Under the Enclosure with eMotors Direct

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eMotors Direct brings you Under the Enclosure, a podcast on electric motor education. Learn about supply chains, how motors run, implementing preventive maintenance strategies, saving on downtime, and tons more. Join us each week for new episodes.

  1. 07/12/2022

    Do You Need an IEEE-841 Motor?

    Since the invention of the AC electric motor, motor manufacturers have been innovating to make the motor more resilient, more capable, and more energy efficient. Some industries have benefitted from these innovations more than others, especially where a standard efficiency motor just doesn’t quite cut it. Heavy, harsh, contaminated, severe-duty environments need higher reliability and better efficiency from their electric motors. Industries like Oil & Gas, Chemical, and Pulp & Paper, face the problem of excessive unplanned downtime due to early motor failures. That is, until the release of the IEEE-841 motor standards in 1986. Who is IEEE? The Institute of Electrical and Electronic Engineers (or IEEE) is the world’s largest technical professional society. It leads the development of industrial standards for telecommunication, electric power, and consumer electronics. History of IEEE Though electricity had technically been around for a while already, it wasn’t widely adopted by society until the late 1800s. And in 1884, in the state of New York, the IEEE was founded to encourage the innovation and development of electrical products and components. The early leaders of the professional organization include some major names like Thomas Edison and Alexander Graham Bell. The membership of IEEE consists of Engineers and Scientists at its core, however, it also encompasses Computer Scientists, Software Developers, IT Professionals, Physicists, and even Medical Doctors. Now, in 2021, the organization has a portfolio of almost 1200 electrical standards for various industries, with many more currently under development. Included in these standards is the IEEE-841 standard. What is IEEE-841? The IEEE-841 standard was developed in 1986 for the continuous and severe-duty operations of the Petroleum and Chemical industries. The environments and processes found within this industry place great mechanical stress on equipment and are often full of contaminants like dirt, dust, water, ice, etc. A standard efficiency electric motor will fail long before its expected lifespan due to stress and contamination, with bearing failure due to lubricant contamination being the number one cause. The goal of the IEEE-841 motor standard was created to improve the reliability, efficiency, and performance of severe duty motors in this industry, effectively helping to prolong the life of the motors and decrease unwanted and costly downtime. The standard has now been widely adopted by other industries, such as Pulp & Paper, and has been globally accepted for electric motors used in the most extreme conditions. What Type of Motors Does IEEE-841 Cover? The IEEE-841 electric motor standard covers “premium-efficiency totally enclosed fan-cooled (TEFC) and totally enclosed nonventilated (TENV), horizontal and vertical, single-speed, squirrel cage polyphase induction motors, 0.75 kW to 370 kW (1 hp to 500 hp), and up to 4000 V nominal, in National Electrical Manufacturers Association (NEMA) frame sizes 143T and larger, for petroleum, chemical, and other severe-duty applications (commonly referred to as premium-efficiency severe-duty motors).” (https://standards.ieee.org/standard/841-2021.html) However, it does exclude sleeve bearings and some additional features which are specific to explosion-proof electric motors. No matter the manufacturer, every single motor advertised as IEEE-841 must meet the specs set out by the standard, with many of them featuring designs and testing that goes above and beyond what is set out by the standard. Additionally, there is a standardization of motor sizes across manufacturers. This allows for easy interchangeability which is convenient when you have difficulties sourcing a certain brand. IEEE-841 Specifications As of the most recent update published on May 28th, 2021, these are the most notable specifications set out by the IEEE-841 standard: Service conditions must be: -25°C to 40°C ambient temperature A maximum altitude of up to 1000m Humid, corrosive, or salty environments Full voltage starting Class I Division II hazardous locations Standard 5-year warranty Totally enclosed fan cooled (TEFC) or totally enclosed non ventilated (TENV) enclosure IP55 protection rating NEMA Design B torque and current characteristics and starting capabilities A minimum of a Class F insulation system Not to exceed a service factor of 1.0 Allows for long-term reliability A short-term overload of no more than 15% is still allowed Stainless steel nameplate Specialized bearings Inner bearing cap L-10 lifespan Cast iron frames, end shields, fan covers, and terminal boxes (corrosion resistant) Specified efficiency ratings based on motor size/guaranteed minimum efficiency Improved seals Corrosion-resistant paint and internals such as stator, rotor, and shaft surfaces Reduced system vibration (.08 ips) Non-sparking fan Must contact the manufacturer when pairing with a speed drive – issues with harmonics and voltage spikes It’s important to note that even if the motor meets and exceeds these specifications, regular maintenance is required to meet the premium efficiency standards. The Dollars and Cents of It When searching for your IEEE-841 electric motor, you may find that the initial purchase cost is higher than that of a similar motor at standard efficiency. So, why invest? When switching to IEEE-841 motors, there is an up to 50% decrease in early motor failures. This equals cost savings due to less unplanned downtime, spoiled product, and wasted employee resources. Less maintenance budget will be directed to motor repair and replacement costs. And an increase in power efficiency equals large cost savings on power consumption over the motor’s lifetime. Summary So, should you consider an IEEE-841 electric motor for your application? If your electric motors will be operating in harsh and contaminated environments and placed under significant mechanical stress, then yes, you should. You’ll benefit from reduced downtime, increased reliability, low noise levels, and high efficiency, all resulting in cost savings for your business.

