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What do your motors really do?

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In 1969, the first home security system was born, consisting of four peepholes and a camera that could be moved to look through any of them, broadcasting the images to a monitor. Nowadays, we can now stream and view a feed of our home security cameras on our mobiles, giving homeowners greater piece of mind. Here, Markus Brettschneider, of ABB’s food and beverage program, explains how food plant managers can add a similar level of connectivity to retrofit most motors with smart sensors to bring their plants to the digital age.

Industry as a whole is utilizing technologies and solutions enabled through the industrial internet of things (IIoT). Gartner predicts that 25 billion devices will be connected to the internet of things by 2020, with some agencies predicting even double this amount. This presents plant managers with a conundrum. Most food manufacturing and processing plants currently have motors powering essential equipment such as mixers, conveyors and packaging machines. These motors are just motors and do not play in the same league as the other intelligent devices in their factories. With years of service often left in the motors, it’s difficult for plant managers to justify replacing motors that work effectively for the sake of an upgrade with any smart features. However, there are alternatives to a complete overhaul in order to connect motors to the IIoT. Instead of investing in new, more intelligent or smart equipment, plant managers should invest in sensors that provide similar functionality to connected devices. For example, ABB offers smart sensors, which can be fitted to almost any standard low voltage induction motor. The pocket-sized sensor, dubbed ABB Ability Smart Sensor, is directly attached in a couple minutes to the motor’s frame, without wiring. By using sensors that feed performance data to the cloud through a smartphone or gateway solution to a secure server, plant managers can bring their motors up to date with the IIoT. This data gives plant managers a full picture — even on mobile devices — of how their motors are working, without having to carry out dangerous hands-on monitoring. Plant managers can then carry out condition based or predictive maintenance, rather than periodic maintenance. Using the right method to monitor motor condition, enables plant managers to reduce unplanned downtime by up to 70 per cent. This is particularly important in the food and beverage industry, where even a short downtime can be extremely costly. Infrastructure failures in this industry cost up to $75,000 per hour and have a serious impact on seasonally produced items such as sugar. This is a cost that plant managers can avoid by using the right performance insight and awareness. An increased awareness of the condition of any motor also leads to a better awareness of how an entire system is performing. For example, a motor overheating or burning out may indicate a problem elsewhere in the production line, such as a line moving too fast and producing waste. Eliminating this problem could improve energy efficiency by up to ten per cent. Motors, the heart of the food and beverage plant, don’t have to be left behind in the age of the IIoT. Just like a home security camera being connected to your mobile phone, a smart sensor could give a motor a new lease of life, making it perform as an integral part of the data-rich factory and providing all the additional benefits that this creates.

Türkiye endüstrisine, alana özel, spesifik yayınlar üreten MONETA Tanıtım’ın sektörel dergilerinin editörlüğünü yapmaktayım. Yeni nesil, dinamik yayıncılık anlayışıyla, dijital ve basılı mecralarda içerik geliştirmek için çalışmaktayız.

Motors

Optimised design for IE3 asynchronous motors

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NORD has optimised the design of its proven IE3 asynchronous motors. The model maintenance applies to numerous details that further improve the electric motors´ function, assembly and operation.NORD has optimised the design of its proven IE3 asynchronous motors with numerous details that achieve a better assembly and cooling.

 The facelift of the IE3 asynchronous motors from NORD DRIVESYSTEMS involves no change of electrical data and outer dimensions. They can be seamlessly used without adjustments in any existing application with NORD IE3 motors. The optimised cooling fin shape, an assembly-optimised fan and a new modern fan cowl enable a better heat dissipation and assembly. The fan cowl can be simply assembled in case a motor-mounted frequency inverter is used. The new cooling fins design enables an unhindered airflow around the terminal box. The revised terminal box is without sharp edges and corners and has reinforced feet for a better motor stability. Another important detail is the optimised incremental encoder mounting. Due to the fan cowl, the encoder is fully shock-resistant and not within the airflow, which further improves the cooling power. Retrofit mounting is also possible due to a plug-on shaft.

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Motors

ABB gets ahead of the game for Ecodesign regulation

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The European Union’s (EU) latest Ecodesign Regulation (EU) 2019/1781 came into effect in October 2019. This regulation sets new requirements from 2021 onwards for the energy performance of an expanding range of low voltage motors. For the first time variable speed drives (VSDs) are also included.

The aim is to contribute to the reduction of greenhouse gas emissions to limit the average global temperature increase to 1.5°C. Hannu Vaananen, Head of Public Affairs, Business Line Motors and Generators, shares some insights on what this regulation means for industrial electric motors.

The detail

The latest Ecodesign implementation applies to low-voltage induction electric motors – rated at less than 1,000 V alternating current (AC) –  and variable speed drives (VSDs). While defining stricter minimum efficiencies, the regulation also expands the range of three-phase single speed motors covered from 0,12 to 1,000 kilowatt (kW). The same power range also applies to the drives. 

