Learn how ATEK Drive Solutions optimizes your systems with reliable and efficient drive solutions for high temperatures.
Why are special high-temperature motors necessary for furnace and melting systems?
Standard motors are designed for ambient temperatures up to approximately 40°C. In furnace and melting systems there are often temperatures of 150°C or more. Under these conditions, insulation, bearings, and lubricants in standard motors fail, leading to frequent failures and production downtimes . High-temperature motors are specifically designed to withstand these extreme conditions.
What design features distinguish high-temperature motors from standard motors?
High-temperature motors use heat-resistant insulation materials (Class H or C), special lubricants (e.g., PFPE greases), customized bearings and often improved cooling concepts (e.g., larger cooling fins, external ventilation). The thermal expansion of the components is also taken into account in the design.
In which industries are high-temperature motors typically used?
They are essential in the steel, glass, ceramics, and cement industries for drives in furnaces, melting plants, dryers, or conveyor systems for hot goods. They can also be found in power plants or waste incineration plants , anywhere where process heat means high ambient temperatures for motors.
How does ATEK Drive Solutions ensure the reliability of its high-temperature drive solutions?
ATEK relies on a combination of decades of experience in gear construction, new competence in servomotors and the use of high-quality, heat-resistant materials.Each solution is carefully designed for the specific application conditions, often as a customized special solution, to ensure maximum reliability and lifespan.
What impact does the ambient temperature have on a motor’s performance (derating)?
As the ambient temperature rises, the maximum allowable power output of a motor decreases to prevent overheating – this is called derating. A motor that delivers 10 kW at 40°C may only provide 7 kW at 150°C. This must be considered in the design of high-temperature motors .
Are high-temperature motors also available for explosion-prone areas (ATEX)?
Yes, for applications in explosion-prone areas that are simultaneously exposed to high temperatures, ATEX-certified high-temperature motors and gear motors can be developed and supplied. ATEK Drive Solutions offers the necessary expertise.
Are the higher acquisition costs for high-temperature motors justified?
Although the acquisition costs are higher than for standard motors, high-temperature motors typically pay for themselves quickly. This happens through significantly longer lifespan, reduced maintenance costs and above all through the avoidance of expensive production downtimes. The total cost of ownership (TCO) is usually lower..
Does ATEK also offer complete drive systems for high-temperature applications?
Yes, ATEK positions itself as a system provider for the entire industrial drive train.This includes gearboxes, brakes, and motors. For high-temperature applications, we develop integrated and optimized system solutions, tailored to the specific requirements of the customer, including comprehensive technical consulting.
High-temperature motors are essential for the reliable operation of furnace and melting system drives , as standard motors quickly fail at process temperatures above 40°C. They ensure the continuity of production in extreme environments..
Special design features such as insulation materials of class H or C, high-temperature lubricants, and adapted cooling methods enable operation at temperatures up to over 200°C. This can reduce unplanned downtimes by up to 25% and significantly extend the lifespan of the drives..
Investment in high-temperature motors leads to a more favorable total cost of ownership (TCO) due to reduced maintenance and avoided production downtimes.. ATEK Drive Solutions offers tailored system solutions. Discover the benefits of ATEK’s high-temperature motors for furnace and melting systems. Boost your productivity and reduce your operating costs – even under extreme conditions!
Drive technology for furnace and melting systems presents special challenges. ATEK Drive Solutions offers you highly specialized high-temperature motors that withstand even the most extreme conditions. Do you need a customized solution? Contact us now.
Entdecken Sie die Vorteile von ATEK’s Hochtemperaturmotoren für Ofen- und Schmelzaggregate. Steigern Sie Ihre Produktivität und senken Sie Ihre Betriebskosten – auch unter extremen Bedingungen!
Die Antriebstechnik für Ofen- und Schmelzaggregate stellt besondere Herausforderungen dar. ATEK Drive Solutions bietet Ihnen hochspezialisierte Hochtemperaturmotoren, die selbst extremsten Bedingungen standhalten. Benötigen Sie eine individuelle Lösung? Nehmen Sie jetzt Contact us!
Do you need a tailored drive solution for your high-temperature application?
Request individual consultation now!
Introduction to high-temperature motors for industrial applications
High-temperature motors for furnace and melting systems: performance under extreme conditions. ATEK Drive Solutions offers reliable drives for high temperatures. Special motors that serve as drives for furnace and melting plants ensure production and performance where standard drives fail.
High-temperature motors: a necessity for extreme environments
Standard motors often fail at process temperatures like 150°C, causing expensive downtimes. High-temperature motors, designed specifically for use in furnace and melting system drives furnaces, ensure reliable continuous operation at full load. For explosion-prone areas, ATEX-certified gear motors are available.
Definition and areas of application
They use heat-resistant materials, special bearings, lubricants, and adapted cooling. Used in steel, glass, ceramics, cement industries for furnace fans or pumps for hot media (>200°C). The necessity of these motors, particularly as robust drives for furnace and melting processes, often only becomes evident after failures.
Why standard motors fail
Standard motors (up to 40°C) quickly suffer insulation damage at 120°C. A 10K increase often halves the insulation lifespan due to material degradation and lubricant failure.Technical challenges and design aspects
Insulation materials
motor components withstand high temperatures through insulation materials of classes H (180°C) or C (>180°C), such as glass fiber, mica, special resins, or polyimide films (up to 220°C). Selecting the correct materials is crucial for safety and lifespan, especially for a high-temperature motor, used in furnace or melting systems .
- The use of insulation materials of classes H (180°C) or C (>180°C) is essential, especially for drives in furnace and melting systems..
- Examples of insulation materials include glass fiber, mica, and polyimide films (up to 220°C).
