"Drive" Down the Cost of Power Transmission

We have seen that high- and premium-efficiency motors can provide dramatic savings over the course of a year's electrical consumption. However, the transmission elements, such as gearboxes, belts, and chain drives are often even more important to conserving energy efficiency."Look what happens when you connect a high- efficiency motor to a V-belt input shaft, a worm gear, and a V-belt out...

11/01/2001


Sections:
Energy and Cost Savings
Recommendations


We have seen that high- and premium-efficiency motors can provide dramatic savings over the course of a year's electrical consumption. However, the transmission elements, such as gearboxes, belts, and chain drives are often even more important to conserving energy efficiency.

"Look what happens when you connect a high- efficiency motor to a V-belt input shaft, a worm gear, and a V-belt output shaft," Jan Lindholm, a SEW-Eurodrive Industry account manager, told us. "The motor has an efficiency of 90%. But when you add those drive elements to it, the efficiency drops to 64%. Replace the worm gear with a helical gear, and the overall efficiency rises to over 69%." (See Comparison chart).

"However," Lindholm told us, "if you can eliminate the two V-belts, replacing them with a hollow shaft helical gear, you boost the efficiency quite significantly. I like to show our customers that you can use a normal motor with an efficiency of 86.5% in combination with a hollow shaft helical gear and end up with an overall efficiency of 84% (Example #4). That's 20 percentage points higher than Example #1: the high-efficiency motor that's attached to the two V-belts and the worm gear reducer."

Energy and Cost Savings

How do these percentages translate to dollars and cents? Let us say the motors in question are 7.5-hp models running 24 hours per day, seven days per week. Within two years, Example #4 will have saved nearly $2,000 in overall costs over Example #1, including purchase cost and power consumption. (Figure 1)

Comparing energy costs over a 10-year period, Example #4 will save over $9,000. (Figure 2). $9,000 in energy savings from a single-motor drive system represents a substantial return on investment.

Recommendations

"I like to recommend hollow shaft helical gears," Lindholm told us. "This is a product we have offered for a long time. Worm gears are good reducers but they have much lower efficiency than helical gears. And the efficiency of a worm gear is not constant. A worm gear can have 60% to 65% efficiency at 1700 rpm, but only 40% to 45% efficiency at 100 rpm. Other factors must be taken into consideration, of course. Worm gears can handle shock load better than a helical gearbox. Many times, the selection of the reducer is based on space limitations. For a conveyor, a right angle reducer is preferred because it can be installed without any protruding parts. We can help with those decisions."

SEW-Eurodrive sales engineers can offer valuable expertise in the integration of all the components in your drive package. Call 1-800-601-6195 or visit www.seweurodrive.com .

Comparison of various reducer types with and without external transmission

Example 1

Example 2

Example 3

Example 4

High-efficiency motor 90.20%

High-efficiency motor 90.20%

Premium-efficiency motor 91.00%

Normal-efficiency motor 86.50%

V-belt input shaft 90.00%

V-belt input shaft 90.00%

Nema adapter on input shaft

Worm gear reducer 87.00%

Helical gear reducer 95.00%

Helical gear reducer 95.00%

Hollow shaft helical gear reducer 97.00%

V-belt output shaft 90.00%

V-belt output shaft 90.00%

V-belt output shaft 90.00%

Overall efficiency 63.56%

Overall efficiency 69.41%

Overall efficiency 77.81%

Overall efficiency 83.91%





No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
2016 Product of the Year; Diagnose bearing failures; Asset performance management; Testing dust collector performance measures
Safety for 18 years, warehouse maintenance tips, Ethernet and the IIoT, GAMS 2016 recap
2016 Engineering Leaders Under 40; Future vision: Where is manufacturing headed?; Electrical distribution, redefined
SCADA at the junction, Managing risk through maintenance, Moving at the speed of data
Safety at every angle, Big Data's impact on operations, bridging the skills gap
The digital oilfield: Utilizing Big Data can yield big savings; Virtualization a real solution; Tracking SIS performance
Applying network redundancy; Overcoming loop tuning challenges; PID control and networks
Driving motor efficiency; Preventing arc flash in mission critical facilities; Integrating alternative power and existing electrical systems
Package boilers; Natural gas infrared heating; Thermal treasure; Standby generation; Natural gas supports green efforts

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role of plant safety and offers advice on best practices.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
This article collection contains several articles on strategic maintenance and understanding all the parts of your plant.
click me