Case study
Custom solution for replacement of a discontinued electric motor
Definition
A custom replacement of a discontinued electric motor is a motor that is engineered to match the form, fit, and function of an existing motor that is no longer manufactured. The goal is one-to-one replacement, restored supply continuity, and reduced risk of unscheduled downtime.
Custom solution for replacement of a discontinued electric motor
BEGE supplies specialized custom drive solutions. We support machine builders with our custom drives to help prevent unscheduled downtime. Our distributor and trusted partner Interbridge put us in touch with a US company that needed replacement electric motors for all their factories.
Background & Assignment
Years ago, the company’s former supplier stopped producing the special motors our customer uses in its factories.
As replacement motors were no longer available, the customer had each defective motor repaired and completely rewound by a local shop. This solution proved to be too costly and time-consuming in the long run, so they were looking for an alternative. It was important that the new supplier could deliver these motors and at the same time offer continuity.
The assignment for BEGE was to supply a replacement electric motor so that the customer’s factories could continue running optimally and without unscheduled downtime.
Customer statement
“BEGE has helped us incredibly well. With the limited information we had, BEGE’s engineers actually developed this specific motor from scratch.”
Approach
Unfortunately, the customer did not have any datasheets or motor drawings and could only show a poorly legible sketch, so we decided to send a defective sample to our head office in the Netherlands.
Our engineers examined and measured the motor and developed an initial concept based on all the dimensions. It turned out that the motor did not have standard NEMA or IEC dimensions.
Working method
- Recover data and dimensions
- Examine a defective sample
- Define specifications
- Develop initial concept
- Redevelop and redesign the motor based on the specifications
Result
As both the shaft and the flange did not have standard dimensions, and the shaft also had a special flattened keyway, our engineers completely redeveloped the motor based on all the specifications.
To make life easier for our customers, we supply motors with a screened cable connected to star 400V with an EMC gland. This makes it easy to exchange any motor one-to-one. The motors are also available in a TENV version and with a special low-profile terminal box cover, enabling installation in tight spaces.
As the new motors are supplied in IE3 and the customer has more than 100 motors, the switch will result in significant energy and cost savings.
Finally, we will maintain a reserved stock for this customer in the Netherlands and the US to enable rapid replacement. Our smart stock system sends an alert so that stock can be replenished on time.
The results in a nutshell:
- An electric motor that is completely identical to the previous motor thanks to custom engineering
- Worry-free thanks to the connected cable and cable gland for fast one-to-one exchange
- IE3 class for energy and cost savings
- TENV and special low-profile terminal box cover for optimal space utilization
- Reserved stock in the Netherlands and the US for rapid replacement
- Smart stock system so BEGE knows when to replenish stock
- Optimal continuity
- Minimal risk of unscheduled downtime
Comparison: options for handling discontinued special motors
| Feature | Repair & rewind at local shop (previous approach) | BEGE custom replacement motor (delivered solution) |
|---|---|---|
| Availability | Dependent on repeated repairs; no new motor supply | New replacement motors available with continuity of supply |
| Time to restore production | Typically slower due to repair and rewinding cycle | Faster, supported by reserved stock in NL and US |
| Fit with existing machine | Original motor reused, but condition varies after repairs | One-to-one exchange; motor engineered to be identical in form/fit/function |
| Standard dimensions (NEMA/IEC) | Not applicable | Custom-engineered because motor dimensions were non-standard |
| Shaft/flange specifics | Kept by reusing the old motor | Custom redesign includes non-standard shaft and flange and a flattened keyway |
| Electrical connection and swap ease | Varies by repair outcome and wiring | Screened cable connected to star 400V with EMC gland for easy one-to-one exchange |
| Efficiency and operating cost | Depends on original design and repair | IE3 motors support energy and cost savings across 100+ motors |
| Installation options | Limited to original form factor | Available in TENV version and with low-profile terminal box cover for tight spaces |
| Operational continuity | Ongoing risk due to limited replacement availability | Improved continuity via reserved stock and smart replenishment alerts |
| Downtime risk | Higher, especially if repairs are delayed | Lower, designed to minimize unscheduled downtime |
Contact
Want to know more about how BEGE can help your business?
Arrange an appointment with our engineers.
FAQs
1) What is the main benefit of a custom replacement motor for a discontinued model?
The main benefit is one-to-one replacement that restores continuity of supply and reduces the risk of unscheduled downtime when the original motor is no longer available.
2) Why didn’t a standard NEMA or IEC motor fit in this case?
The examined motor did not have standard NEMA or IEC dimensions, and it also had non-standard shaft and flange dimensions.
3) What did BEGE do when the customer had no datasheets or drawings?
BEGE requested a defective sample motor and examined and measured it at its head office in the Netherlands to recover data and dimensions for engineering.
4) What specific mechanical features required redesign?
Both the flange and shaft were non-standard, and the shaft had a special flattened keyway, so the motor had to be redeveloped to match these specifications.
5) How does the supplied cable and EMC gland help maintenance teams?
A screened cable connected to star 400V with an EMC gland makes it easier to swap motors quickly as a one-to-one exchange.
6) What efficiency class were the replacement motors supplied in?
The replacement motors were supplied in IE3, which supports energy and cost savings—especially relevant when the fleet includes more than 100 motors.
7) What options are available for tight installation spaces?
The motors are available with a special low-profile terminal box cover, enabling installation in tight spaces.
8) What does TENV mean in the context of the offered motor variants?
TENV refers to a motor version offered as an option in this case to suit installation and application needs; BEGE indicates these motors are available in a TENV version.
9) How did BEGE improve replacement speed across multiple factory sites?
BEGE maintains reserved stock in both the Netherlands and the US, enabling rapid replacement when a motor is needed.
10) How does the smart stock system support continuity?
The smart stock system sends an alert when replenishment is needed, helping ensure stock is refilled on time to maintain continuity.