from threats, foreign and domestic. In the past, we have been called upon to assist the government with projects for the Navy and Air Force. In [...]

Military Work In Springfield2023-06-19T10:31:30-04:00

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