    8 min

  2. 02/28/2022

    Selecting the Right Controls for Your Electric Motor

    Whether you’ve already purchased an electric motor or are still in the planning stage, familiarizing yourself with the different electric motor controls can help you maximize the productivity and efficiency of your operation while extending the service life of your motor, electronics, and all the mechanical assets connected to your motor. Motor control is any switch or device used to start, stop, or control the speed of an electric motor. Because each application has unique objectives and operating parameters, it is often necessary to control the motor's speed and protect it from a variety of risks specific to your usage. To select the right control for your application, the first step is to take a look at what you need the motor to do, and then select the motor control that gives you the capabilities you require. Soft Starters If your motor will be started under substantial load, especially if it occurs frequently, there is a high risk of damage from the electrical and mechanical shock that occurs when full power is applied to a motor at standstill. Depending on the load, a motor may experience a current surge up to five times the rated level at start-up, which can damage sensitive electronics and overheat the motor windings, drastically reducing its service life. This current surge also makes the motor accelerate suddenly, causing mechanical shock that can damage the motor bearings, gearbox and driven load. Over time, this will greatly increase maintenance, operational downtime, and parts replacement costs. It is highly recommended to install a soft starter to safely manage your motor's start-up process if your motor is started under a substantial load. The soft starter ramps up the power to the motor slowly, alleviating current surges and preventing overheating in the windings. This means that your motor will accelerate slowly and smoothly, protecting the motor, gearbox and load. You can also customize the soft starter's start-up parameters, including the time it takes to reach full speed, to suit your project needs. When your electric motor is required to run at full speed all the time, a soft starter may be sufficient. However, to precisely control and manage your motor's speed during all phases of operation and respond to changes in operational conditions, speed control is necessary. Speed Controls Speed controls enable your electric motor's speed to be continuously adjusted to meet the requirements of your operation, giving you the ability to maximize efficiency and performance at all times. Speed controls can replace soft starters to safely bring an electric motor up to speed, maintain a specific speed or adjust to changing circumstances. They are often capable of providing dynamic braking, which is useful for quickly and smoothly bringing a heavy load to a stop. AC and DC speed controls operate on different principles, but they are designed to achieve the same result. AC motor speed controls are commonly divided into two categories: Variable Frequency Drives (VFDs), and Vector Controls, also known as Field Oriented Controls (FOC). VFDs manage the speed of the motor by modifying the frequency of the power supply and are the most common and cost-effective way to control the speed of an AC motor. However, they lose precision at lower speeds and are unable to create holding torque in a motor. Vector Control drives enable the speed of an AC motor to be precisely controlled over the entire speed range, even giving a motor capability to provide full torque at zero speed (holding torque). They achieve this by managing the motor's speed and torque separately, using a sophisticated control algorithm to produce the desired output. This enables servo-like control of an AC motor, a capability that was previously only available with DC motors. Vector Control drives are generally more expensive than VFDs, but their precise speed-control capability is essential for many finely-tuned, responsive electric motor applications. A special Vector Duty or Servo motor is needed for this type of drive. DC motor speed control is much simpler, as it only requires management of the input voltage, which is usually achieved using a PWM voltage regulator. DC speed controls also provide good precision over the entire speed range of the motor. Magnetic Starters A magnetic starter is a device that enables an electric motor to be started and stopped safely, especially when operating a heavy load. Magnetic starters offer controls for the operator and safety protections to prevent damage to the motor in case of overload. Magnetic starters consist of an electromagnetic contactor or switch and a thermal overload relay. The relay is usually closed manually by the operator pushing the start button. It is then held in a closed position by an electromagnetic force that can be automatically cut off when a hazardous situation is detected. The relay opens when excessive current passes through or overheating occurs, opening the switch and cutting off power to the motor to protect it from damage. If you start your motor with a heavy load, or it experiences intermittent high load during operation, it is recommended to use a magnetic starter to protect your motor from damaging surge currents. Summary Selecting the right motor controls gives you the capability to fine-tune the productivity of your application and protect valuable assets from electrical and mechanical damage. Here at eMotors Direct, we offer a comprehensive range of electric motors, gearboxes, and motor controls, giving you the components you need to build a complete package that meets all your performance objectives.

