Revere Electric

Why Buying a New Electric Motor is Better for Your Bottom Line

2021-12-02T16:41:19+00:00

With over 20 years’ experience in the electric motor industry, I have come to realize; there are no set rules when it comes to replacing a motor.

There are many factors to consider. The general rule is to replace the electric motor if the cost of repair is around 60%-70% of the cost of new. However, there are also exceptions to this rule and many other factors to consider.

Motor Age:

Older electric motors, typically those that are 15 years or older, are not very efficient. The energy costs associated with running the electric motor far outweigh the cost of purchasing new.

And if you decide to recondition the electric motor, but do not rewind it; than you will not have a warranty on the winding. That's important to keep in mind. In my career, I have seen many electric motors “blow” after being reconditioned; and at that point, the only thing you can do is replace the motor. In this scenario, you spent money on the recondition and then needed to replace it, so you simply wasted money with the recondition.

Motors may also fail prematurely; it is wise to evaluate your application and environment. Instead of repairing, you may consider a new motor that may cost a little more but will last a lot longer.

Motor Efficiency:

Another factor to consider is efficiency. As previously mentioned, older electric motors are not very efficient. When you purchase a new electric motor, you get the opportunity to significantly decrease your energy bills and increase productivity and profitability at the same time.

Motor Availability:

Finally, down time costs you money. You can have an electric motor repaired in 2-3 weeks and a new electric motor purchase can be found in stock and delivered within a few days. In many cases, time is of the essence and knowing that you can purchase a new electric motor quickly; along with the efficiency advantages, makes purchasing a new electric motor highly desirable.

As the Motor Specialist at Revere Electric Supply, I can help you find the best motor for your application. My relationships with the manufacturers in the industry are second to none. I understand the intricacies of the motor industry and would be happy to use my knowledge and skill set to ensure you purchase a new motor that will decrease downtime, increase productivity, increase efficiencies, and ultimately; increase your bottom line. I can’t wait to help you with your next motor application.

Bill Senica: bsenica@revereelectric.com

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Automation Fair Mechatronics Highlights

2020-01-29T17:33:53+00:00

Big Things Come in Small Packages and That is Especially True When It Comes to adding Mechatronics and Your Rockwell Automation Solution

By Mike Stock, Mechatronics Product Manager

As I walked the Rockwell Automation Fair in Chicago last November, I was impressed by the number of Encompass Partners that recently launched Ethernet motion to their product line. What does that mean? It means that motion manufacturers are creating add on instructions for the Allen Bradley Logix family of controllers, simplifying integration into your Allen Bradley solution. Here are some of the products that I am excited about and you should be too:

LinMot was showing both large linear motors directly driven by Kinetix 5700 drives and smaller linear motors driven by their C1250-CM. The C1250-CM now includes CIPSync which allows coordinated motion with Rockwell motion instructions. Check out this Automation Fair highlight reel:

Wittenstein launched Simco drives with CIP Sync drives with both in cabinet and on machine options. These drives control cyber dynamic motors and linear actuators. Learn more Here

AMCI introduced the SV160E2 Integrated DC Servo drive + motor + controller. A great addition to their integrated stepper lineup. More information here

Mechatronics is an integral part of the Allen Bradley solution. Revere has a mechatronics solutions team with over 100 years of combined experience in designing, maintaining and troubleshooting motion solutions.

Interested in learning how mechatronics fits into your next application? Contact us anytime

Kinetix 5700 Regenerative Bus Supply

2019-08-09T17:46:13+00:00

Kinetix 5700 Regenerative Bus Supply ( AFE) and Large Frame Inverters

Automation is everywhere. Think about it. Robotics is becoming more and more prevalent and industrial manufacturers are constantly seeking larger controls and larger systems. Have you ever wondered how all of that is affecting our Nation’s power grid? Rockwell Automation not only thinks about it, they are actually doing something about it by bringing new innovative products to the market that help conserve power. One such new product is the Regenerative Bus Supply Kinetix 5700 and Large Frame Inverters.

What is a Regenerative Buss Supply? Well, to put it simply, it is a power supply that allows the energy from your system (that was wasted in heat before) to be put back into the AC power source. Doing this creates the following advantages:

Mounting Flexibility: These drives can be mounted to the left or the right of the Regenerative Bus Supply.
Hi power density design to reduce the footprint of your servo system.
Wide range of input voltage 324-528VAC with continuous rated amps. When you use a Regenerative Bus Supply you can have up to 90 meters motor length (based on motor type) and up to 1200M total system cable length.
Reduce System Wiring: The drive uses an integrated L-C harmonic filter, which means there is one less module to mount and wire.

Also, when it comes to power there are Power Supplies up to 207A (Rated DC Amps) available with CIP Energy capabilities that include onboard diagnostic for power quality monitoring which provide real time analytics. Having a built-in power quality management tool with unity power factor for efficient power usage and minimized harmonics allows customers to meet IEEE519 requirements.

The Large frame inverters expand the Kinetix 5700 to up to 112KW with Safe Torque Off (STO) and Advanced Safety. They still allow you to Bookshelf zero stack mount and use the single cable Technology form the servo motors. It includes DC Common Bus Capabilities that allow the excess energy back through the common bus, which captures the electrical energy that is normally wasted when stopping or cycling a motor.

