Common Problems in Torque Motors & How to Fix Them
Torque motors are widely used in industrial machines because they deliver high torque at low speeds, run smoothly, and support continuous operation. Whether used in textile, printing, packaging, robotics, or winding machines, torque motors play a critical role in ensuring precision and reliability. However, like any industrial motor, they can develop issues over time due to load variations, poor maintenance, or environmental conditions.
This detailed guide explains the most common problems in torque motors and provides clear, practical solutions to fix them—helping industries reduce downtime and maintain consistent performance.
- Overheating of the Torque Motor
Overheating is one of the most frequent issues in torque motors. It happens when the motor is pushed beyond its load capacity or faces cooling-related problems.
Causes
- Excessive load or torque requirement
- Blocked ventilation or poor airflow
- High ambient temperatures
- Continuous duty beyond rated specifications
- Misaligned or jammed mechanical parts increasing resistance
How to Fix
- Reduce load to within the motor’s rated torque capacity
- Clean cooling vents and ensure proper airflow
- Add external cooling or install the motor in a ventilated area
- Inspect the machine for mechanical friction
- Use a temperature sensor or overload protection system
Pro Tip from Anubhuti Power System:
Always check motor temperature after long runs. Overheating reduces the life of motor windings.
- Irregular Speed or Torque Fluctuations
Torque motors are designed for constant torque operation, so any fluctuation indicates an underlying issue.
Causes
- Voltage instability
- Faulty drive/controller
- Worn-out bearings
- Excessive friction in the connected load
- Inconsistent power supply
How to Fix
- Stabilize input power with a servo stabilizer
- Recalibrate or replace the motor controller
- Inspect and lubricate bearings
- Remove mechanical friction by realigning load components
- Ensure drive settings match motor specifications
- Excessive Noise or Vibration
A torque motor normally operates smoothly. Loud noise or vibration indicates mechanical or electrical imbalance.
Causes
- Damaged bearings
- Loose mounting bolts
- Unbalanced rotating components
- Misalignment with load equipment
- Electrical imbalance
How to Fix
- Replace worn bearings
- Tighten all motor mounting points
- Balance rotating shafts or drums
- Correct alignment between motor and load
- Inspect stator–rotor gap for variations
Note: Ignoring vibration can lead to major shaft damage.
- Motor Not Starting or Slow to Start
If a torque motor fails to start or starts slowly, it impacts production efficiency.
Causes
- Faulty controller or drive
- Open or short circuit in winding
- Low voltage supply
- Capacitor failure (in some models)
- Mechanical blockage
How to Fix
- Test the controller output using a multimeter
- Inspect winding resistance
- Ensure proper voltage
- Replace start capacitors if applicable
- Check and clear any mechanical jams
At Anubhuti Power System, we often find that slow-start issues are linked to controller misconfigurations rather than motor faults.
- Excessive Current Draw
When the motor pulls more current than specified, it indicates stress or electrical faults.
Causes
- Overloaded motor
- Shorted winding
- Locked rotor condition
- Incorrect drive settings
- Shaft misalignment increasing load
How to Fix
- Reduce the mechanical load
- Test windings for insulation resistance
- Correct rotor clearance
- Reset drive parameters to recommended values
- Align motor with connected equipment
- Rotor Sticking or Jerky Movement
Torque motors must rotate smoothly. Jerky or stuck movement disrupts machine accuracy.
Causes
- Debris or dust inside the motor
- Bearing failure
- Rotor imbalance
- Winding damage
- Incorrect magnetic field from controller
How to Fix
- Clean internal motor parts
- Replace damaged bearings
- Balance rotor assembly
- Rewind motor if winding is burnt
- Reprogram or replace the controller
- Reduced Torque Output
When the motor fails to deliver the expected torque, production slows down.
Causes
- Weak magnetic field
- Drive current limitations
- Mechanical resistance in load
- Partial winding damage
- Low supply voltage
How to Fix
- Increase current settings within safe limits
- Repair damaged windings
- Remove mechanical resistance
- Ensure correct voltage supply
- Replace old controller with higher-capacity drive
- Motor Overrunning or Uncontrolled Speed
Torque motors must maintain controlled, stable rotation. Uncontrolled speed is dangerous and can damage machines.
Causes
- Faulty encoder/feedback system
- Incorrect drive tuning
- Loose connections
- Control signal failure
How to Fix
- Check encoder/feedback signals
- Reconfigure or change drive settings
- Tighten all electrical connections
- Replace defective sensors
How to Prevent Torque Motor Problems
Regular maintenance can prevent most torque motor failures.
Maintenance Checklist
- Lubricate bearings routinely
- Clean motor body and ventilation paths
- Inspect electrical connections weekly
- Monitor temperature during operation
- Calibrate controller settings monthly
- Ensure proper alignment with machine load
Why Choose Anubhuti Power System for Torque Motors
Anubhuti Power System delivers high-performance torque motors designed for long life, stable torque output, and industrial-grade reliability. We provide:
- Custom torque motor solutions
- High-efficiency brushless and frameless torque motors
- Technical support and troubleshooting
- Long-lasting, heavy-duty motor designs
- Replacement and maintenance services
Our products are built to handle continuous-duty applications with precision and durability.