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FEATURE
DRIVES, CONTROLS & MOTORS
DRIVING ENERGY EFFICIENCY Inefficient motor-driven systems cost
companies money, however according
to Richard Wingate, UK managing director at Rubix, solutions are available
task they are undertaking. Therefore, the use of VSDs helps optimise the amount of energy the motors consume, delivering better system efficiency.
3. Mechanical equipment Gearboxes are designed to improve efficiency and they can play a key part in reducing energy usage. The more efficient the gearing, the less power is lost. Here, energy efficiency can be enhanced by right sizing the gearing for the application and replacing worn or old
a facility’s electricity consumption. According to research by Rubix, however, with most motor-driven systems operating inefficiently, they are wasting a huge amount of energy. Any good engineer knows that energy losses
M
occur at many points in a motor-driven system. This means that while the energy efficiency of an individual motor might be high, the efficiency of the system as a whole can still be low. So, if you want to maximise the system’s efficiency, you must optimise both the individual components within it and how they function collectively. It is estimated that energy savings of between 20-30% can be achieved by optimising the whole motor-driven system. So, if these systems account for 70% of energy usage, then a 30% saving represents 21% off the total. Rubix has identified four areas of focus which will yield immediate benefits to energy efficiency:
1. Motors Within motor-driven systems, motors account for a significant proportion of energy consumption at any manufacturing site. Efficiency can be improved by sizing the correct motor for the application and by using energy- efficient motors from brands such as Mecaline. If you can’t replace a motor with a more modern unit, then think about correctly regulating motor speed instead using a variable speed drive.
2. Variable speed drives Variable speed drives, which control the speed of motors and other machinery, can often be retrofitted to existing equipment, helping to deliver a strong return on investment. Fundamentally, they make sure motors only use as much energy as is required for the
46 DESIGN SOLUTIONS OCTOBER 2024
otor-driven systems – including compressors, pumps and fans – typically account for more than 70% of
inefficient gearboxes. In addition, modern industrial gear lubricants with proven energy efficiency qualities will improve the drive.
4. Driven applications Between 20% and 40% of energy used by compressors is lost through air leaks, so identifying and fixing air leaks and replacing parts can mean energy efficiency. In addition, if V-belt drives are working with worn pulleys, energy consumption will be higher. Furthermore, intelligent pumps with
variable speed control can be used to deliver significant cost and energy savings.
ADDITIONAL MEASURES Motors and other machinery deployed in industrial processes are typically designed for a long working life. This means that investing in improving their efficiency will deliver a strong return over their lifespan. Bringing in a sector expert like Rubix can further optimise your savings in five main ways: 1. Asset tracking: Rubix offers asset tracking
surveys to provide an overview of a company’s critical assets, including examining each of the components individually – motors, drives, gearboxes – as well as the system as a whole. 2. ROI calculator: Our research has found that more than 70% of industrial motors across Europe have an energy efficiency rating of IE2 or lower, so there is likely to be significant scope for achieving energy savings by upgrading to more efficient alternatives, such as IE4 motors. These motors are even more energy efficient than the former IE3 versions thanks to a lower electricity consumption – a real advantage for total cost of ownership (TCO). To help build the business case, Rubix has
developed a proprietary motor efficiency calculator which works out the energy
consumption gains that can be achieved by repairing or replacing a motor. 3. Repair/replace programme: Rubix provides
access to a broad range of energy efficient products from well-known suppliers as well as its own exclusive brands. 4. Air leak surveys and remedies: Air leaks are one of the largest sources of avoidable energy waste. Rubix offers specialist air leak surveys, featuring a comprehensive audit detailing leaks,
energy loss, cost and CO2e impact. 5. Agnostic condition monitoring: Assets in good condition are more energy efficient, meaning ongoing condition monitoring will help you find potential points of failure before they become issues, thereby preventing overall energy wastage.
“The use of
variable speed drives (VSDs) helps optimise the amount of energy the motors consume, delivering better system efficiency”
Rubix offers an online condition monitoring
platform to track the performance of key machines such as motors, fans, gearboxes and pumps. It can deploy a range of online sensors and gateways using wireless mesh technology in the facility and set companies up on the live Rubix Condition Monitoring Platform.
A HUGE OPPORTUNITY At Rubix, we believe there is a huge opportunity to make motor-driven systems twice as efficient. This will significantly reduce energy costs in manufacturing while playing a key role in supporting emissions reduction targets.
Rubix
www.rubix.com
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