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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