Enabling motor management to improve energy efficiency

Electric motors consume around 60% of the electricity used in manufacturing industries, and for heavy industries, this number increased up to 90%. Yet Schneider Electric believes modern motor management principles are not applied to help reduce electricity costs.

Industrial motor applications are widespread for conveyors, pumps, compressors, agitators, fans, and similar duties. Yet despite their importance, traditional motor management approaches often fail to optimise performance.

There is a tendency not to change a plant that is running, with support focusing on problem areas. But addressing unplanned motor downtime only addresses issues after incurring costly delays.

The challenge for operators is controlling motor energy costs whilst maintaining operational resilience. Motor failure and stoppage damage are expensive and a risk to people and the environment. One approach is to integrate motor control and protection solutions.

Robust communication between the motor and the automation systems plays an important role. Minimising instances of motor failure will reduce costs whilst increasing productivity. Moreover, as users track energy data from motors that are better aligned to duty, costs fall.

Migrating to advanced motor management

Machines are complex and use equipment from a variety of suppliers. By considering the machine as a whole and using fewer suppliers delivers efficiencies. Furthermore, it supports using automated configuration tools like EcoStruxure Motor Control Configurator. This simplifies how OEMs and panel builders generate quick and comprehensive solutions. These tools have been proven to reduce design and selection times by up to 40%.

For heavy industry applications, large motors have a bigger impact on electrical design. Selecting the optimal starting solution and transformer size are critical for power quality. Specifically, making the right early design decisions shape the installation evolution over time.

Gather energy performance data

Process oriented drives ATV600 and ATV900 offer improved intelligence and control of motors. They ensure operation at the motor’s best efficiency point to reduce energy use at least 30%.

Furthermore, TeSys Island intelligent motor starters, and digital load management solutions also contribute. They make it much easier to optimize machine performance. Each load feeder provides data to optimize the machine and the process. It also provides actual line current data.

They also offer machine builders the option of remote monitoring for installed devices. This provides users with access to a cloud-based predictive maintenance service.

Software analytics

Intelligent motor management means maintenance staff need not be near components to troubleshoot them. Pre-alarming and pre-set behavioural parameters help resolve abnormal operations before stoppages occur.

Data from EcoStruxure Asset Advisor also helps predict machine performance and maintenance needs. Advanced analytics help to improve TCO, with potential failure modes available from actionable web dashboards. Timeline reports and recommendations provide extra operational support for people on-site.

Developing an integrated motor management system in this way reduces costs, boosts energy efficiency and improves productivity.


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