Around the globe, Toyota are well known for being at the forefront of process innovation; setting high standards with a high level of attention to detail. Their newest production facility in the township of Caleras de Amexhe in Guanajuato, México is no exception to this rule. We're proud to say that the AuCom CSXi has passed the Toyota test, with multiple CSXi units already installed at the new facility that is expected to begin full-time production by the end of 2019.

Each vehicle manufactured by Toyota must go through multiple tests before going to the market. One of the most common tests consists of a water shower applied to the outside of the vehicle to verify that there is no ingress of water into the vehicle.

To perform this test, the vehicle is placed in a shower test room which sprays water at constant pressure through a hydraulic spray system divided into three sections: lateral (both sides), upper and lower (as shown in figure 1). Each section has an independent water distribution system, so it is necessary to implement a pumping system for each section.

Knowledge of expected motor start current and start duration is an important part of designing a functional and efficient system, especially when there are limitations to the electrical supply.

Mention ‘holistic’ and ‘eco’ in the same sentence and people will think you are talking environmentalism or personal health, but the two concepts are becoming synonymous with modern motor control strategies.

CAPIEL (the European Coordinating Committee of Manufacturers of Electrical Switchgear and Controlgear)’s recent position paper on taking an eco-smart approach toward the use of premium efficiency motors – “Ecodesign requirements for Electric Motors – Towards a System-Approach” - stated that ‘Real-life energy efficiency can only be achieved through a system-approach. Both motor and its control node must match the intended application requirements’.

Motors of all sizes and uses often need large amounts of energy when required to quickly accelerate to full speed and both soft starters and variable frequency drives can be used to reduce inrush currents and limit torque. The decision to pick one, however, is decided by the application, system requirements, and cost implications. It requires a holistic approach.

We are quite possibly witnessing the beginning of an electric motor market boom as stricter energy efficiency regulations are being rolled out around the world. The higher energy efficient standards were predicted to cause worldwide overhauls of newer motor technology, resulting in significant market growth over the coming years.

According to a market report published by Credence Research “Electric Motors Market – Growth, Share, Opportunities, Competitive Analysis, and Forecast 2015 – 2022,” the global electric motors market is expected surpass US$ 135 Bn by 2022.

IE3 motors are now mandatory in Europe for new installations between 7.5 kW and 375 kW, in line with many other jurisdictions in the world.

At the recent energy efficiency in motor-driven systems (Eemods) conference in Finland the new regulations were presented as necessary to help meet the EC’s 2030 target of cutting greenhouse gas emission levels by 40% compared to 1990 levels, as well as cutting energy consumption by 27% by that date. These proposed changes could affect up to 89 million motors and more than four million variable-speed drives sold in the EU every year.

The new EC regulations are expected to increase growth for the replacement market. The rise of industrialisation and the construction industry is predicted to contribute to an increase in the growth of premium efficiency motors.

With an estimated 80% of electric motor applications being fixed speed processes perhaps it isn’t surprising that variable speed drives are consistently being misapplied. Many motor driven systems are being designed with VSDs to add flexibility that isn’t needed, compromising efficiency while adding to capital and operating costs.

US-based JDA consulting engineers (now part of global consulting firm Exp Global.) offer an interesting discussion of this phenomenon in a blog on the Staticworx website. “As JDA's team commissions large, complex mechanical plants, we find more systems where the VSD is practically abandoned in place. Rather than providing the precise control of flow and pressure or reducing energy consumption and demand, the VSDs appear to be "stuck" at a single speed.”

The United Kingdom's Department for Transport this week unveiled a new strategy for the country that featured proposals for encouraging driverless cars, drones and even commercial spaceports.

Transport secretary Patrick McLoughlin was quoted as saying "Driverless cars and commercial space flight might seem like something science fiction, but the economic potential of the new technology is huge and I am determined the UK gets maximum benefit."

In the world of industrial motor control we need to deal with fact more than science fiction, but the pressure to automate and innovate is relentless. These trends, embodied in the concept of Industry 4.0, means we have to reimagine the role of established technologies in industrial applications, and that includes the application of soft starters.

A key to clear communication and interoperability is having a shared understanding of the meaning behind terms and phrases. 

The United States motor industry recognises the importance of nameplates using standardised jargon among all manufacturers and has been enforcing usage of the correct terminology for the past 90 years. Using the same terminology and education around the meaning of the terminology has paid off. Having a common motor nameplate language has helped make motors interchangeable and personnel able to correctly understand the specific features of the motor they are installing or replacing.

What are the trade-offs in oversizing a motor for your next application?

Oversizing motors for any particular application is becoming more popular, as engineers seek to provide some ‘insurance’ for a new system. Insurance against possible system failure (and resulting damage to their reputation), and insurance for unanticipated future demands on the application.

An Automation World study on oversizing has asserted that over half of engineers choose to over specify motors. It seems like a ‘no-brainer’ – put in place a motor with plenty of margin of error for rated load, and use a variable speed drive (VSD) to throttle it to meet the system’s actual power needs. Peace of mind guaranteed.