- Special lubricants such as synthetic high-temperature greases or solid lubricants are necessary, as standard greases fail.
- PFPE greases can provide over 20,000 operating hours at high temperatures and reduce wear.
- Effective heat dissipation is achieved through increased cooling fins, self-ventilation, forced ventilation, or water cooling.
- A well-thought-out cooling concept is crucial for extending the motor’s lifespan under extreme conditions.
Lubrication
Standard greases fail at high temperatures like 150°C. Synthetic high-temperature greases or solid lubricants are stable up to over 250°C, such as PFPE greases for over 20,000 operating hours in dry kiln bearings. This reduces wear and maintenance, especially for drives for furnaces and melting systems , is essential.
Cooling methods
Heat dissipation occurs through increased cooling fins, self-ventilation, forced ventilation, or water cooling. A motor in an aluminum melting operation (180°C ambient) – a typical application for a high-temperature motor in melting system drives – maintains its rated temperature. A well-thought-out cooling concept significantly extends lifespan. Our special gearboxes-expertise helps with specific solutions.Application areas and industry specifics
Furnace and melting plant drives
drives for furnace and melting systems, such as roll ways in the steel industry (e.g., transporting 800°C hot slabs), require heat resistance as well as robustness against vibrations and dust. A reliable high-temperature motor drive for such Furnace and melting plant drives is essential here. Special seals, reinforced bearings, and temperature-compensated brakes are often necessary.
Steel industry
High-temperature motors reduced unplanned downtimes of walking beam furnaces in a steel plant by 15%. They operate at up to 120°C, withstand thermal shocks, abrasive dusts, and mechanical stresses. Such motors for furnace drives are a must, often as part of complex melting system drives..
Glass industry
Near glass furnaces (>600°C), reliable drives ensure product quality through constant performance despite temperature fluctuations. High-temperature resistant brakes for furnace doors are often used here, frequently in conjunction with a specialized im Einsatz, häufig in Verbindung mit einem spezialisierten high-temperature motor for furnace drives.
Cement industry
Motors for rotary kilns or clinker coolers must withstand temperatures up to 200°C, dust, and continuous operation. Our solutions, often with heavy-duty drives and designed as robust high-temperature motors for furnace and similar aggregates have proven themselves.Selection criteria and cost-effectiveness
Performance parameters
The derating behavior (power reduction due to heat) is High-temperature motors crucial. A 10 kW motor (at 40°C) can only deliver 7 kW at 150°C. Accurate knowledge of the load profile and maximum ambient temperature is essential for sizing, especially concerning a high-temperature motor for demanding furnace and melting aggregate drives is important.
- Considering the derating behavior (power reduction due to heat) when selecting motors for high-temperature applications in furnaces and smelting.
- Accurate knowledge of the load profile and maximum ambient temperature is crucial for correct sizing.
- Tuning of torque characteristics, speed, and temperature resistance to the specific application.
- Importance of considering starting torque, operating torque, maximum speed, and temperature dependence.
- Initially higher acquisition costs amortize through longer lifespan and lower maintenance.
- Advantageous Total Cost of Ownership (TCO) due to avoided production downtime and higher availability.
Torque and speed
For a furnace car drive (180°C, 150 Nm, 10 rpm), special gear motors are required, which are designed as high-temperature motors for such furnace drives. The tuning of torque characteristics, speed, and temperature resistance is central.
- Consider starting torque
- Ensure operating torque
- Define maximum speed
- Consider temperature dependence
Economic aspects
Higher acquisition costs for High-temperature motors, especially for specialized drives for furnace and melting systems, often amortize through longer lifespan, less maintenance, and avoided production downtime. The Total Cost of Ownership (TCO) is usually more advantageous due to lower operating costs and higher availability.Innovations and future trends
Material research
New ceramic materials and composite insulation systems aim for motor operation over 300°C, with better temperature resistance and thermal conductivity. Nanocomposites can improve the thermal stability of winding insulation by 20%. Materials science is a key factor in the further development of High-temperature motors, which is used in furnace and melting system drives .
Digitalization and automation
Integrated sensors in High-temperature motors report critical conditions (e.g., temperature, vibration) early to control systems. Predictive maintenance avoids failures; a cement plant thus reduced downtime of its furnace drives by 25% through the use of optimized motors. Smart motors with condition monitoring, often as part of the drive solutions for melting aggregates, optimize maintenance strategies.
Predictive maintenance
Operational data analysis (temperature, vibrations, current) enables precise maintenance forecasts, avoids unnecessary stops and failures. A chemical company saves over 50,000 euros annually on stirring drive systems. We also integrate this into temperature-resistant gear units, which are often components of drive systems for furnace and melting processes that are based on robust high-temperature motors.Conclusion
Summary of key points
High-temperature motors are essential for reliable processes in thermally extreme environments. Their special design (heat-resistant materials, lubrication, cooling) ensures performance where standard drives fail – this is especially true for the high-temperature motor, which serves as the heart of furnace and melting aggregate drives. A careful selection based on requirement analysis and cost-effectiveness is crucial. The investment pays off through higher availability and lower lifecycle costs.
ATEK Drive Solutions as your partner
With expertise in drive technology and a portfolio ranging from standard components to custom special drives und gear motors , we develop optimal solutions, including the specialized high-temperature motor for your furnace and melting aggregate drives. Over 1,000 successful high-temperature projects demonstrate our experience. We deliver well-thought-out system solutions, not just products.
For processes that require maximum performance at extreme heat: Trust in High-temperature motors from ATEK Drive Solutions, especially our proven solutions as drives for furnace and melting systems. Request a customized offer.
