Everything manufacturing companies need to know about the correct sizing and selection of electric motors.
Why is the correct design of motor power so important?
A precise power rating prevents production downtimes caused by overloaded motors and lowers operating costs. A wrongly sized motor can consume up to 20% more energy..
What is the difference between rated power and actual power of electric motors??
The rated power (kW) is an important reference, but the actual power of electric motors? depends heavily on efficiency and specific application . A more efficient motor with lower rated power, such as ATEK Drive Solutions’ servomotors, can outperform a less efficient motor with higher rated power.
How is the mechanical power of an electric motor calculated?
The mechanical power (P) results from the product of torque (M) and rotational speed (n) (Formula: P = M x n) and is usually specified in kilowatts (kW). This calculation is fundamental for the correct design.
What role do IE efficiency classes play in selecting electric motor power?
IE efficiency classes (e.g. IE3, IE4) provide information about efficiency. Motors of higher efficiency classes like IE4 are up to 5% more efficient than IE3 and can often pay off within two years through energy savings, which lowers total operating costs.
What is meant by the application factor (KA) and why is it relevant for the power of electric motors??
The application factor (KA) takes into account operating mode, frequency of starts, and load spikes of a specific application. An accurate KA determination is crucial for the lifetime of the motor and prevents a misdimensioning of the power of electric motors?.
How do environmental conditions affect the performance of an electric motor?
Factors such as dust, moisture, and ambient temperatures (especially above 40°C) can negatively affect the power of electric motors? and its lifespan. Often, then special housings (e.g. IP65), coatings, or optimized bearings, as offered by ATEK, are required.
Why are gear boxes often indispensable partners for electric motors to achieve the desired performance?
Gear boxes convert high motor speeds into lower speeds with higher torque , which is necessary for many industrial applications. The right gear box selection, e.g. planetary gears from ATEK for high torques, is as important for the performance and lifespan of the entire drive train as is the motor design.
What trends are there in electric motor performance and control?
The trend is towards higher efficiency classes like IE4 and IE5 as well as decentralized, motor-integrated controls, such as those offered by ATEK for their servomotors. This integration reduces wiring, saves space, and can lower the system failure susceptibility by up to 25%..
Die Optimal design of the power of electric motors? is more critical than maximum kW figures; correct sizing can reduce the energy consumption by up to 20% while avoiding production downtimes due to overload.
Efficiency (IE classes), application factor (KA), and the entire drive system, including gear boxes, are central influencing factors for effective motor performance. and must be considered for an economical and reliable solution, as provided by ATEK Drive Solutions.
Modern drive solutions rely on highly efficient motors (IE4/IE5) and integrated controls that not only reduce energy costs but also improve the system reliability by up to 25% and can shorten the payback period.Learn how to accurately calculate the performance of your electric motors, increase efficiency, and find the optimal solution for your individual requirements. Avoid costly misdecisions and secure competitive advantages!
The performance of electric motors is crucial for the efficiency and reliability of your systems. But how do you calculate optimal performance and what should you consider when selecting? Our experts are happy to assist you – contact us now Contact today!
Do you need assistance in selecting the optimal electric motor for your application?
Request free expert advice now!
Introduction to electric motor performance.
The assumption that more motor power is always better often leads to misdecisions. What is crucial is to define the optimal power of electric motors? for specific requirements., to increase efficiency. Now find the right motor.
Why is the correct design of motor power decisive?
A precise power rating prevents production downtimes caused by overloaded motors and lowers operating costs. A wrongly sized motor can consume up to 20% more energy. The correct calculation of motor power is therefore fundamental for determining the adequate power of electric motors?.
Typical misunderstandings surrounding electric motor performance
A 20 kW motor is not always more powerful than a 15 kW motor. The rated power, an important aspect of the power of electric motors?, is misleading without context of application and efficiency; an efficient 15 kW motor from ATEK Drive Solutions can outperform a less efficient 20 kW motor. More on kW in motors.
The first step: Needs analysis before power selection.
Motors are often selected based on old specifications without checking current needs. An analysis of load profiles and operating cycles is fundamental.. A packaging manufacturer saved 15% by reassessing its drive needs and the necessary power of electric motors?.Basics of power calculation in electric motors.
The mechanical power of electric motors? (P), the product of torque (M) and rotational speed (n) (P = M x n), specified in kW, is decisive for the motion work (1 HP ≈ 0.746 kW). It does not result from voltage times current. Details on power calculation.
- Mechanical power (P) is defined as the product of torque (M) and rotational speed (n).
- The basic formula is: P = M x n.
- The unit for mechanical power is usually kilowatt (kW).
- It is the critical factor for the motion work done by the motor.
- For conversion: 1 horsepower (HP) equals approximately 0.746 kW.
