Drives and Motor Control
In pump, fan, conveyor and press applications we control motors with drives to cut energy consumption and mechanical wear.
Inverter projects and axis control
- Drive selection report
- Parameter backup
- Commissioning record
- Before/after consumption comparison
In inverter projects the gain comes from choosing the right control method. On variable-flow pumps and fans the cubic law makes speed reduction translate into a marked drop in consumption; on conveyors and hoists, ramps, braking resistors and torque control take priority. Drive, filter and cabling are sized together, considering motor nameplate data, duty profile and harmonic limits.
Scope
- Application and duty profile analysis
- Drive and motor sizing
- Harmonics and filter assessment
- Parameterisation and commissioning
- Energy consumption measurement
Deliverables
- Drive selection report
- Parameter backup
- Commissioning record
- Before/after consumption comparison
Does this apply to you?
If even one of these sounds familiar, it is worth a conversation. In the survey we first measure the current state together.
- Pump or fan flow is adjusted by throttling a valve or damper.
- Motors start direct-on-line, causing a grid surge and mechanical stress at every start.
- Conveyor speed should change with the product but runs fixed.
- Motor loads make up a large share of the bill but nobody knows where it goes.
How we run this kind of project
- 01
Deriving the duty profile
We establish whether the application is variable or constant torque, and measure running hours and the flow or speed requirement. Only this gives a realistic estimate of the gain.
- 02
Drive and motor sizing
Motor nameplate data, starting torque, overload requirement and duty cycle are assessed together. Where needed, braking resistor and control method (V/f, vector) are defined.
- 03
Harmonics and EMC assessment
Depending on total drive power relative to the plant, the need for line reactors or filters is decided. Motor cable screening, earthing and routing are planned for EMC.
- 04
Parameterisation and commissioning
Ramps, protection limits and the control loop are set. Parameter backups are taken and a commissioning record is prepared.
- 05
Before/after measurement
Consumption is measured under the same production conditions and compared. The return on the investment is shown by measurement, not estimation.
We measure what changed when the project ends
- Energy consumption
- On variable-flow pumps and fans the cubic law produces a marked reduction.
- Mechanical wear
- Soft starting extends the life of belts, couplings and bearings.
- Process control
- Flow, pressure or speed can be held constant in closed loop.
Frequently asked about Drives and Motor Control
Does every motor deserve a drive?
No. On constant-torque loads with few running hours the payback stretches out. Prioritisation comes from measuring the duty profile: variable-flow pumps and fans with long running hours top the list.
Will my older motors run on a drive?
Most standard induction motors will, but insulation class, cooling method and reduced cooling at low speed must be checked. With long cable runs an output filter may be needed against voltage overshoot at the motor terminals.
If the drive fails, does production stop?
On critical lines we recommend a bypass circuit or a stocked spare drive. Because we keep the parameter backup on file, a replacement can be commissioned quickly on site.
Other engineering areas
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