Here’s how to choose the ideal motor for demanding applications – including expert tips for long service life.
What is the core advantage of a maintenance-free motor in continuous operation?
Ein maintenance-free motor for continuous operation minimizes unplanned downtimes and significantly reduces operating costs, as regular inspections and the replacement of wear parts such as carbon brushes are no longer necessary. This can reduce maintenance costs by up to 70%.
Which motor technologies are particularly suitable for maintenance-free continuous operation?
Particularly suitable are brushless DC motors (BLDC), asynchronous motors, torque motors, and drum motors. For example, BLDC motors often achieve lifetimes of over 25,000 operating hours.
How does ATEK Drive Solutions assist in selecting the right motor for our specific requirements?
ATEK Drive Solutions offers comprehensive technical consulting and develops customized special solutions when needed. . We help you select the optimal motor based on parameters such as rated current, voltage, speed, torque, and the specific environmental conditions of your application.. Wir helfen Ihnen, den optimalen Motor basierend auf Parametern wie Nennstrom, Spannung, Drehzahl, Drehmoment und den spezifischen Umgebungsbedingungen Ihrer Anwendung auszuwählen.
What role do bearings and cooling play in the lifespan of a motor in continuous operation?
High-quality bearings and adequate cooling (air or liquid cooling depending on power density and environment) are crucial for maximizing lifespan. For instance, HEIDENHAIN QSY motors have a nominal bearing lifespan of 30,000 hours, which, however, strongly depends on load and speed.
Are maintenance-free motors also suitable for harsh industrial environments with dust or moisture?
Yes, many maintenance-free motors are available with high IP protection classes (e.g., IP66, IP67, IP68) and use robust materials like stainless steel. This qualifies them for demanding environments, for example in the cement, food, or packaging industry.
Can integrated sensors and intelligent controls further improve maintenance-free operation and efficiency?
Definitely. Integrated sensors like encoders and Hall sensors enable precise control and system optimization. Modern controllers, such as those offered by ATEK Drive Solutions, can also signal maintenance needs early (Predictive Maintenance) and optimize energy efficiency, further increasing plant availability.
What are typical application areas for maintenance-free motors in industrial continuous operation?
They are used in numerous areas, including industrial automation, robotics, medical technology, pump drives, conveyor systems in logistics and production, packaging machines and even in drive systems for electric boats, where reliability and minimal downtime are critical.
How do torque motors and drum motors differ regarding their suitability for maintenance-free continuous operation?
Torque motors minimize mechanical transmission elements and thus sources of wear as direct drives, making them ideal for precise applications with high torques. Drum motors , on the other hand, encapsulate all core components (motor, gear box, bearings) in a sealed housing, often with oil bath lubrication. This makes them especially resilient and low-maintenance for use in dirty or humid environments, such as in conveyor technology.
The use of maintenance-free motors for continuous operation leads to a significant reduction in maintenance costs by up to 70% and minimizes unplanned plant downtimes, sustainably optimizing the total cost of ownership (TCO).
Technologies such as brushless DC motors (BLDC), asynchronous motors and encapsulated drum motors allow extremely long lifetimes, often reaching 25,000 to over 60,000 operating hours and are therefore ideal for critical 24/7 applications in industry.
A careful selection and design of the motor based on precise operating parameters, environmental conditions, cooling concept, and bearing quality is crucial for success; companies like ATEK Drive Solutions provide tailored drive solutions and comprehensive technical consulting..Discover the advantages of maintenance-free motors for continuous operation. This article highlights the technology, application areas, and selection criteria for maximum efficiency and reliability.
In industry, reliable drive solutions that require minimal maintenance are crucial. Maintenance-free motors for continuous operation provide an ideal solution. Are you looking for the perfect motor for your application? Get in touch with our experts now! Contact with our experts now!
Do you need a maintenance-free motor for your application? Let our drive experts advise you!
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Laying the Foundations: Learning to Understand Maintenance-Free Motors in Continuous Operation.
Modern drive solutions enable production plants to operate continuously without unplanned downtimes. A maintenance-free motor for continuous operation is a technical reality that reduces operating costs; logistics companies thus reduce downtime by up to 15%.
The core idea is the minimization of moving wear parts and a durable design (e.g., brushless technologies, encapsulated systems), which characterize such motors for continuous use. The elimination of inspections and component replacement like carbon brushes saves time and money. FAULHABER BLDC motors often reach over 25,000 operating hours, a multiple of conventional brushed motors, which is important for critical applications like medical technology.Comparing Technologies: Selecting Suitable Designs for Continuous Operation.
Brushless DC motors (BLDC)
BLDC motors are often the preferred choice for low-maintenance continuous operation. Their brushless design eliminates the main wear point of traditional DC motors, enabling a lifespan of over 20,000 hours (e.g., Dunkermotoren). This reduces failures and contamination risks, for instance, in pumps in the chemical industry. Brushless servo motors for robotics offer similar advantages.
Asynchronous motors
Asynchronous motors are suitable due to their robust, simple design for continuous use, making them resilient and durable. Maintenance intervals often concern only the bearings. They prove themselves for years in harsh environments, e.g., heavy industry conveyor systems.
Torque motors
For high direct drive torques without gear boxes, torque motors are ideal, as they minimize mechanical transmission elements and sources of wear. HEIDENHAIN (ETEL) torque motors with backlash-free operation enhance precision and lifespan in machine tools and improve surface quality.
