The growing threat of counterfeit electronic components

A recent report by the European Commission shows that in 2023 EU customs seized around 152 million counterfeit and potentially dangerous products worth approximately €3.4 billion: an increase of 77% compared to the previous year. These figures clearly illustrate how strongly counterfeits are putting pressure on the European market and how complex the control of global supply chains has become.

For the industry, especially manufacturers of motors, drive systems, and control electronics, these developments are highly relevant. Counterfeit or inferior drives, PCBs, or sensors are increasingly entering the market via international trade routes and can cause serious failures in machines or safety-critical applications.

In addition to financial damage, manufacturers also face reputational risks if counterfeit components are associated with their brands.

Source: European Commission

Our practical case with the Yaskawa SGMSH-30DCA6F-OY and insights into marketplace trading

For an urgent customer order we searched for the Yaskawa SGMSH-30DCA6F-OY and found a supposedly new unit on the German eBay marketplace with professional images and fast delivery. However, closer inspection revealed that the shipment originated from China, raising doubts about its origin.

Although the nameplate appeared new and the shaft highly polished, technical measurements and disassembly of the motor showed used components and wear marks.

The actual delivery time was 12 days instead of the promised 3–4 days, making planning difficult for industrial buyers.

Externally, the motor appears new with a shiny shaft and fresh nameplate. Electrically, it shows no irregularities, but the Yaskawa software revealed discrepancies: The encoder dates from 2006, the nameplate from 2018 — a sign of refurbishment or replacement.

Inside, we found wear marks and used parts. Motors advertised as “new” are often cosmetically refurbished older units, posing risks for industrial users such as hidden wear, reduced lifespan, and unexpected failures.

Our inspection process includes documentation, electrical measurements, test runs, software reading, and mechanical assessment. For buyers we recommend: Check encoder data, verify supplier addresses, and request inspection reports to minimize risks.

Mitsubishi MR-J200A-D33: Emergency repair and another case of a counterfeit device from Asia

A customer sent us a supposed Mitsubishi MR-J200A-D33 servo drive for urgent repair because his wire EDM machines were down. The initial inspection showed that the device had been completely rebuilt internally: Instead of the expected D33 version, it was a standard MR-J200A without the required extension. The customer had recently purchased the device from an Asian dealer who claimed it was fully functional.

Our analysis revealed a manipulated nameplate and numerous used components such as electrolytic capacitors, ISO amplifiers, and optocouplers. In addition, the communication board was incompatible with the machine control system, making operation impossible. After contacting us, the customer sent his original defective D33 unit via express, which we completely overhauled and put back into operation within one day.

During the overhaul we routinely inspect all critical assemblies, such as power semiconductors, driver modules, capacitors, optocouplers, and control boards, and replace them preventively if necessary. Even functioning components are replaced when approaching end-of-life to ensure long-term operational reliability.

After completion of the repair, a multi-stage testing process follows: First a no-load test to check basic functions, then a load test under rated load in practical conditions. We monitor parameters such as temperature, current consumption, and signal quality. Only after error-free results is the device approved and returned to the customer. Functional testing is performed using the Mitsubishi AC servo motor HA-SE152W2.