Servo motors are indispensable in various industrial applications, providing precision control and accuracy. However, like any mechanical or electrical component, servo motors are not immune to failures. When these essential devices malfunction, it can lead to costly downtime and disruptions in production. With years of experience in industrial machines and process automation, Motion Tronic is here to help unravel the causes behind servo motor failures as a framework to avoid expensive interruptions.




Overheating is a prevalent cause of servo motor failures. These motors are designed to operate within specific temperature ranges, and exceeding these limits can lead to insulation degradation, winding damage, and overall deterioration of the motor’s performance. Overheating may result from inadequate cooling mechanisms, excessive loads, or prolonged operation at high speeds. Regular maintenance and ensuring proper ventilation can mitigate the risk of overheating and extend the lifespan of servo motors.


Electrical Issues


Electrical anomalies pose a noteworthy threat to the functionality of servo motors. Issues such as power surges, voltage spikes, and electrical noise can wreak havoc on the delicate components within the motor. Voltage irregularities, in particular, can lead to insulation breakdown, winding shorts, and damage to the control circuitry. At Motion Tronic, we recommend employing surge protectors, voltage regulators, and proper grounding practices to safeguard servo motors from these electrical pitfalls.




Contamination is a silent slayer when it comes to servo motor failures. Dust, dirt, moisture, and other foreign particles can infiltrate the motor housing, causing abrasion, corrosion, and insulation degradation. Regular cleaning and sealing mechanisms can help prevent contamination-related issues. We recommend placing servo motors strategically in clean environments and implementing protective measures, such as covers and filters, to act as defences against harmful particles.


Mechanical Wear and Tear


Servo motors are constantly moving and are continuously under mechanical stress during operation. Over time, this can lead to wear and tear on various components, including bearings and gears. Degraded bearings, in particular, can cause increased friction, heat generation, and reduced overall efficiency. Remember to implement routine inspections and lubrication schedules. Promptly replace worn-out components to help prevent mechanical failures and ensure the longevity of servo motors.


Feedback Device Failures


The accuracy of servo motors relies heavily on feedback devices, such as encoders and resolvers, which provide real-time information about the motor’s position and speed. Failures in these feedback devices result in inaccurate positioning, erratic movements, and loss of control. Regularly calibrate and check the integrity of feedback devices to timeously detect and address issues before they compromise the overall performance of the servo motor.


Environmental Factors


The operating environment plays a pivotal role in the health of servo motors. Extreme temperatures, high humidity, and exposure to harsh chemicals can accelerate the deterioration of motor components. It’s crucial to consider the environmental conditions in which servo motors operate and take appropriate measures to shield them from adverse surroundings.


Manufacturer Defects


While advancements in manufacturing technology have significantly improved the reliability of servo motors, occasional defects can still occur. Manufacturing defects may manifest as design flaws, subpar materials, or errors in the assembly process. At Motion Tronic, we always recommend sourcing motors from reputable manufacturers who conduct quality assurance checks.


Understanding the factors that contribute to servo motor failures is the first step to maintaining optimal performance. From there, you can take measures to prevent breakdowns. Regular maintenance, proactive monitoring, and sticking to recommended operating conditions are essential, but it’s best not to try and fix a servo motor yourself. Rather, contact an expert with specialised repair and diagnostic equipment for full service. At Motion Tronic, we have the knowledge, the best equipment and a 12-month warranty on all servo motor repairs we do. Our qualified servo specialists have years of hands-on technical training and practical repair experience. Moreover, all repairs are run-tested and returned with a detailed failure report. If you’d like to get your important servo motors repaired professionally and avoid taking risks that could cost you, contact Motion Tronic today.


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