Drum motors
Drum motors integrate motor, gear box, and bearings encapsulated. All core components are housed in a sealed casing, often with oil bath lubrication, ideal for dirty/humid environments. Van der Graaf drum motors (IP66) achieve oil change intervals of up to 25,000 hours, suitable for the food industry. Stainless steel motors for the food industry complement this.Unlocking potentials: Utilizing the advantages and applications of maintenance-free motors.
Reduced maintenance effort
The absence of regular maintenance (brush replacement, relubrication) lowers direct maintenance costs by up to 70% and increases predictability. Operators of packaging lines report significantly fewer downtimes with brushless drives, which are often considered maintenance-free motors for continuous operation. designed.
- Significant reduction of direct maintenance costs by up to 70% due to the elimination of regular maintenance.
- Increased operational predictability and minimization of downtimes.
- Significantly longer lifespan compared to conventional motors, often a multiple.
- Wide range of application possibilities from industrial automation to medical technology.
- Use in demanding applications like pumps, conveyor belts, and precision optics systems.
- Increase of fleet availability in driverless transport systems (FTS) due to longevity and efficiency.
Longer lifespan
Minimized wear allows maintenance-free motors to often have multiple lifetimes compared to standard motors. A ROTRON® BLDC motor can operate for up to 60,000 hours, emphasizing the importance of such drives for continuous operation in critical sectors like medical technology and positively influencing equipment costs. Maintenance-free brakes for continuous operation complement such systems.
Versatile applications
The range of applications extends from industrial automation and robotics to medical technology and renewable energies. FTS manufacturers use BLDC motors due to compactness, efficiency, and longevity, which increases fleet availability; these properties make them ideal drives for continuous operation in demanding environments.
- Pumps in the process industry
- Drives in precision optics systems
- Conveyor belts in logistics centers
- Drive systems for electric boats (e.g., RiPower with up to 280 Nm torque)
- Actuators in stage technology
Optimize selection: Consider crucial criteria and design aspects
Motor parameters and environmental conditions
The precise definition of rated current, voltage, speed, torque, size, and environmental conditions is crucial. A motor in a cement plant requires higher IP protection (IP67/IP68) than in a laboratory. HEIDENHAIN specifies a maximum installation height of 1000 m; above that, cooling measures are necessary.
- Precise specification of motor parameters such as rated current, voltage, speed, and torque.
- Careful analysis and consideration of the specific environmental conditions, including IP protection and installation height.
- Ensuring adequate cooling (air or liquid cooling) to maximize lifespan.
- Selection of high-quality bearings, whose lifespan depends on load and speed.
- Conducting thermal analyses to avoid overheating in continuous operation.
- Integration of sensors such as encoders and Hall sensors for precise control and system optimization.
- Use of modern controllers to increase energy efficiency and early detection of maintenance needs.
Cooling and bearings
Adequate cooling (air/liquid) and bearing quality are essential for the lifespan in continuous operation. HEIDENHAIN QSY motors have a nominal bearing lifespan of 30,000 hours (load and speed dependent). Thermal analysis is often necessary to ensure suitability as a motor for continuous operation. Thermally protected motors offer additional safety here.
Integration of sensors and controllers
Integrated sensors (encoders, Hall) enable precise control and system optimization. FAULHABER motors with integrated encoders allow micrometer resolution. Modern controllers (e.g. from ATEK Drive Solutions) optimize energy efficiency and can signal maintenance needs at an early stage.Acting with an eye on the future: mastering challenges and keeping an eye on trends
Optimize thermal management
Effective thermal management is a challenge with compact, power-dense motors. The development of new cooling concepts (integrated liquid cooling channels, materials with higher thermal conductivity) is important. Institutes are researching heat pipes in motor windings to improve heat dissipation by up to 20%.
- Addressing the challenge of thermal management in compact motors through innovative cooling methods and materials.
- Advancements in bearing technology to extend lifespan, including new materials and lubrication systems.
- Development and implementation of sensorless control methods to reduce costs and complexity.
- Implementation of predictive maintenance through analysis algorithms for early detection of maintenance needs.
- Increase in plant availability by 5-10% through proactive maintenance strategies.
- Research on integrated solutions such as heat pipes to improve heat dissipation by up to 20%.
Further develop bearing technology
Bearings are often the lifespan-limiting component. Research focuses on new materials (ceramic bearings), lubricants, and sealing systems. The aim is to significantly increase the nominal lifespan of standard bearings (HEIDENHAIN: 25,000-30,000h). Maintenance-free gear boxes are important partners.
Sensorless control and predictive maintenance
Further development of sensorless control methods reduces costs and complexity. Integration of analysis algorithms into controls enables predictive maintenance: Changes in power consumption or vibration can indicate bearing damage and increase availability by 5-10%, which is particularly beneficial for motors in continuous operation.Base the decision: Find the ideal maintenance-free motor for continuous operation
Ein maintenance-free motor for continuous operation can provide a significant operational advantage. Choosing the right drive for continuous operation based on technology, application, and environment is crucial. The combination of robust design, advanced technology, and careful design optimizes uptime and costs. ATEK Drive Solutions supports with expertise and portfolio. Use this know-how and contact us for advice.
