When it comes to industrial operations, your equipment is only as reliable as its weakest component. From circuit boards and power supplies to servo motors and encoders, industrial electronic components are built to perform in rugged environments—but they won’t last forever. Understanding the factors that affect their lifespan can help you make smarter maintenance decisions, avoid costly downtime, and extend the working life of your gear.
What Affects Component Lifespan?
Several key factors influence how long your industrial electronics will last:
1. Operating Environment
Dust, dirt, heat, humidity, and exposure to chemicals can all wear down components prematurely. For example, VFDs (variable frequency drives) often fail due to overheating caused by dust buildup and poor airflow. Circuit boards exposed to moisture can suffer from corrosion, especially if left unrepaired for even a short period.
2. Electrical Stress
Power surges, voltage spikes, or reversed polarity can wreak havoc on components. Capacitors, transistors, and ICs are especially vulnerable to these fluctuations. Preventive measures like surge protectors and regular voltage checks can make a big difference.
3. Mechanical Wear and Tear
Servo motors, encoders, and I/O cards that involve physical movement are subject to bearing failure, misalignment, and vibration-related damage over time. For example, encoders can fail due to worn ball bearings or contamination from dust or oil.
4. Poor Maintenance
Skipping regular inspections and cleanings shortens lifespan. A loose connection might seem minor, but it can cause arcing and permanent damage to internal components. Preventive maintenance—including cleaning, torque checks, and thermal inspections—is essential for long-term reliability.
How Long Do Components Typically Last?
While exact lifespans vary based on use and environment, here are some rough averages:
- Servo motors: 5–15 years depending on load and maintenance
- Encoders: 3–10 years, particularly if exposed to contaminants
- Circuit boards: 7–20 years, with aging capacitors being a common failure point
- Power supplies: 5–10 years, especially if they run hot or face frequent surges
- I/O Cards: 7–12 years, depending on load cycling and environmental conditions
Tips to Extend Lifespan
- Keep It Clean: Regularly remove dust and debris. Clean fans and heat sinks to prevent overheating.
- Control the Environment: Install cooling systems and dehumidifiers where needed. Store spares in dry, temperature-controlled spaces.
- Use Quality Parts: Always invest in OEM or high-quality replacement parts. Bargain components often cost more in downtime and repeat failures.
- Schedule Preventive Maintenance: Don’t wait until something breaks. Plan regular checks and stick to them.
- Work with Experts: For complex diagnostics and repairs, use a qualified industrial electronics repair center.
When to Repair vs. Replace
If your equipment is down and you’re deciding between repair and replacement, consider the age, cost, and availability of the component. Repairs are often the more cost-effective route, especially for hard-to-source or high-end components. In fact, many electronic parts can be repaired for a fraction of the cost of a new one—even those damaged by moisture or electrical faults.
Final Thoughts
Industrial electronic components don’t last forever, but with the right care and strategy, you can extend their usefulness and avoid surprise failures. For help diagnosing and repairing aging or failing components, turn to a trusted repair service like ACS Industrial. Our team offers free evaluations and fast turnaround to keep your operations running.
Call ACS Industrial for Repairs and Service for Your Industrial Electronic Components!
Knowing how to keep industrial electronic components running can be tough, but you don’t have to do it alone. At ACS Industrial Services, we specialize in preventative maintenance and repair services for industrial electronic equipment.
With over 20 years of experience, ACS is a leading industrial repair service provider when things break. We repair many different components of machinery across various makes and models. We provide a rapid turnaround time. Most repairs are back in your hands within 7-15 business days, with our Rush Repair Service typically shipping in just 3-5 business days.
Contact us for a FREE evaluation and a no-obligation quote, or call (800) 605-6419.