    7 min

  3. 01/14/2022

    The Future of Supply Chain Management

    Regardless of industry, modern businesses are moving from an outdated linear supply chain model to a new paradigm that leverages technological tools to improve visibility, forecasting, and stock management. Let us introduce you to the key technologies and practices driving this shift and what they can offer for you and your business.

    7 min

  4. 12/20/2021

    What You Need to Know About Gearbox Service Factor

    Service factor plays a crucial role in a long-lasting, reliable gearbox. Service factor is a way to measure how well a gearbox or a gearbox motor will handle specific demands and operating conditions, depending on the application. Let's take a look at why the gearbox service factor is essential, what it means, and how to optimize it for your requirements. Why Is Gearbox Service Factor Important? When choosing an industrial gearbox, it's essential to account for typical usage and operating demands. Doing this will enable you to select a gearbox that won't experience rapid wear and tear or premature failure, costing your business lost productivity and parts replacement. Two electric motor drives of the same size doing the same primary function may be subject to entirely different stress levels when operated in other conditions. Especially in harsh industrial environments, it can be challenging to predict the maximum stress levels that a gearbox will experience. Gearboxes that start and frequently stop, cyclic loads, high peak loads, vibration, high duty cycles (i.e. running 24 hours/day), and high ambient temperatures will experience a shorter lifespan. High-stress environments greatly accelerate the average rate of wear and tear. This massive usage results in a service life that is much shorter than expected. Typically, choosing the correct gearbox designed for higher horsepower applications extends its life span exponentially. But higher horsepower gearboxes are more expensive, so you may be wondering how much oversizing you need for your application. To answer this question, let's first examine what gearbox service factor is. What Is Gearbox Service Factor? The gearbox service factor is the ratio between the horsepower that a gearbox is rated to handle and the horsepower required for the application. In practical terms, it defines a performance safety margin that may be required by incredibly demanding tasks to help ensure long-lasting and trouble-free operation. For example, a service factor of 1.0 means that a gearbox only meets the application's design horsepower requirements, without any safety margin. A service factor of 2.0 indicates a gearbox that can handle double the required application horsepower and is highly oversized for the task. The gearbox's service factor directly impacts the durability and resistance to pitting and bending fatigue of the gear teeth. As a general rule, the gears' longevity is proportional to the increase in service factor raised to the 8.78th power. For example, a 30% additional service factor will result in a 10x increase in the gears' lifetime. But how exactly is the service factor calculated for different types of gearbox applications? How Do I Calculate My Gearbox Service Factor? To choose the right gearbox, calculate the service factor you require and then match it to the rating on the gearbox to determine if it will be suitable. Calculating the service factor required of a gearbox is not an exact science. Numerous operating conditions have different impacts on how well the gearbox will perform. The gearbox properties, including gearing, the construction materials, bearing quality and design characteristics, affect its ability to withstand its demands. Calculating the service factor is based on practical experience guidelines rather than empirical formulas. The American Gearbox Manufacturers Association (AGMA) provides widely used standards for determining a gearbox's service factor. These are guidelines that primarily consider the type of application and the duty cycle to provide a good value based on gearbox manufacturers' extensive experience supplying different industries. Manufacturers use these guidelines to determine the service factor rating for a gearbox used in a specific application. For example, for typical industrial tasks, a value of 1.4 is adequate. However, this rating can increase depending on how long the gearbox is in use and load characteristics. Suppose your gearbox will be operating in exceptionally stressful circumstances, or you're unsure of the operating conditions. In that case, select a higher service factor, or consult with a trusted gearbox supplier to determine whether it can handle the demands you'll put on it. What Is Gearbox Service Class? Many manufacturers use the concept of service class rather than a service factor value to simplify matching a gearbox to an application. A service class essentially corresponds to a range of service factor values, and each service class is around a commonly used service factor. Because calculating service factor isn't precise, using a service class instead can be more useful than a numerical value and provide a small margin of safety when selecting the right gearbox for the task. There are three main service classes in common usage. Service class I corresponds to a minimum service factor of 1.25. Service Class II corresponds to a minimum service factor of 1.40, and Service Class III corresponds to a minimum service factor of 2.0. Class I gearboxes would be used in typical industrial tasks, while Class III gearboxes uses would be in a very heavy-duty application that requires exceptional resilience. Summary Determining a gearbox's service factor is a crucial step in selecting one that will perform reliably and help ensure your application's lasting productivity. To get started building your perfect gearbox, visit our Gear Reducer Builder, or get in touch with us today to speak with our experienced team who will help you find the right gearbox for your needs.

