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mill motor

Winding Redesign

An employee owned manufacturer in NW Ohio had a critical GE 400/200 HP large frame two speed Mill motor failure. After we received and inspected the motor, the form coil winding had failed. This was the first winding failure on this motor in 30 yrs. Unfortunately they had no spare. The search began for an E-OK motor to rebuild in order to reduce the downtime based on the time required for a form coil re-wind. Six motors were potential replacements but all would require major field motor base and fitment requirements. During a discussion with the customer they stated the 400 [...]

Winding Redesign2023-06-07T10:22:06-04:00

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

Steel Rolling Tandem Mill Motor

A steel manufacturer sent in a steel rolling tandem mill motor after the armature equalizer insulation had failed to ground due to age and time of service. The bearings, bearing journals, and bearing housings were severely damaged. A team of different Horner Divisions came together to complete this project. Machining Services did an extensive amount of machine work on the shaft and bearing housing. They also turned and undercut the armature when the rewind was completed. Fan and Fabrication manufactured new bearing seal inserts. Horner Coatings sprayed and machined the shaft and bearing housings. They also did the welding of the [...]

Steel Rolling Tandem Mill Motor2022-05-16T11:59:45-04:00

Finish Ball Mill Motor

A 1350 HP Synchronous Motor out of a cement plant in Ohio was called out to bid and Horner won that bid. This finish mill motor comes out of a cement plant in the ball mill. The ball mill is a big round pipe that is full of steel balls the size of a softball. As the pipe turns it has blades welded on the inside which carry the balls up to the top of a 16-foot diameter pipe and the balls fall to the bottom of the pipe where the rocks are. The weight of the balls smash the rock [...]

Finish Ball Mill Motor2022-01-28T15:09:16-05:00

DC Steel Mill Motors

The Horner Springfield division received a call from a steel mill customer, located in Columbus OH. They had a failure on a tandem pair of 850 HP DC motors on their rolling mill operation. Horner Industrial Springfield division had previously rebuilt their spare DC tandem mill motor set, including rewinding one of the armatures. Springfield field service techs removed the failed motors and installed the stored rebuilt motors, at the customer’s site. We also contracted with our local rigger to remove the 16,000 lb. motors and deliver them to our shop. There are still a lot of DC motors in operation [...]

DC Steel Mill Motors2022-01-26T22:35:54-05:00

Rolling Mill Gearbox Repair

A customer recently sent in a gearbox that is part of their rolling mill. The rolling mill uses a metal alloy to make engine bearings for large Diesel engines. This line on the mill brings in thicker material and rolls it out thinner to the desired thickness. Much like a rolling pin does with dough. The problem with the gearbox was when it was put under load it would vibrate like crazy. When the gearbox ran unloaded it ran smooth. It was found that the shaft was bent, and the gears were in bad shape. We worked with a quality manufacturer [...]

Rolling Mill Gearbox Repair2021-02-18T18:45:06-05:00

2000 HP Aluminum Plant DC Motors

An Aluminum Rolling and Recycling plant, a good Horner customer in Terre Haute brought Todd Cochran (Sales) a problem/ or opportunity to Indianapolis Field Service. The customer has two, 2,000 HP DC motors coupled together, to deliver 4,000 HP to their mill. These motors are about 5-6 foot square, and 10 feet long each. The inside motor, the one coupled between the mill and the second motor, failed and had to be replaced with a spare. This is not something they can shut down for a couple of days. Of course this happens when the Indianapolis Field Service group is working [...]

2000 HP Aluminum Plant DC Motors2021-01-08T23:55:43-05:00

Made In Japan, Rebuilt In The US

Everyone is well aware of the quality of Japanese autos in today’s market. In the 1980’s, the Japanese raised the quality bar in the automotive industry, resulting in cars that were of a higher quality and remained in service for many more miles than most of the domestic autos of that time. This off-shore challenge resulted in the upgrade of quality for all American automakers, just to remain in business. This quality concept also applies to the motor repair business and is why our company has Quality Manager like Vernon Pratt, to help us keep quality at the forefront of our [...]

Made In Japan, Rebuilt In The US2020-03-12T15:46:06-04:00

1500 HP Aggregate Mill Motor

A large aggregate company in Southern Indiana that Horner Industrial has serviced for years contacted Horner as they had a 1,500 HP 180 rpm Open Frame AC Wound Rotor/Synchronous motor that needed to be removed, rewound, and reinstalled. This motor was manufactured in the 1950’s and it was one heavy piece of iron. (42,000lbs) Once it was removed, transporting it posed a challenge to Horner’s Logistics Department as it had to be transported on a special “low-boy” semi-trailer due to its size. We had to make sure that it would pass under all the overpasses on I-65 from Louisville to Indianapolis. [...]

1500 HP Aggregate Mill Motor2019-09-10T16:00:16-04:00

Loose Motor Bases: Motor Vibration (A Simple Solution)

When analyzing motors, it is easy to read more into a problem than actually exists. This case history illustrates the need to always look for the simple solution first. While at a power plant working on a large fan, the vibration analyst requested that a large mill motor be examined. The motor had been sent out to motor shops twice. In each instance, the vibration remained high when the motor was put back into operation. Attempts were made to field balance the motor, however, they were unsuccessful. The motor continued to have amplitudes of 8 mils of vibration, all of which [...]

Loose Motor Bases: Motor Vibration (A Simple Solution)2019-09-09T18:02:12-04:00
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