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Motor and System Control Recommendations
Andrew Hansen
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01/29/2021
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Top IAC Recommendation Series: Motor and System Control Recommendations
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[00:00:06.030]
Implementing different types
[00:00:07.280]
of system controllers can be beneficial to food processors.
[00:00:10.700]
In this video, I will discuss a couple different methods
[00:00:13.290]
in which programmable logic controllers,
[00:00:15.330]
or PLCs can be used to optimize processes.
[00:00:18.600]
A variable frequency drive, or VFD, is a type
[00:00:21.510]
of adjustable speed drive that controls
[00:00:23.610]
the speed at which a motor operates.
[00:00:25.760]
VFDs should be installed on motors
[00:00:27.630]
that do not need to run at full speed,
[00:00:29.500]
or experience varying load requirements
[00:00:31.430]
throughout a normal operating period.
[00:00:33.370]
Variable frequency drives are paired
[00:00:35.370]
with external sensors that measure things
[00:00:37.330]
like flow, liquid level, or pressure.
[00:00:39.860]
These sensors relay information back to the PLC
[00:00:42.770]
which then adjusts the motor speed
[00:00:44.520]
by adjusting the supplied voltage and frequency.
[00:00:47.430]
For centrifugal pumps and fans savings will be realized
[00:00:50.470]
by applying the fan affinity loss.
[00:00:52.660]
From this equation, two relations can be realized.
[00:00:55.780]
First, the provided flow varies directly
[00:00:58.380]
with the rotational speed.
[00:01:00.140]
Second, the input power requirement varies
[00:01:02.490]
as the cube root of the speed ratio.
[00:01:05.120]
In other words, reducing the rotational speed
[00:01:07.270]
and also flow by 20% can reduce
[00:01:09.560]
the input power requirements by nearly 50%.
[00:01:12.400]
Retrofitting existing equipment
[00:01:13.940]
with VFDs has been recommended 319 times to food processors.
[00:01:18.380]
Facilities see an average savings of $21,100.
[00:01:22.200]
And this upgrade costs an average of $27,500 to implement.
[00:01:26.680]
In addition to VFDs, food processors can benefit
[00:01:29.690]
from on-off control systems.
[00:01:31.680]
For example, adding a control system with sensors
[00:01:34.350]
and a PLC to conveyors can reduce the runtime.
[00:01:37.930]
With this controller installed conveyors will only
[00:01:40.460]
be powered when the product is placed on it,
[00:01:42.420]
reducing the electricity consumed.
[00:01:44.460]
It has been recommended to install systems similar
[00:01:47.010]
to the one described above 77 times.
[00:01:49.610]
On average, food processors can save $20,300 annually.
[00:01:53.810]
The average implementation cost
[00:01:55.290]
of this recommendation is $13,900 and you can expect
[00:01:58.900]
to have the initial investment payback in only one year.
[00:02:02.400]
This concludes our list of recommendations related
[00:02:04.840]
to control systems, thanks for watching.
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