    7 min

  5. 11/19/2021

    Electric Motor Safety

    Maintaining a safe work environment is paramount in industrial settings that involve high-voltage infrastructure and rapidly moving components. Proper electric motor safety is an essential step toward achieving trouble-free operation. Safety practices span across motor installation, everyday operation, and maintenance. It is necessary to develop and consistently follow proper safety procedures during each phase to achieve the best outcomes for your company and personnel. With the right approach, the risk of accident can be minimized, and a safe and productive working environment maintained. Motor Installation Safety Before installing a motor or developing electric motor safety procedures for your application, it is essential to become familiar with local and national safety codes related to your industry, as well as risk factors specific to the type of motor you have purchased. Please read the information provided by the manufacturer and always follow their recommendations. After developing comprehensive safety procedures for your operation, ensure that all operators and technicians involved are familiar with the procedures and apply them consistently. Find manufacturer technical specifications, data packages, warranty policies, features sheets and dimensional drawings to inform your safety procedures for motors on our product pages. Following the right steps during the installation of the motor helps prevent accidents that can cause injury and damage to infrastructure. Before installing the motor, inspect it thoroughly for defects or damage. If any issues are found, contact the seller before commencing installation. To reduce the risk of accident, check that the motor characteristics are adequate for the requirements of the application and that the voltage and connections on the motor match the power supply. When installing the motor, ensure that it is properly grounded and all connections are tight. This helps protect against electrical shock if the motor connects with the skin. Install all necessary safety measures such as thermal protection and electrical fuses, which protect the motor and prevent potential accidents such as fires caused by overheating. Ensure that the motor is securely mounted and properly aligned and connected to the load. Before start-up, it is advisable to run the motor in-place without a load to ensure that it has been installed correctly. This is a good time to review safety procedures for the operator and relevant personnel, including start-up, shutdown and emergency stop procedures. During normal operation of the motor, including start-up and shutdown, it is essential to develop consistent procedures that protect the safety of not just the motor but any personnel in the area. When starting a motor, make sure that all personnel in the area are alert and aware of it. Motor Operation Safety One of the best ways to spot problems with a motor in advance is for operators to use sight, smell and temperature to detect abnormal circumstances. However, this can be dangerous unless operators are properly informed. A motor's surface can be extremely hot during normal operation, especially after sudden changes in the load that draw unusually high current, and this temperature can persist well after the motor has been stopped. Correct safety gear should be used around running motors, and fingers and other objects kept away from ventilation ports and other points of entry into the motor. Everyone should keep a safe distance from moving or rotating components of the motor or driven load. When power outages occur, make sure that the motor power is cut off so that it does not start unexpectedly when power returns. Motor Maintenance Safety Whether routine or not, electric motor maintenance involves repeatedly handling and testing the motor. Maintenance personnel work near hot and rapidly moving components. Besides being qualified to disassemble and service the motor, maintenance personnel should be trained in proper power lockout procedures, safety gear, first aid and any relevant safety codes. This ensures that maintenance is a low-risk operation and productivity can be restored as quickly and safely as possible when a fault occurs. Locking out power before working on the motor is extremely important, and it is not enough to simply switch it off. Power can be suddenly and unexpectedly restored if the motor was stopped by a thermal protector, which can automatically re-connect power when the motor has cooled down. The motor may also be inadvertently switched on by someone unaware. Proper power lockout involves physically locking the main power switch in the off position, for example, by enabling each technician to apply their own padlock before working on the motor. The main power switch should also be clearly labelled with a warning to ensure that operators know that maintenance is being performed. Before handling the motor, ensure that the work environment is safe and that the motor has been fully de-energized. Capacitors can store a lethal charge and must be properly drained if they are to be handled. Ensure that the motor has cooled down sufficiently so that it does not present a risk of burn. Check the work area for pools of liquid or leaked lubricant, increasing the risk of an accident. Summary Prioritizing personnel safety by developing and adhering to strict electric motor safety procedures helps ensure that operators and technicians carry out their jobs smoothly and effectively, maximizing productivity and reducing the impact of maintenance schedules on your business.

