Increase efficiency, reduce costs: The advantages of modern frequency converters for your industrial applications
What is the main advantage of using a frequency converter in my production facility?
The main advantage is the optimization of your system. Frequency converters enable a precise control of motors, which leads to significant energy savings, an improved process efficiency and a longer lifespan of your machines. For example, energy costs for fan drives can be reduced by up to 40%.
How exactly does a frequency converter reduce energy costs?
A frequency converter adjusts the speed of the motor precisely to the actual demand of the application. Instead of running motors constantly at full power, only the energy that is really needed is consumed. This can lead to energy savings of up to 70% .
What should I pay attention to when selecting a frequency converter for my motor?
Important are the compatibility of motor and frequency converter (according to DIN VDE 0530-25), the correct sizing regarding input voltage, output power, and frequency range. Also consider EMC aspects, required safety functions (e.g., STO) and the necessary communication interfaces for your control environment.
What role does EMC compatibility play in frequency converters?
Frequency converters generate high-frequency disturbances through rapid switching actions. Good EMC compatibility, often achieved through integrated or external filters and shielded cables, is crucial to avoid disturbances to other devices and ensure compliance with standards (e.g., EN 61000-3) . This also protects the motor and can reduce bearing currents.
Can frequency converters extend the lifespan of my machines?
Yes, by soft starts and stops, frequency converters reduce the mechanical stress on motors, gear boxes, and the entire machine. This leads to less wear and can extend the maintenance intervals by up to 25% Wartungsintervalle um bis zu 25% verlängern, positively influencing the overall lifespan of the system.
What is the difference between U/f control and vector control in frequency converters?
Die U/f control is a simple method, adjusting the voltage proportional to the frequency and sufficient for many standard applications. The vector control, on the other hand, provides a more precise control of torque and speed, even with load changes, and enhances the dynamics and efficiency of the drive. It can improve the torque control by up to 30%.
When is energy recovery in frequency converters sensible?
Energy recovery is particularly sensible in applications with frequent braking operations or loads that can feed energy back into the system , such as in elevators, cranes, or centrifuges. Regenerative converters can reduce energy costs by up to 15% , by feeding braking energy back into the grid instead of converting it into heat.How does ATEK Drive Solutions support the selection and integration of frequency converters?
ATEK Drive Solutions offers comprehensive consulting as a system provider
for the entire drive train , including the optimal coordination of motors, gear boxes, and brakes with suitable control and regulation systems such as frequency converters. We help you, einschließlich der optimalen Abstimmung von Motoren, Getrieben und Bremsen mit passenden Steuerungs- und Regelungssystemen wie Frequenzumrichtern. Wir helfen Ihnen, find the right drive solution for your specific application, to achieve maximum efficiency and performance .
Frequency converters are crucial for reducing energy costs in the industry, with saving potentials of up to 70% for pumps and fans through demand-oriented speed control.
In addition to energy efficiency, frequency converters allow for a precise process control, which improves the product quality (e.g., 15% less rejects) and extends the lifespan of machine components by up to 25%.
The proper selection and integration, including motor compatibility (DIN VDE 0530-25) und EMC measures (EN 61000-3), are essential for the maximum performance and reliability of frequency converter systems.Discover how frequency converters can optimize your machine performance, save energy, and extend the lifespan of your systems. Learn all about technology, applications, and the benefits of ATEK solutions.
Are you ready to take your drive technology to the next level? Frequency converters are the key to more efficiency and precision. Contact us at ATEK Drive Solutions and let us find the optimal solution for your requirements together.
Do you need individual consulting for selecting the optimal frequency converter for your application?
Get a free consultation now!
Introduction to frequency converters
Efficient drive technology reduces costs. Frequency converters significantly optimize systems. ATEK Drive Solutions helps harness this potential for future-proof drive systems.
The role of modern frequency converters
Up to 70% of industrial energy is attributed to electric motors. Modern Frequency converters are more than just speed controllers: They are strategic tools for significantly reducing energy costs and optimizing processes – an often underestimated potential. For example, a production operation reduced electricity costs for fan drives by 40% through demand-oriented speed adjustment, effectively with a motor for HVAC systems.
Precise control as the key to efficiency
A packaging operation reduced its reject rate by 15% through precise motor control with frequency converters. These versatile drive controllers enable sensitive adjustment to dynamic loads, extend the lifespan of components like ATEK gear boxes, and ensure product quality. A core aspect of the performance of every motor with frequency converters.Operation and technical fundamentals
The flow of electricity: The heart of the frequency converter
The power grid delivers a fixed frequency, motors often require variable. Frequency converters This is adjusted: Grid AC is converted to DC and smoothed in the intermediate circuit. An inverter generates variable AC. A correctly sized intermediate circuit with capacitors ensures stable DC voltage, increases system reliability by over 20%, and is crucial for every FU-compatible motor.
