dc 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

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

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

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

Terre Haute Industrial Equipment Repair Working The Weekend

Terre Haute has been busy with a lot of work from great customers. Recently a plastics recycling customer called about high vibration on a dryer auger. This customer recycles the plastic processing it into industrial resins that are used to make plastic bags. The stainless-steel auger is used to convey plastic pellets during the washing process, prior to drying and packaging. Due to high vibration the auger was pulled and sent to the Terre Haute shop for repair. Jeremy Brown, machinist, dynamically balanced the auger and sent it back the recycling facility to be put back into production. Another project that [...]

Terre Haute Industrial Equipment Repair Working The Weekend2023-06-16T13:28:51-04:00

3000 HP Cement Motor

After having successfully cutting coils from a stator on site four times previously, the 3,000 HP stator finally died and had to be scheduled to be rewound at a cement plant in KY. The removal of the motor is not the conventional way you think of a motor being removed, you start by removing the outside wall of the building it is in, and then sticking the boom of the crane inside the building to be able to lift the motor. standing at a safe distance from the equipment, the motor does not look all that large, but as if gets [...]

3000 HP Cement Motor2023-03-15T10:11:23-04:00

Aluminum Plant Outage

A major aluminum manufacturer contracts Horner EMDS (Electro Mechanical Diagnostic Services) to perform monthly vibration data collection and analysis. EMDS identified a mill gearbox input shaft bearing issue. In 2022, the monthly vibration analysis indicated the bearing issue increasing. The vibration analysis was discussed with the customer and the vibration data collection increased to twice weekly. At the same time, customer was planning a major outage to on-site repair the gearbox. The March outage was scheduled. Horner provided 24 hour per day, 5-day work schedule. On a Monday the outage started. Mark Rosebrock was lead tech on day shift and Matt [...]

Aluminum Plant Outage2023-03-14T11:27:59-04:00

Aluminum Foil Plant Preventative Maintenance

One of Louisville’s largest customers pro- duces aluminum foil. Manufacturing foil starts with aluminum rolls up to 1/2” thick. This plant takes the ½” thick thru mill 6, which reduces the foil thickness to less than 0.100” thickness. From mill 6, the rolls are rolled thinner in mills 3-4-5. After several passes thru these mills, the rolls go to mill 1-2 to roll to thickness required for commercial or residential use. Standard household or standard duty aluminum foil is 0.00063” thick and extra heavy duty foil is 0.00094” thick. Both thinner than 1 thousandth of an inch. Rolling aluminum foil this [...]

Aluminum Foil Plant Preventative Maintenance2023-03-13T10:55:03-04:00

Power Generation Plant Water Pump Motors

A coal fired power generation plant had a planned outage to maintain equipment and Horner was onsite to remove 2 1250HP vertical pump motors. These motors pull water from the reservoir for cooling purposes and heat exchangers. These motors were taken out for routine maintenance, basic reconditioning and to replace bearings. Onsite to help with the removal was Indianapolis Field Service Don Pence, Louisville Field Service Joe Dupont and Terre Haute’s Eddie Piper and Jeremy Brown. Crane service had to be scheduled and coordinated to pull the motors out. The bearings for these motors are specialized thrust bearings and were replaced [...]

Power Generation Plant Water Pump Motors2023-03-13T10:23:54-04:00

Slip Ring Rebuild

A customer called overnight because they had a slip ring failure on one of two synchronous motors and that halted production. Horner was on site in the morning to assess the situation and it was determined that an on site repair was not feasible. The unit was disassembled and transported to the Terre Haute shop for rebuild. By securing customer supplied brushes, brushholders (which are now obsolete), Horner stock to fabricate insulators and with the help of Horner Machining Services, we were able to have the unit back on site within just a few days. Horner was onsite for the eight [...]

Slip Ring Rebuild2023-03-03T11:44:31-05:00

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