    7 min

  6. 11/05/2021

    Selecting Electric Motors for Hazardous Locations

    Electric motors are often required at potentially explosive or flammable sites, such as chemical plants, coal mines, or petrochemical plants. Accidents could result in damage, injury, or loss of life. This makes it vitally important to select a motor that won't create an ignition source. Let’s take a look at the four key criteria used to classify different types of hazardous locations and how electric motors are designed and rated to operate safely within them. Understand The Hazard When selecting a motor for a hazardous location, the first step is to classify the site according to the standards that apply in your local area. In the US, hazardous location classification is determined by the National Electrical Code (NEC), while the Canadian Electrical Code (CEC) applies in Canada. In practice, site classification is complex and requires a thorough inspection and analysis of every aspect of the motor's environment. Consult the relevant safety authorities in your local area for detailed guidance. The following sections will give you a broad overview of the four main criteria used. 1. Class The Class of a hazardous location describes the form that the principal hazardous material takes within it. There are three Classes, in order of highest to lowest risk of ignition. Class I locations contain highly flammable gases and vapours in the atmosphere, which could be explosive when ignited. Examples include petroleum refining plants, gas plants, spray painting facilities and refuelling areas. Class II locations contain combustible or electrically conductive dust particles in the air. Materials such as coal dust or flour and conductive particles such as aluminum and magnesium dust can become highly explosive when dispersed in the air at sufficient concentrations. Class III locations describe environments where combustible material is present in a larger particulate form, such as filings and shavings, usually settled on surfaces. Examples include industries where the processing of wood or textiles takes place. 2.Division The Division of a hazardous location describes the conditions under which the principal hazardous material is present, and there are two divisions. Division I locations designate areas where the material is present under normal operating conditions, either as part of the process itself or during a scheduled activity such as maintenance. Division II locations are those where the material is exposed only under abnormal conditions. The material will usually be present in a contained volume such as inside sealed pipes or tanks, potentially coming into contact with the motor only during an accident such as a rupture or leak. 3. Group The Group that a hazardous location belongs to represents the behaviour of the principal combustible material after ignition. There are seven Groups labelled from A to G. Groups A, B, C, and D describe flammable or explosive gases, vapours, and liquids, in order of highest to lowest risk. For example, acetylene, a particularly volatile gas that burns intensely, belongs to Group A, while Group D contains the less dangerous ethanol. Groups E, F and G contain combustible dust that would create a Class II hazard in order of higher to lower risk. Materials range from aluminum dust in Group Eto corn, sugar and wheat flour in Group G. 4. Auto-Ignition Temperature It is important to obtain the Auto-Ignition Temperature (AIT) of the hazardous materials in the vicinity of a motor. This is the minimum temperature at which a material will ignite independently, without any other ignition source. As you will see in the following sections, this is a key part of determining whether a motor is suitable for the site. In practice, the AIT value is not simple to obtain, as it depends on environmental factors such as oxygen concentration and environmental pressure. Mixtures