Motors are used in all industries. In fact, everything that moves and turns is propelled by an electric motor. From small, standard motors found in fans, pumps and conveyors to (very) large motors that drive wind turbines, for example. Large motors usually require customisation, as smaller ones are mostly mass-produced and widely used. Selecting the right motor for your application is a meticulous process, in which a wide variety of criteria play a role. We will list the most important steps for you here.
What do you need the motor for? And in what kind of production environment will the motor be used? The answer to these questions will provide initial guidance on what kind of motor is suitable for the specific application. Power requirements, speed and where the motor needs to be installed are other determining factors. What steps should you follow when selecting the appropriate small, standard 3-phase motor for your application?
The first step in choosing the right motor involves determining torque and revolutions per minute. You need this to calculate the desired power. That’s because the motor inside an application needs a certain torque and speed to cause a turning moment. Therefore, the questions you should initially be asking are: what do I need to move, how fast do I need to move it and how heavy is it? To further specify the function of the motor, it is also useful to know whether the motor is just intended to run something, provide constant speed or put something in place. The more accurately you can determine the function of a particular motor, the better the choice of motor type will be. After all, some motors are more suited to a particular function than others.
The next important step in the selection process is to analyse the production environment in which the motor will need to operate. Will the motor be used in a laboratory environment where nothing much happens, or will it be running in a setting where it is exposed to one or more production factors? Choosing the right engine depends on, among other things:
The next step is determining the installation space for the motor. In some production environments, this space can be quite limited. An example might be AGV systems (Automated Guided Vehicles). Although these should all be able to lift pallets, the space underneath is very limited. In principle, some motors have a higher power density than others. And one type of motor might also be more compact and deliver more power with the same design than another. If space is indeed a challenge, you could look into applying separate parts of a motor, such as a rotor or stator, separately. The benefit of an electric motor is that it comes in different designs and can therefore be mounted in several ways:
The design (or mounting method) is indicated by a European IEC34-7 standard code. This standard defines the dimensions of a motor. These include shaft diameter, shaft length, shaft height and bore spacing. This is particularly valid for standard induction motors. Other engines either follow no or a different standard (NEMA). So, if you have a standard induction motor that meets the IEC34 standard, you should select from electric motor suppliers that are able to supply these IEC34 standard motors.
The frequency of movement produced by the motor largely determines its lifespan. Are we talking about an application that needs to go back and forth once a day, or is it something that runs 24/7? An example might be brush motors. Although these contain brushes for transferring energy, they wear out as they are used more often. Brush motors are nevertheless a great solution for something that needs to move back and forth occasionally, as the brushes will last between 3,000 and 5,000 hours. They are obviously less suitable for applications that run continuously.
A motor converts electrical energy into mechanical energy. The efficiency between electrical energy and mechanical energy represents the efficiency of a motor. For example, car engines have very poor efficiency. You have to put a lot of energy into them to get back a certain amount of mechanical energy. Efficiency classes range from IE1 to IE4, with the highest number representing the most efficiency.
Applications involving the integration of a new motor may no longer use motors with efficiency classes IE1 and IE2. And from 2025, you will only be allowed to buy IE4 motors. Although these engines are more expensive, the extra costs associated with them are recouped in two years at most, and from then on you can start saving on costs. Companies don’t often see this investment in the short term; however, they usually take action when the current motor needs to be replaced, at which point they see that it can also save them money in the long run.
Steps 1 to 5 deal with the characteristics of the motor itself. But how should you control the motor? What kind of interface should the motor have with your system? If you have a system with a controller, and you want to be able to turn it on/off based on a particular output, or you want to have the option of checking the various statuses, so that you can continuously monitor the performance of the motor, the options in these situations are quite wide. There is plenty of choice between different manufacturers, where some have the option of hooking up to an existing system while others don’t. Here, customisation plays a major role.
In this context, the power system also comes into play. What kind of power system do I have? Can the motor be connected to the mains (AC)? Or is it a battery-powered system? If so, this will entail different demands being placed on the motor. A major trend these days involves controls being increasingly integrated into the engine. The benefit of this is that the whole unit is coordinated and compact. As such, the user doesn’t need to buy a separate control box with cables, which reduces the risk of malfunction.