For more information on the Regenerative Bus Supply Contact your Revere Motion Specialist.

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Easier Linear Motion with Exlar

2018-02-15T22:18:38+00:00

Linear Motion Requirements Come in All Shapes and Sizes. So do Exlar Actuators!

Why Roller

Rollerscrews can operate with more force than ball screws for an equivalent physicalsize.
Rollerscrews have a friction advantage. Rollers are contained in a ring and do notcontact each other, while recirculating balls have friction from the ballsrubbing against each other while moving through the track.
Increasedspeeds. In any recirculating ball system, the U turn in the ball path isfrequently what limits the speed. Using planetary rollers, Exlar's roller screwactuators can operate efficiently up to 6000 rpm. Higher operating speeds canincrease the optimal use of servo motors and reduce the need for intermediategearboxes.

Exlar's actuators are versatile and dependable. What's their secret? The utilization of roller screws.

Why Roller Screws?

Roller screws can operate with more force than ball screws for an equivalent physical size.
Roller screws have a friction advantage. Rollers are contained in a ring and do not contact each other, while recirculating balls have friction from the balls rubbing against each other while moving through the track.
Increased speeds. In any recirculating ball system, the U turn in the ball path is frequently what limits the speed. Using planetary rollers, Exlar's roller screw actuators can operate efficiently up to 6000 rpm. Higher operating speeds can increase the optimal use of servo motors and reduce the need for intermediate gearboxes.

Where Should We Use Roller Screws?

Exlar roller screws can be used to improve upon pneumatic cylinder arrangements in many applications. Sometimes fragile products or increasing customer speed requirements can push the limits of pneumatic motion solutions. Pairing a roller screw with a servo motor can provide precise acceleration and deceleration; as well as jerk adjustment to minimize product tip overs, spillage and slippage. Sometimes new product requirements require programmable or multiple start stop points. Exlar roller screws allow for flexibility and control and allow rotary servo motors to be translated to linear motion.
Higher force applications that have traditionally been the domain of hydraulic cylinders can be accommodated by roller screws. Exlar roller screw actuators are available with force capacities up to 40t (80,000 pound/36,300 kg). High force applications frequently require dedicated hydraulic power units and that comes with maintenance chores. Utilizing electric actuators instead of hydraulic will save on the costs of these chores.
Utilizing Exlar roller screws with Rockwell Automation Integrated Motion allows speed and force monitoring throughout the stroke to allow for more precise process outcomes.

So, if you are looking to convert rotary motion into linear motion, Exlar roller screws are the answer. The advantages can include; speed of operation, precision control,reduced maintenance and reduced costs.

Want to learn more? Contact your Revere Motion Specialist for more information or to discuss specific applications.

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Lowest Cost Solution to Meet Your IEEE-519 Requirement

2017-08-29T21:29:37+00:00

The IEEE-519 Standard (Recommended Practices and Requirements for Harmonic Control in Electric Power Systems), established levels of voltage distortion acceptable to the distribution system and has been a standard among the industry for over 35 years.

There have been multiple revisions over the years; with the latest one treating the relationship of harmonic voltages to the harmonic currents flowing within industrial plants. The new IEEE 519, published in 1992, sets forth limits for both harmonic voltages on the utility transmission and distribution system and harmonic currents within the industrial distribution systems.

Since harmonic voltages are generated by the passage of harmonic currents through distribution system impedances, by controlling the currents or system impedances within the industrial facility, one can control harmonic voltages on the utility distribution.

Over the course of the last year, we have seen a rise in the number of customers who are specifying the IEEE-519 standard. If you were asked to meet the standard, would you know which mitigation method to use?

As a leader in the IEEE-519 Standard, Revere’s partner TCI, has the products, the knowledge and the support to create a custom solution to help you meet any IEEE-519 standard specification.

TCI has recently launched their HarmonicGuard Solution Center. The Solution Center features a dynamic analysis tool that uses your basic system data to generate accurate harmonic and power quality analysis for your unique application. Check it out: TCI HarmonicGuard Solution Center

Additional Resources

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Increase Efficiencies and Save Energy with Power Regeneration

2017-08-29T21:08:59+00:00

Power regeneration is the process of recovering kinetic energy created by a motor, often controlled by a Variable Frequency Drive (VFD), during stopping or braking and converting that energy to electricity, and feeding it back into the power grid. Using power regeneration increases efficiencies and helps to reduce energy costs. If you are not regenerating, to handle the excess energy, you would have to make sure that there was a braking circuit on the VFD and then install regenerative resistors that would then dissipate the excess energy through heat. This option would increase panel space and cause issues for panel designers; as they would have to deal with the additional heat that is being generated by the resistor in the panel. Additionally, most of the time, the regen resistor is placed somewhere outside of the panel, away from the heat sensitive components and that wastes the energy created by the motor.