of several different materials can complicate this step further, and a conservative estimate may be required. Choosing A Motor Once a site has been classified, it is time to choose a suitable motor. Let’s look at the types and ratings of electric motors designed for hazardous locations. Motor Ratings Hazardous location motors usually come with a rating for the Class, Division, and Group for which they are suitable. For a long time, only Division I motors were rated, so many motors do not have a Division rating as they were rated for Division I locations by default. Division I motors can operate in Division II locations but may be over-engineered and unnecessarily costly compared to Division II rated motors. Electric motors also come with a T-code rating, which specifies the maximum temperature that any part of the motor surface that might become exposed to a hazardous material will reach, including in the event of burnout, power overload or locked rotor. This temperature rating must be compared to the AIT of hazardous materials at a site to determine if the motor surfaces pose a risk of ignition. Motor ratings must be authorized by safety authorities such as the Underwriters Laboratories (UL) in North America or the Canadian Standards Association (CSA). Explosion-Proof Motors Explosion-proof motors, which are a requirement for Class I, Division I locations, must be able to contain an internal explosion of a specified hazardous material without creating an ignition source for the environment around them. This is based on the assumption that over some time, the gases and vapours in the atmosphere around the motor could make their way inside, coming into contact with internal elements that could produce a spark or generate excessive heat, especially during a fault. Explosion-proof motors are designed with thick, hardened cases to contain the pressure of an initial explosion, and they must allow hot gases to escape in a controlled way that does not create an ignition source. To do this, they use flame paths, which are long, narrow corridors through which burning gases can escape while being cooled to a safe temperature. Flame paths are usually built into the shaft or body of the motor. Division II Motors These can often be regular TEFC motors that have been CSA approved for use in Division II areas. They must include a secondary nameplate with the CSA rating, Class/Division/Group rating and a Temperature Code. Dust-Ignition Proof Motors In Class II locations, where the hazardous material is present in the form of airborne dust, a dust-ignition proof motor is required. This type of motor features dust-proof seals and bearings that prevent dust from entering the motor altogether. It is important to determine the T-code rating of dust-ignition proof motors properly. They often accumulate a layer of dust on the outside of the motor body that inhibits cooling and increases the surface temperature. Using VFDs In Hazardous Locations Variable Frequency Drives (VFDs) modify the frequency of an AC power supply, enabling speed control of AC electric motors. However, they often create extra heat inside the motor due to the creation of harmonic frequencies in the motor windings. Additionally, when VFDs are used to run a motor slower than the motor’s base speed, it can greatly affect a shaft-mounted fan's ability to provide cooling. Explosion Proof Inverter duty motors designed to work with VFDs while mitigating these heating effects are available. It is important to keep in mind that these motors must meet the Division, Class, Group and T-code ratings of the area and be rated for VFD use. Summary Now that you are familiar with the key concepts used in hazardous location classification, as well as the motors designed for different types of hazards, you have taken the first step toward selecting the right electric motor for your needs. https://www.emotorsdirect.ca/motors/explosion-proof