So far, we have mostly talked about the motor and controls. But that's not all. Most motors have high rotational speed and low torque. As far as most systems are concerned, you want the opposite: high torque and low rpm. Similar to your bike and car, there’s a gear somewhere in between, and this usually comes with the motor. The same goes for the reduction gear, where you again have the same choices. Depending on the application, you should also assess which one is most suitable for it. Lifespan and noise are important in this respect. You can also expand the scope of your search by including the drive in the selection process; after all, even if the motor lasts for years, it won’t be of much use to you if the drive unit breaks down within a year. Selection is certainly important in this respect too; with drive technology often coming without maintenance, it simply has to last for a number of years.
ERIKS represents a number of major electric motor manufacturers. As a result, our range consists of motors that meet current standards and have the necessary quality so that they can be used in any production environment. We make calculations and specialise in programming drive systems so that we can provide our customers with the best possible advice when it comes to choosing a motor that best suits their application. We also create and manufacture completely engineered solutions ourselves. By getting us involved early on in the selection or design process, we will be able to develop solutions with you that lead to cost savings and more efficient production.
Want to know more about how to choose the best electric motor for your application and how ERIKS can assist you in doing so? Contact us - we are happy to tell you more.
Maintaining industrial and commercial machinery requires many tasks. One of the most significant responsibilities is inspecting, maintaining and repairing electrical motors. You need to ensure facility tools meet safety standards and efficiency requirements, and choosing a suitable electric motor is a key part of that job.
Electric motors power numerous industrial and commercial applications and support many functions, like powering machine compressors, pumps and tools.
However, not all electric motors are equal, and some suit specific applications better than others. Considering factors like speed, torque, duty cycle, load compatibility and maintenance requirements can help you select a compatible electric motor for your industrial facility.
Suitable torque is necessary for driving electric motor startup and acceleration speeds. Applications require varying amounts of force to start up and accelerate load to a specific rate in a set time. You’ll need to consider a piece of equipment’s torque requirements when choosing an electric motor to ensure it can operate without excessive strain.
Your electric motor’s output speed must be compatible with your needs. Some electric motors suit high-speed applications, while others are better for moderate- to low-speed processes. Your application might also require adjustable controls that accommodate specific increments. Understanding different motor designs and output capabilities is vital for selecting a suitable range for your applications:
Do you need an AC or DC motor? Selecting a suitable power source is vital for running your equipment effectively. DC motors allow for fine speed control since their rpm output is directly affected by the amount of voltage supplied. AC motors require a variable frequency drive for speed variation but offer greater efficiency. An AC motor tends to excel in low- to medium-speed operations, while DC performs better when higher speeds are needed.
Does the motor offer different speed ranges and control settings? Some applications require a definite operating speed, while others need adjustable rates. You can add a controller or drive to your DC or AC electric motor to manage torque and rotation. A controller can also regulate different application speeds, weights and loads.
The motor’s operating lifetime determines the life span of a product or tool. Consider how long you’ll need the motor to last and how much time and money you plan to put into maintaining it. Brushless DC and stepper motors have fewer wear components and tend to last longer, while brushed DC motors deteriorate more quickly.
The duty cycle determines how long the motor can run over production cycles. You might run applications continuously or over short periods. A longer run time will require a motor with a higher duty cycle to ensure you don’t lose power. You can use a smaller motor if you only need it intermittently and it will have enough rest time to return to ambient temperature.
The environmental temperature will affect a motor’s duty cycle, as the objective behind limiting run time is preventing overheating and any resulting damage.
The enclosure ranking depends on the conditions a motor must operate under. Consider the environment surrounding the installation — will the motor be exposed to moisture, dirt, debris or extreme heat? Neglecting to provide proper protection during installation is one of the most common causes of motor failure.
You’ll need suitable protection for your motor depending on your working conditions. For example, food and beverage industries might need stainless steel castings to protect machinery motors from spills, corrosion and wear.
Some electric motors can run on batteries or a power outlet. Depending on the facility, you’ll need to decide if you’ll connect a motor to the power grid, inverter or batteries. The voltage must be compatible with your motor if you use a wall socket or outlet. Smaller tools and lower power applications can use standard voltage, but you will likely need to draw more power for industrial motors.
Depending on your working conditions, a motor can require climate protection. Consider the temperature of the facility. Is it a hot or cold environment? Understanding the climate will help you select a motor with suitable materials or coverings.
Some applications require both backward and forward rotation. