Case studies: Preventive maintenance of over 120 motors and frequency converters

Project duration: 537 hours

Customer Expectation

Our customer, a leading company in the food industry, performs annual maintenance on numerous systems, particularly frequency converters and motors. These measures are part of a strategy to ensure the long-term reliability of critical equipment.

This year's preventive maintenance program includes:

72 motors from 110–400 kW

51 frequency converters in the same power range

The goal is to detect failures early, optimize interventions, and ensure production continuity during peak periods.

DV GROUP Solutions

Our technical solution meets the customer's requirements and takes their budget into account:

Preventive maintenance: Dust extraction, functional testing, and a report with recommended actions

Disassembly and assembly of power units for cleaning hard-to-reach areas

Shock wave diagnostics for early detection of deviations and direct tuning of critical equipment

Despite their newness, the converters are already exhibiting overheating caused by dust and contamination, which leads to rapid aging. The original IP23 protection level is not sufficient for this.

To remedy this, severely affected devices are dried and cleaned in our workshop. In addition, installed filter towers increase the protection level to IP43, which offers better protection against fine dust and is adapted to the site conditions.

Customer benefits and advantages

Maintaining a new equipment fleet despite overheating

Avoiding unplanned downtimes in critical systems

Improved protection level of the frequency converters

Optimized maintenance planning in summer

Safe production restart