{"id":8086,"date":"2020-03-18T10:00:00","date_gmt":"2020-03-18T15:00:00","guid":{"rendered":"https:\/\/blog.misumiusa.com\/?p=8086"},"modified":"2021-10-29T15:55:10","modified_gmt":"2021-10-29T20:55:10","slug":"vfd-and-the-drive-towards-savings","status":"publish","type":"post","link":"https:\/\/us.misumi-ec.com\/blog\/vfd-and-the-drive-towards-savings\/","title":{"rendered":"VFD and the Drive Towards Savings"},"content":{"rendered":"\n

Programmable logic controllers (PLC\u2019s) and human-machine interfaces (HMI) are the cornerstones of modern automation.  These systems serve as the brains of an industrial machine and ensure the various aspects of the machine are running correctly.  Depending on the size of the machine, several large PLC\u2019s might be used or just one on a much smaller machine.  These critical devices can become very expensive, so it is important to select the proper one for your machine.<\/p>\n\n\n\n

In this blog, we would like to explore a somewhat newer technology that is designed to save money.  A variable frequency drive, or VFD, is designed to control the speed of an electric motor to match the immediate needs of an application.  Many of these motors operate at 100% speed all the time even if it is not necessary.  A VFD is used to alter the total amount of energy being sent to the motor by monitoring various inputs and determining whether to increase or decrease the amount of energy being sent to a motor.<\/p>\n\n\n\n

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VFD<\/figcaption><\/figure><\/div>\n\n\n\n

For example, if you are running a machine and need to pump\ncoolant throughout it, then the pump motor may run continuously at 1,000\nRPM.  However, if production has slowed\nor if the machine is operating much cooler than usual then running the motor at\nthat rate is wasteful.  Placing VFD\nwithin the system, along with other sensors, will determine if the pump needs\nto be slowed down and automatically adjust the energy being sent to the\nmotor.  During slower production times,\nthe pump motor may be reduced to only 600 RPM thereby saving energy.<\/p>\n\n\n\n

The great thing about motors is that the energy savings are non-linear, meaning that a reduction of speed from 1,000 RPM to 600 does not reduce energy consumption by 40%.  There is a cubic relation to energy savings meaning that a VFD placed in the system will consume 60% x 60% x 60% = 22% of energy than at 1,000 RPM.  For this scenario, the VFD will save nearly 80% of the money spent on energy when running at a reduced speed (detailed article here<\/a>).<\/p>\n\n\n\n

When motors are designed into a system, one is selected that\nis powerful enough to handle the largest task or load.  Basically, it is done to make sure the motor\nis not met with a significant challenge. \nWithout a motor controller of some kind, the system will run full speed\neven if it is excess.  Most of the time\nit is probably not necessary and therefore wastes energy and, therefore, money.<\/p>\n\n\n\n

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WEG Motor<\/a><\/figcaption><\/figure><\/div>\n\n\n\n

The importance of a VFD system is how it helps save\nsignificant money over time. \nEfficiencies produced by the VFD are such that the system will likely\npay for itself in a relatively short amount of time.  The primary areas of savings come from a\nreduction of:<\/p>\n\n\n\n