Electrical Failure in Electromagnetic Chucks

The most common problem we see with electromagnetic chucks is electrical failure. It is difficult for our customers to understand how and why it happens. And it is even more challenging to comprehend the cost associated with correcting the electrical failure, especially in large electromagnetic chucks.

It is crucial to address any electrical problems promptly to prevent further damage and potential safety hazards.

To better understand what happens when an electromagnetic chuck fails, let’s first discuss the basics of electrical circuits. An electrical circuit is a closed loop or path that allows electricity to flow. Typically, it consists of a power source, a conductor, and a load. The more solid the connection, the better the flow of electricity and the longer the connection lasts.

Applying this to electromagnetic chucks, the power source would be the controller, the conductor would be the electrical wires, and the load would be the coils within the chuck. Any deterioration of these items or the connections within the circuit will weaken the chuck’s performance and eventually lead to failure.

At the first sign of chuck failure, operation of the machine should stop, and qualified, trained technicians should begin assessing the source of the failure. Keep in mind that electrical failure can be caused by a problem anywhere in the electrical circuit of the chuck.

Technicians with experience and proper training can identify problems in an electrical circuit quite easily.

If the failure occurs within the power source or the controller, it may be repairable. The age of the controller is the first factor in determining if it is repairable. If you are using equipment that is older, outdated, or the manufacturer is out of business, it is best to consider purchasing a new controller with state-of-the-art technology.

Keep in mind that the chuck controller is acting as a rectifier, so checking your building’s power is also a good idea when troubleshooting electrical failure in electromagnetic chucks. Again, this should be done by a qualified, licensed electrician.

If the electrical failure of the electromagnetic chuck occurs in the conductor of the electrical circuit, then it would be the wiring connections from the controller throughout the entire circuit.  Troubleshooting to make sure the connection is solid and safe is challenging with electromagnetic chucks, especially large ones, because the circuit can be huge.

We do not recommend opening electromagnetic chucks in the field to examine the circuit. This process can be very time-consuming and labor-intensive. Additionally, disturbing the wiring of the coils within the magnet can lead to increased labor and costs should the magnet need to be repaired.

Industrial fluid pooling inside an electromagnetic chuck.

Lastly, if an electrical failure occurs in the load of the circuit of an electromagnetic chuck, it will mean that the coils inside the body of the magnet have failed.  While copper is durable and an excellent conductor of electrical current, it is essential to use the best gauge and quality of copper to ensure a quality circuit.

When an electromagnetic chuck fails, it is a serious safety issue and will lead to a loss in production. If a chuck fails, parts can become airborne and may cause severe damage to equipment and cause harm to the operator and nearby personnel. Loss of production can translate into a business losing thousands of dollars while troubleshooting and repairs take place.

Qualified electrical technicians with specialized tools can help with troubleshooting electrical failures.

Proper scheduled maintenance on equipment, having spare workholding and components onsite, with knowledgeable, trained personnel, can all help reduce electrical failures in electromagnetic chucks and the monetary fallout from the failure. Educating yourself about the signs of electrical failure in electromagnetic chucks and their causes is another safeguard to minimize machine downtime.

Fluctuations in temperature due to heating and cooling can cause electrical components to expand and contract, eventually leading to loose connections, increased resistance, and potentially overheated electrical circuits. What causes fluctuations in temperature in an electromagnetic chuck? Prolonged use and leaving the magnet on when the machine is idle.

Operators need to be instructed to shut down the magnet during breaks and at the end of their shift.

Operators need to be instructed to shut down the magnet during breaks and at the end of their shift. Under no circumstances should an electromagnetic chuck be left on while unattended, particularly overnight and on weekends.

High production comes from machines working continuously. Scheduled maintenance and cleaning of machines, including electromagnetic chucks, is essential to keeping the equipment running well. Any signs of fraying wires, discoloration, or scorching anywhere in the circuit are signs that a larger problem is developing.

Industrial fluids and electricity are a dangerous combination. When fluids enter the electrical circuit of an electromagnetic chuck, severe problems can occur almost instantaneously. This is why it is necessary to shut down equipment immediately when signs of chuck failure show.  This will protect your operators and maintenance personnel from serious harm while troubleshooting the problem and finding a resolution.

Blown fuses, power surges, buzzing, and humming noises are all signs that your controller or building power source may be causing problems that will lead to an electrical failure in your electromagnetic chuck. Using a combination of visual inspections, specialized tools, and logical troubleshooting from experienced, qualified electrical technicians can help identify the source of the problem. Once that is done, a plan can be formulated to correct the problem.

At the first signs of performance reduction in electromagnetic chucks, we recommend gathering electrical readings from the chuck by a qualified person. Simply keeping a log of daily or weekly readings can signal signs that a problem is developing. Being proactive with the maintenance of your electromagnetic chuck and its electrical circuit can save a business by limiting downtime and repair costs.

A new electrical circuit to provide many years of performance in holding your workpieces when properly maintained.

It is crucial to address any electrical problems promptly to prevent further damage and potential safety hazards. If your electromagnetic chuck shows signs of failure, our technicians may be able to assist you in determining the cause and how to fix the problem. Often, the best answer is to re-coil the chuck.  By doing so, it gives the chuck a new electrical circuit to provide many years of performance in holding your workpieces when properly maintained.

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Obsidian Manufacturing Industries, Inc. is a Rockford, IL, manufacturing company and is the OEM for Magna-Lock USA workholding, MagnaLift & Power-Grip lift magnets, and Arter Precision Grinding Machines, as well as providing surface grinding services. They are located at 5015 28th Ave. in Rockford, IL, with a phone number of 815-962-8700. Check out more at obsidianmfg.com/brands