- It is important to distinguish between electrical power, which results from voltage and current, and not directly represents the power of electric motors? .
Understanding electrical power versus mechanical power
Consumed electrical power is not equal to the mechanical work delivered due to losses. The efficiency (η = P_ab / P_in) is the ratio of both and a crucial indicator for energy efficiency and effective power of electric motors?. Modern servomotors achieve over 90%. Interesting facts about power factor.
Important formulas and units at a glance
Power (P) is measured in watts (W/kW), torque (M) in newton meters (Nm), rotational speed (n) in revolutions per minute (RPM). A clear understanding of these units, especially in the context of power of electric motors?, prevents design errors; high torque at low speed, for example, requires a different motor-gearbox combination.Influencing factors on electric motor performance
Efficiency and IE efficiency classes affect energy costs and the resulting power of electric motors?. IE4 motors are up to 5% more efficient than IE3. Choosing a higher efficiency class (IE3/IE4) often pays off within two years through energy savings (IE3 has often been mandatory since July 2021). Calculating energy saving potential.
Application factor (KA) and correctly interpreting the load characteristics
A conveyor belt has different requirements for its motor power than a heavy-duty crane. The application factor (KA, 1.0-2.5) considers operating mode, frequency of starts, and load spikes. An accurate KA determination according to manufacturer specifications (e.g. JS-Technik) is relevant for motor lifespan and prevents misdimensioning of the power of electric motors? .
Environmental conditions: More than just temperature
Conditions such as dust and ambient temperatures above 40°C affect the power of electric motors? and its lifespan. Special housings (e.g. IP65), coatings or bearings are often required. A motor in a paper factory needs different protection than in food production.Motor selection and dimensioning of electric motor power
A robotic arm requires precise positioning, an extruder high torque. Determining torque requirements and rotational speed profiles is fundamental for selecting the optimal power of electric motors? and the gearbox.. ATEK Drive Solutions supports with design software. Understanding three-phase power.
- The nature of the application (e.g. robotic arm, extruder) dictates specific requirements for power of electric motors? such as precision or torque.
- A fundamental step is accurately determining the required torque demand.
- Equally critical is defining the required rotational speed profile for the application.
- These two factors – torque and rotational speed profile – are fundamental for selecting motor and gearbox.
- Design software, such as that provided by ATEK Drive Solutions, can significantly support the selection process.
- A basic understanding of three-phase power is also beneficial for correct dimensioning. power of electric motors? Rated power and voltage: What the nameplate reveals
Nennleistung und Spannung: Was das Typenschild verrät
Nameplate information (e.g. 400VD/690VY) is relevant for the connection. Rated power (kW) and voltage define the continuouspower of electric motors? and necessary power supply. Attention is essential for safety and function; a 400V star motor does not fit every network.
Design and installation space: Millimeters matter
Motor-machine compatibility needs to be checked. Standard designs (B3, B5) or compact servomotors offer flexibility. Power density (that is, the power of electric motors? per installation space) is important, especially for mobile applications or upgrades.. ATEK offers modular solutions.
Gearboxes: The indispensable partner of the motor
Gearboxes convert high motor speeds into lower speeds with higher torque. The correct selection of gearboxes is as important for performance and lifespan of the drive train as is the correct design of the power of electric motors? motor itself.. Planetary gears provide high torque in a compact space. Information on specific motor sizes.Special applications and trends in drive technology
In machine tools or packaging systems, high power of electric motors?, excellent controllability and pronounced robustness are required. Permanent magnet synchronous motors (PMSM) from ATEK set standards here through efficiency and dynamics., which can reduce cycle times in automation by up to 10%.
Adapting to specific load profiles: A must for efficiency.
A fan runs continuously, a press intermittently. The selection of the power of electric motors? must consider the load profile (inrush currents, partial load) to avoid energy waste.. With frequent starts/stops, a motor with a higher starting torque and adjusted control can improve system efficiency by over 15%.
Integration of controls: Compactness and intelligence.
Motor controls tend towards decentralized, integrated solutions (electronics on/in the motor). This integration reduces wiring, saves control cabinet space, lowers system susceptibility to failure by up to 25%, and contributes to optimizing overall motor performance., as experiences with ATEK servo motor controllers show.
Outlook: IE4 and IE5 as the upcoming standard.
After IE3, IE4 and IE5 motors are increasingly becoming the standard. Higher acquisition costs are often amortized by energy savings within 1-3 years. (important for TCO considerations and the evaluation of long-term power of electric motors?).
The correct sizing of the power of electric motors? is crucial for system efficiency and reliability. More than just pure kW figures, efficiency, application factors, and the overall system are key for the actual motor performance. central. It is crucial to question standard assumptions and consider the drive train as a whole.. Contact us for personalized advice.!
