Traditionally, motors run at one speed, as fast as possible or not at all. While some applications require motors to run very fast, other applications only require motors to run at a fraction of the speed.
Running motors at faster speeds than required can lead to wasted energy, unnecessary utility costs, and the need for periodic replacement parts. Engineers should consider how to reduce the speed of investment in the technology or process without reducing productivity.
Converting Energy
Engineers can invest in variable speed drives (VSDs) to manage energy wastage.A VSD can be retrofitted with a single-speed motor and converts fixed input power to a variable voltage. It then manages the output speed of the motor based on the changing needs of the facility.
Adding a VSD has the potential to reduce a facility's energy consumption by at least 10 percent.
Slowing down
Constant speed motors accelerate very quickly to reach their correct operating speed, requiring high currents and generating a lot of heat as a result. Over time, this start-up process causes a lot of wear and tear, which can eventually shorten the life of the equipment. To prevent excessive wear, some manufacturers limit the number of times a motor can be started per hour.
Engineers can minimize this wear by using a soft starter device in their AC motors. A soft start will temporarily limit the current to the motor, thus preventing increased mechanical wear and overheating of electrical components.
Moving things around
Improving motor efficiency doesn't require installing expensive equipment. By making small changes to their facilities, manufacturers can save energy, which can reduce utility costs. For example, motors are typically kept running when not needed, and unnecessary use can add up to 2,000 costs per motor per year in electricity and maintenance costs.
Engineers should regularly monitor the surroundings of motors to ensure they are operating at peak efficiency. Keeping motors away from hot areas of the facility can reduce overheating. Keeping motors clean and away from machines that may emit large amounts of dust or debris can also help prevent breakage.
Implementing a predictive maintenance program can help improve a plant's energy use over time. By knowing the condition of the machine, engineers can plan maintenance before a breakage occurs, avoiding unplanned downtime. If breakages do occur, manufacturers can save money by choosing refurbished parts from a reliable supplier rather than investing in a brand new model.
If manufacturers have to replace parts to get back into production, they should consider ecologically obsolete technology. These are parts that have become obsolete and are no longer sold by original equipment manufacturers (OEMs). However, eco-obsolete technology, while not brand new, still adheres to energy-efficiency standards and is therefore a cost-effective option for manufacturers.