HSD Spindle Repair

HSD Spindle Repair

We specialize in the repair of HSD spindle motors, HSD motors, and HSD spindles.  Spindles we have repaired include the HSD ES919, HSD ES929, HSD ES988, HSD ES798, and the SEV HSD AT and MT spindle routers.  Our repairs will typically cost 1/2, or less than 1/2 the price of a new spindle.  Plus, we upgrade the original non-sealed bearing design, to a sealed / shielded bearing design at all bearing locations.  We keep bearings in stock for these motors to allow us to keep pace with our repair volume.  Lead-time can be as short as 2-3 days.  Contact us for new manual collet and nut spindles or automatic tool change spindles as well.

HSD Spindle Repair Quotes

HSD, ES779, 26AC12/2012016190, 13.4 HP, 22000rpm, 380v, 733 Hz

HSD ES779L spindle R2013285

Inspection Results

  • The spindle journal diameters show no appreciable wear and are acceptable for proper bearing fits.
  • The upper bearing housing inner diameter meets design specifications and shows no appreciable wear. No modification is required.
  • The lower bearing housing inner diameter meets design specifications and shows no appreciable wear. No modification is required.
  • The taper runout is acceptable. Our proposal provides no repair to the spindle taper.
  • The upper and lower bearings show some wear on the inner and outer diameters.
  • The tool pressure test checks fine.
  • The stator passed the phase and insulation tests.
  • Two of the proximity switches do not work and will be replaced. We will also replace the sensor cable.
  • The “coolant in” port has some erosion. We will spot face this opening.
  • The unit will be assembled and tested.

HSD, ES360L-4P0900K6H1, 8kW, 24000rpm, 380v, 800 Hz

Inspection Results

  • The spindle journal diameters show no appreciable wear and are acceptable for proper bearing fits.
  • The upper bearing housing inner diameter meets design specifications and shows no appreciable wear. No modification is required.
  • The lower bearing housing inner diameter meets design specifications and shows no appreciable wear. No modification is required.
  • The taper runout is acceptable. Our proposal provides no repair to the spindle taper.
  • The upper and lower bearings show some wear on the inner and outer diameters.
  • The stator passed the phase and insulation tests. There is an exposed wire that had a loose piece of shrink wrap. The shrink wrap may have moved causing a ground fault. We will add a new piece of shrink wrap.
  • There is a slight rub on the rotor but we do not believe this caused the ground fault.
  • The proximity switches work fine and will be set at time of assembly.
  • The unit will be assembled and tested.

SM-C93, M2005447, 6 HP, 18000rpm, 380v, 300 Hz

Inspection Results

  • The spindle journal diameters show no appreciable wear and are acceptable for proper bearing fits.
  • The upper bearing housing inner diameter meets design specifications and shows no appreciable wear. No modification is required.
  • The lower bearing housing inner diameter meets design specifications and shows no appreciable wear. No modification is required.
  • The taper runout is acceptable. Our proposal provides no repair to the spindle taper.
  • The upper and lower bearings show some wear on the inner and outer diameters.
  • The stator passed the phase and insulation tests.
  • The fan housing is broken. We have a used one in good condition that we can use.
  • We will add the right angle connector to the motor.
  • The unit will be assembled and tested.

HSD, ES915, M2012228, 8.9 HP, 24000rpm, 220/380v, 400 Hz

Inspection Results

  • The spindle journal diameters show no appreciable wear and are acceptable for proper bearing fits.
  • The upper bearing housing inner diameter meets design specifications and shows no appreciable wear. No modification is required.
  • The lower bearing housing inner diameter meets design specifications and shows no appreciable wear. No modification is required.
  • The taper runout is acceptable. Our proposal provides no repair to the spindle taper.
  • The upper and lower bearings show some wear on the inner and outer diameters. The lower bearings sound rough.
  • The tool pressure test checks fine.
  • The stator passed the phase and insulation tests.
  • The fan housing is missing. We will replace the fan and housing.
  • The proximity switches work fine and will be set at time of assembly.
  • The electrical connector box on the motor is broke. We will replace the connector.
  • The unit will be assembled and tested.

 

The Repair Process

  1. Disassembled and cleaned.
  2. Inspected dimensionally and visually.
  3. Quoted for repair.
  4. The rotor is assembled with new precision grade sealed / shielded ceramic bearings.
  5. Rotor taper is ground to true the taper, and/or the bearing journals are plated and re-ground to proper bearing tolerance and total indicated runout.
  6. As required, the lower, middle and upper bearing housings may be bored, bushed, and reground to proper concentricity and dimensional tolerance.
  7. The rotor is re-assembled and dynamically balanced.
  8. The rotor is installed in the housing.
  9. The unit is run tested for 5-10 hours with testing of vibration, temperature, and noise levels.
  10. The drawbar is tested to ensure proper locking of the tool holder and the unit is shipped.

Important factors when rebuilding high speed routers

Four factors are of primary importance when rebuilding a high speed router operating at 10,000 to 30,000 RPM.

  1. The condition of the machine before the rebuild along with accurately diagnosing any and all problems.
  2. Installing proper replacement parts including spindle grade bearings and parts with OEM tolerances that are known only to OEM’s such as Ekstrom-Carlson.  We are not simply a machine shop or an electrical rewind shop.
  3. Precision tolerance machinery and tooling including grinding, plating and balancing equipment.
  4. Experience and quality workmanship of the repair technician.

Spindle Rebuilds

At Ekstrom-Carlson, a complete factory rebuild includes a thorough inspection and a detailed repair quotation based on the supply of new parts from stock (when available). Comparison of parts to detailed prints, when required, ensures that no corners are cut.  All spindle rotating elements are balanced to ISO G2.5 tolerances or better, the best in the industry.  Re-balancing is critical, even on “simple bearing replacement repairs.”

New parts to original design specifications will be installed by our Service Technicians for complete unit responsibility.

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