- Rectification: Converts AC to DC.
- Intermediate circuit: Stores and smooths DC energy.
- Inversion: Generates variable AC for the motor.
Control methods and PWM: Precision through technology
Depending on the application, U/f control or vector control is needed. Demanding applications like hoists (e.g., with Siemens controls) require more precision. While U/f keeps the motor flow constant, vector control improves torque control during load changes by up to 30%. This is often realized via PWM, comparable to the advantages of a controllable gear motor with integrated frequency converter.Application areas and benefits
Diverse applications in the industry
A waterworks saved five-figure energy costs annually through speed-regulated pumps – typical for the use of frequency converters. They optimize pumps and fans (50-70% energy savings possible) and enable soft starts in conveyor systems. Precise robotic movements, often with ATEK servomotors, are another field, as an alternative to soft starters as an alternative to frequency converters.
- Optimization of pumps and fans with potential energy savings of 50-70%.
- Enabling soft starts in conveyor systems, which reduces mechanical stress.
- Application in precise robotic applications, often in combination with servomotors.
- Extension of machine maintenance intervals by up to 25% through gentler operation.
- Improvement of product quality through precise and adaptable process control.
- Reduction of mechanical stress on system components and thus longer lifespan.
- Improvement of overall equipment effectiveness (OEE) through optimized processes and fewer failures.
Concrete advantages: More than just energy savings
Frequency converters extend machine maintenance intervals by up to 25% and enhance product quality. This is achieved through reduced mechanical stress and precise process control by the converter. In addition to energy savings, OEE improves, even with 230V motors with control.
- Energy savings through demand-oriented control with a Frequency converters.
- Process optimization through precise control.
- System protection through soft starts.
- Extended lifespan of components.
Selection criteria and important aspects
Optimal coordination: Motor and frequency converter
Motor overheating occurred with a standard motor that was unsuitable for operation with a Frequency converters that reduced its lifespan by 60%. The crucial factor is motor selection according to DIN VDE 0530-25, so the insulation withstands voltage spikes caused by the frequency converter. Mismatches are costly and reduce efficiency, for example, by increasing slip in induction motors.
- Input voltage and frequency of the frequency converter.
- Output power and frequency range of the drive controller.
- Required protection class (IP class).
- Necessary safety functions (e.g., STO).
Managing EMC, filters, and braking energy cleverly
Control failures or high braking energy costs are possible problems with insufficient design of the Frequency converters-system. EMC filters (EN 61000-3) and the choice between braking resistor or energy recovery are important. Regenerative converters save up to 15% in energy costs for cranes and ensure system availability, similar to Gear motor for energy recovery.Current trends and future developments
Intelligent control and sustainability
Self-optimizing drive systems meet high energy efficiency standards. Modern frequency converters with sensorless vector control, AI approaches, and IE2 efficiency (EN 50598-2), e.g. from Danfoss, adaptively adjust and increase efficiency by another 5-10%. A valuable optimization for any controllable gear motor with integrated frequency converter, which supports sustainable production goals.
- Development towards intelligent and self-optimizing drive systems to maximize energy efficiency, wherein Frequency converters play a key role.
- Use of advanced control technologies such as sensorless vector control and artificial intelligence (AI) in frequency converters.
- Focus on compliance with high energy efficiency standards, for example IE2 according to EN 50598-2, for Frequency converters and motors.
- Adaptive adjustment of the Frequency converters to operating conditions for further efficiency gains of 5-10%.
- Increasing digitization and networking of frequency converters in the context of the Industrial Internet of Things (IIoT).
- Integration into Smart Factory concepts through standardized interfaces such as OPC UA, making Frequency converters frequency converters (FUs) important data providers.
- Enabling predictive maintenance by analyzing operational data from the Frequency converters, which can lead to a reduction in unplanned downtime.
- Supporting the achievement of sustainability goals in production through energy-efficient operation with frequency converters.
digitization and networking in the IIoT age
A company reduces unplanned downtime by 20% through predictive maintenance with operational data from the frequency converter. IIoT integration via OPC UA makes frequency converters data providers for the Smart Factory. This enables proactive maintenance, also relevant for energy-optimized HVAC systems, which are often controlled by frequency converters.
Frequency converters are strategic tools, not just speed controllers. A profound understanding of the system is essential for selecting the right drive controller. Drive optimization through Frequency converters is an important step towards greater efficiency and sustainability. ATEK Drive Solutions advises you on future-proof drive solutions with frequency converters.