    9 min

  7. 10/29/2021

    How to Select Your Next Industrial Motor

    Regardless of the application, you and your team need to depend on your electric motor to operate consistently. Not all industrial applications are the same, but you can determine which motor will be best suited for your job by using this checklist. Consider these six factors when selecting your next industrial motor: 1. Size and Power 2. Reliability 3. Durability 4. Cost-Effectiveness 5. Precision 6. Safety By understanding these characteristics and why they are required, you can select a motor that will offer cost-effective performance over its full-service lifetime. From food processing to chemical manufacturing, this checklist applies. 1. Size and Power Industrial applications often require large, powerful motors capable of delivering high productivity over many hours. In these conditions, an electric motor that isn’t adequately sized will quickly deteriorate and wear out, causing downtime and loss of productivity while incurring a replacement cost. When choosing an industrial motor, confirm it’s rated for the power required during the most intensive part of its operation, typically during acceleration and peak load times. If the required speed is lower than the motor’s base speed, a gearbox solution allows for a smaller, more cost-effective motor operating at a higher efficiency. Industrial motors' duty cycle can be very high, especially when they’re the primary component in an operation. Ensure the rated duty cycle of the motor can be operated for its condition, or the motor will experience overheating and shorter service life. 2. Reliability Industrial motors are often utilized in high-use applications that depend on consistent performance and productivity. By selecting industrial motors that are reliable and require minimal maintenance, plants can save on unplanned maintenance costs. The use of brushes in the commutator of a motor can become problematic in these conditions, as the brushes quickly wear down and require periodic replacement that causes significant downtime. Because of this, brushed DC motors can be less reliable and potentially unsuited to high duty-cycle operations. As an alternative, AC induction motors have a simpler, brushless, low-maintenance design that is well suited for intensive industrial use. Please look at our AC & DC Motor Speed Control to learn about the difference in controls for both motors. If a motor requires regular maintenance, ensure it’s easy to dismount to reduce the downtime of the application. 3. Durability Motor environments often contain pollutants such as moisture, dust, oil, and corrosive chemicals. To maintain performance, the motor must be able to operate effectively in this environment without becoming damaged. The crucial factor in a motor's durability is its enclosure, which protects the vulnerable windings from encountering harmful pollutants. Open Drip-Proof (ODP) motors should only be used in clean, dry climate-controlled environments, as they provide little protection against airborne contaminants. For highly polluted environments, Totally Enclosed Fan Cooled (TEFC) motors are a great option, as they prevent the free exchange of air from the interior to the exterior motor body. Washdown duty motors use TEFC enclosure to protect the motor from regular washing. To gauge whether an enclosure provides enough protection, its IP (Ingress Protection) rating should match or exceed the conditions that the motor is subjected to. 4. Cost-Effectiveness In many motor applications, the cost of the motor is not the only consideration. Depending on the job, the costs may include the electric motor, gearbox (if required), and any other peripherals such as speed control, which are required for the motor to perform its function. The AC induction motor is the most cost-effective solution for medium to large applications that do not require precise speed control. If a speed control is required, consider incorporating this as part of your project budget and timeline, as speed controls can be complex to set-up with AC motors. For medium to large applications, the speed controller pricing is usually offset by the savings on the cost of the motor. DC motors are relatively expensive for their complex designs in medium to large applications. Speed control is simpler compared to AC motors, especially for smaller applications. They can effectively compete in terms of the total cost of the motor solution. 5. Precision Many industrial applications such as robotics, actuation, and manufacturing automation require a different kind of motor solution that performs complex tasks consistently at high precision. The two main types of motors used in these applications are stepper motors and servo motors. Stepper motors rotate a fixed amount known as a ‘step,’ providing holding torque when that step is reached. This makes them ideal for situations where the motor will rotate a specified amount and then come to a stop, such as in manufacturing and machine tools applications. Servo motors are motor packages with precise speed and torque control capable of precise complex-motion performance. DC motors can be effectively controlled over a wide speed range with a simple circuit, as they dominated the servo motor industry for many years. However, improved AC motor speed controllers, such as Vector Control drives, have made it possible for cost-effective AC motors to provide servo-like precision and holding torque. They are a great option for medium to large applications. 6. Safety Depending on your industry, a higher level of safety may be required for the motor environment. In the chemical and petroleum industry, where the atmosphere is volatile, an explosion-proof motor may be required by law. These motors can contain an internal explosion of a specified substance without igniting the surrounding atmosphere, providing much-needed protection to personnel and infrastructure in the vicinity. In food manufacture and processing, minimizing the risk of pathogens is a high priority. All the equipment, including motors, need to be regularly washed down and thoroughly cleaned. A fully enclosed washdown-duty motor would be ideal for this environment, with the physical exterior using approved paint or a paint-free stainless-steel body. Check out our Electric Motor Safetyarticle for additional tips on maintaining motor safety. Summary Industrial motors often face exceptionally tough operating conditions, and downtime can be very costly for the operating company and those dependent on the productivity of the application. When selecting an industrial motor, it is important to prioritize the key characteristics required for the conditions that it will operate in to ensure it provides long-lasting performance.