Revere can mitigate these issues with Bonitron’s Line Regeneration Modules. Now you can take that excess energy and use it to send it back onto the utility. This would decrease the costs associated with the application and in turn, make the system dramatically more efficient. With Modules for applications ranging from 208VAC to 600 VAC, Bonitron has options for all three-phase industrial regenerative applications. If you would like more information, please check out the links below or contact your Revere Electric representative to schedule a meeting to discuss how this could be used in your applications.

Bonitron's Website

Bonitron Regen_130004_20160919.pdf

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E-drive Electric Actuators – The Next Step in High Performance High Force Linear Applications

2017-08-04T16:48:14+00:00

Servo controlled electric actuators are a great way to improve upon the costs and performance of hydraulic systems. E-drive actuators utilize roller screw technology to obtain precise, smooth motion as well as excellent rigidity. The use of Servo motors to power the actuators allows for precise control that is easily operated with a range of controls, from simple indexing systems up to complex CIP motion, and can be easily integrated with any control system. Replacing hydraulic systems with electric saves maintenance as well. No hoses to replace, filters to change, O-rings to leak or air bleeding requirements.

E-drive actuators can save a great deal of energy in many systems as well. The servo only draws power when motion is required, whereas hydraulic power units frequently present a continuous demand. Electric actuator systems are reliable, with no risk of messy or energy consuming leaks.

E-drive actuators can be used to replace hydraulic and large pneumatic cylinders any time a performance improvement is required. In clamping applications, E-drive actuators with servomotors can allow the use of different clamping pressures for different parts. When changing setups, the units can have a rapid mode while retaining smooth controlled motion as they near their destination. In pressing applications, the servo control allows monitoring of force throughout the stroke of the unit. In complex applications, hold pressure can vary over time, per a predetermined curve.

E-drive actuators can replace hydraulic units ranging in size from 200 pounds up to 33 tons. Just like hydraulic cylinders they can be mounted in a variety of ways, including foot mounts, face mounts, as well as clevis and trunnions. Rods are available with threads, holes or rod end bearings. They’re built to withstand difficult environments, units with T316L stainless steel are good up to IP66 with an air purge.

If you have a linear force application that could benefit from improved performance, E-drive linear actuators can be a great solution. Contact your Revere Electric Motion Specialist or Account Manager to find out more.

E-drive Products

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Have you Ever Wondered Why There is Tremendous Energy Savings Using Variable Frequency Drives (VFD) on Fan and Pump Applications?

2017-03-10T22:24:28+00:00

Why Variable Frequency Drives

Did you know that manufacturers spend over $30 Billion on electricity annually, with motors consuming around 64% of the electrical spend? Another fact - half of those motors are controlling fans & pumps. As a result, end users are turning to VFD’s as an alternative to fixed speed controllers and throttling methods, such as dampers & valves, to help negate the rising costs of energy.

Significant opportunities exist to reduce energy consumption by altering how the flow is controlled. This is where VFD’s and Premium Efficient Motors come into play. Controlling flow with speed regulation, rather than mechanical valves or dampers, provides a significant reduction in power required to run the fan or pump.

However, in many flow applications, a mechanical throttling device is used to limit flow. Although this is an effective means of control, it wastes mechanical and electrical energy. The graph below shows you the energy usage using both a damper/valve and a VFD. The damper/valve’s energy usage is shown as the upper curve in the graph below, while the lower curve demonstrates energy usage when using a VFD. Because a VFD alters frequency of an AC motor; speed, flow and energy consumption are reduced in the system. The energy saved is represented in the green shaded area.

Affinity Laws - Fans

Centrifugal loads offer the greatest potential for energy savings by using VFD’s to control speed. Energy consumption in these load types follow the Affinity Laws, which means:

• Flow is Proportional to Speed
• Pressure is Proportional to the Square of Speed
• HP is Proportional to the Cube of Speed

That means if an application only requires 80% flow, the fan or pump will run at 80% of the rated speed and only requires 50% of rated power. In other words, reducing speed by 20% requires only 50% of the Power!

Using VFD’s on centrifugal fans takes advantage of the fan curve that occurs when the speed of the fan is changed and can be quantified with the affinity laws:

Affinity Laws - Pumps

Varying the speed on a centrifugal pump takes advantage of the change in pump characteristics when the impeller speed is changed.

Thus, applying a VFD to the pump allows control of the pump’s speed electrically, while only using the energy needed to produce a given flow. Also, the pressure is reduced, which helps reduce the mechanical stresses generated by throttling devices.

The affinity laws below are used to predict the operation of the pump at any operating point based on the original pump characteristics:

Peak Demand Charges

One final note is that adding a VFD to your system gives you the ability to reduce peak demand charges on your electrical bill. VFD’s affect peak-demand electricity prices that the utility charges to companies that exceed a preset limit; such as when motors started across-the-line draw large peaks of current.

VFD’s help reduce the peaks by supplying the power needed by the specific applicaition, and gradually ramping the motor up to speed to reduce the current drawn.

Resources

Here are some resources for VFD's:

Rockwell Automation Energy Saving Calculator

RA Energy Savings VFD White Paper (Centrifugal Fans)

RA Energy Savings VFD White Paper (Centrifugal Pumps)

Want more information? Contact Your Revere Account Manager or fill out our on-line Solutions Inquiry Form .