The regulation only concerns the efficiency of standard VDSs. To allow to maximize savings on system level, regenerative and low harmonic drives have been excluded. On the motor side Ex and brake motors are now in the scope of the regulation.

The regulation will be implemented in two steps with the first starting on July 1, 2021. The second stage, which expands the scope further and increases the requirements for motors, commences two years later, on July 1, 2023. Super-premium-efficiency motors (IE4) will become mandatory for three-phase motors with 2, 4, or 6 poles between 75-200 kW. 

What is the significance for industry?

According to the International Energy Agency (IEA), electric motors account for 40% of total global electricity consumption, while industrial motors account for 30%. Lighting, a far better-known culprit, weighs in at just 19%. Using electric motors that offer the highest levels of energy efficiency can therefore play a crucial role in containing worldwide energy consumption and in reducing CO2 emissions.

So how is ABB helping this all-important cause?

We have pre-empted the new regulation as we can already provide our customers with compliant motors. This also applies to our variable speed drives – including the ACS880, ACH580, ACQ580, ACS 580, ACS480 and ACS380 product lines – as well as motor types that were previously exempt, such as Ex motors, Totally Enclosed Air Over (TEAO) motors, and motors for 60 Hz networks. Customers can, therefore, buy our products with full confidence.  

One of the most affordable and effective ways to increase energy efficiency is to use VSDs in combination with high-efficiency motors. Our drives can reduce energy consumption by 30% to 50% by regulating the speed of, for example, the motor of a pump or fan. In extreme cases consumption can drop by 90%. 

When it comes to new regulations, it’s essential to be ahead of the game as it ensures that customers have future-proof products. This is especially important as, on average, projects can take three years to move from the planning phase to the active phase.

Saving energy is a highly effective way to reduce greenhouse gas emissions and save money at the same time. That’s why we work with policymakers all the time to expand regulations that cover additional motors and drive systems. Our commitment is not only to our clients but also to a greener world.

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Motors

STOBER develops new generation of planetary gear units

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The new generation of servo planetary gear units from STÖBER Antriebstechnik offers drives that are the most compact on the market in their power range and with their diversity of combinations and options. What’s more, any motor series can be directly attached in any available size. This variability allows STOBER to create the right drive solution for any application. In contrast to the prior generation, STOBER also equips the new planetary geared motors with an electronic nameplate, which makes commissioning controllers and drive controllers much faster.

STOBER has developed the third generation of servo geared motors, which are the most compact drive solutions on the market with their level of versatility. To achieve this, the lengths of the new gear units were significantly reduced. All STOBER motors, such as the EZ series or sensorless Lean motors, can be directly attached without an adapter, in any desired size.

Thanks to this compactness, the user benefits from a smaller installation space, lower weight, greater torque and a resulting power density that is increased by up to 65%. The mass moment of inertia is lower because the motor adapter is no longer needed, which allows the full dynamics of the drive to be used. This is a real advantage for the customer, particularly noticeable with small and medium sizes in shorter cycle times.

The new generation also features the highest backlash stability and ruggedness. The excellent housing and gearing quality ensure high acceleration torques as well as the highest running accuracy and precision at the same time. Users benefit from acceleration torques increased by 60%, a speed increase of 45% and an increase of the torsional stiffness by up to 50%.

Flexibility from the Motor Attachment to the Bearing System

The most impressive feature of the new generation of planetary gear units is its enormous variability. This means that not only are the gear units able to be combined with different STOBER motors via direct attachment, they can also be attached to all third-party motors in any size using variable adapters. The drive specialist offers a one-of-a-kind interface technology for this purpose. STOBER motor adapters are available with different couplings as well as in the ServoStop variant with an integrated brake. The adapters can also be combined with standard or reduced-play gear units. In particular, the large design of the STOBER adapter with an extra-large motor plate makes it possible to connect the most compact STOBER gear units with motors of very large sizes—a truly unique selling point.

Depending on the application, another advantage compared to the competition is that the right bearing can be selected, whether deep-groove ball, cylindrical roller or angular contact bearing. These low-friction bearings enable generally higher speeds.

Thanks to this enormous variety, engineers have all the options in the design phase to put together exactly the right drive solution for any application. A smaller motor to optimize efficiency? A smaller drive controller might go well with that—which also lowers costs.

Easier Commissioning Thanks to Added Electronic Nameplate

Another special feature of the new generation is the electronic nameplate. In combination with the STOBER electronics, every geared motor automatically sends its electronic, mechanically relevant data by plug and play to the corresponding drive controller upon commissioning. As a result, the geared motors are uniquely identified. This eliminates high-effort, error-prone parameterization, which shortens the total system configuration significantly.

STOBER will present the new generation of servo planetary gear units for the first time at the SPS IPC Drives in Nuremberg, hall 3A booth 451 at the end of November. Sizes 2, 3 and 4 will be available from 1st October 2019, sizes 5 and 7 from 1st March 2020 and sizes 8 and 9 from 1st May 2020.

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