    7 min

  8. 10/05/2021

    Battle of the Brands: Leeson vs Baldor

    So, you’ve input the ratings you need your new motor to meet, and your choices are down to two motors. Seemingly identical, the ratings on the product data sheet match your requirements precisely. The only difference? One motor is a Baldor motor, and the other a Leeson. How do you make your selection between these two top brands? Below, we’ll cover the history of these manufacturers and how to choose the correct motor for the job. History of Baldor Two employees at St. Louis Electric Company saw a chance to upgrade the design of the electric motors their company manufactured. The two friends were Emil Doerr, the plant supervisor, and Edwin Ballman, a talented electrical engineer with an affinity for inventing. In 1920, they pooled their savings and leaped into entrepreneurship. Baldor motors was born. Baldor’s brand mission to “make a better motor” served them well as they grew bigger and bigger over the decades. The company only faced two years of losses in its century-long history. Coming off of one of those years (1960 due to the impending “Energy Crisis”), the company’s leadership looked at their product offering and knew it was time for a change. Baldor began to focus on offering services rather than just motors; instead of a small line of standard motors, they began to manufacture custom motors for various industrial purposes. By 1965, they had the widest range of motors on the market. The company always embraced change; they brought the electric motor industry to new heights and dominated the motor efficiency race. In 2011, Baldor was acquired by ABB Ltd. Their motors are still sold as Baldor-reliance, and the brand is held under the ABB umbrella. They are now headquartered in Fort Smith, Arkansas, with 15 manufacturing locations across eight states. History of Leeson A lot of people don’t know that the history of Baldor is also the history of Leeson. In fact, the two companies share family ties. In 1939, three of Emil Doerr’s sons created Doerr Electric, which was brought under the Emerson umbrella and eventually sold to Nidec. One of the sons who created Doerr electric was named Lee Doerr. Lee also had three sons, all just as passionate about motors as their father and grandfather. To continue the familial tradition, Lee’s three sons created Leeson Motors in 1972. Throughout the decades, Leeson Motors acquired four industrial manufacturing companies, and were eventually acquired themselves in 2000 by Regal-Beloit Corp. Leeson motors are still Leeson branded but are now manufactured and sold under the Regal-Beloit umbrella. Best Uses for Baldor Baldor motors are best known for their (link to energy efficiency post). Their line of Super-E® motors meets and exceeds the NEMA Premium® efficiency standards. The standard industrial motor sits around 88% efficiency, while the Baldor•Reliance® Super-E® motors are upwards of 94.5% efficient. Best Uses for Leeson Leeson motors have developed a reputation for handling the harshest conditions found in industrial applications. And you’ll also find that their warranty period can be almost double that of their competitors. Summary When it comes down to it, you can’t go wrong with either brand. Both are top manufacturers in North America, utilizing the latest in electric motor technologies. With decades of design evolution under their belts, either brand is a top choice if the motor has the ratings required for the application. Your choice comes down to brand preference and loyalty. Keep in mind that it’s a good idea to select one brand and stick with it. You can reduce your spares inventory and ensure you always have the right motor on hand by standardizing your brand selection.

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