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Three ways to reduce the cost of motors

Mar 22, 2021

Three ways to reduce the cost of motors

Traditionally, the motor runs at a speed, as fast as possible or not at all. Although some applications require the motor to run very fast, other applications only require the motor to run at a fraction of the speed. The running speed of the motor exceeding the required speed may result in waste of energy, unnecessary utility costs and the need for regular replacement of parts. Engineers should consider how to invest in technology or process to reduce the speed of the motor without reducing productivity.



1. Convert energy


Engineers can invest in variable speed drives (VSD) to manage energy waste. The VSD can be converted into a single-speed motor and convert a fixed input power into a variable voltage. Then, it will manage the output speed of the motor according to the variable demand of the equipment. Adding VSD can reduce the energy consumption of the facility by at least 10%.


Two, slow down


The fixed-speed motor accelerates very fast to reach its correct operating speed, which requires a large current and therefore generates a lot of heat. Over time, the start-up process will cause a lot of wear and tear, which will ultimately shorten the life of the equipment. In order to prevent excessive wear and tear, some manufacturers limit the number of motor starts per hour. Engineers can use soft starter equipment with AC motors to reduce this wear. Soft start will temporarily limit the current flowing to the motor, thereby avoiding increased mechanical wear and overheating of electrical components. ‘’


Three, clean up the surroundings


Improving motor efficiency does not have to involve the installation of expensive equipment. By making small changes to the facility, manufacturers can save energy and thereby reduce utility costs. For example, motors are usually running when they are not needed, and unnecessary use can increase the electricity and maintenance costs of each motor by as much as £2,000 per year. Engineers should regularly monitor the surrounding environment of the motor to ensure that it can operate at maximum efficiency. Keeping the motor away from high temperature areas in the facility can reduce overheating. Keeping the motor clean and away from machines that may emit a lot of dust or debris will also help prevent damage. Implementing a predictive maintenance plan can help improve the plant's energy use over the long term.


By understanding the condition of the machine, engineers can plan maintenance before failures occur, avoiding unplanned downtime. If damage does occur, the manufacturer can choose to purchase refurbished parts from a reliable supplier, thereby saving costs instead of buying a brand new model. If the manufacturer must replace parts to resume production, it should consider using outdated technology. These parts are obsolete and are no longer sold by original equipment manufacturers (OEM). However, although it is not a new technology, the outdated technology still meets energy efficiency standards, so it is a cost-effective choice for manufacturers.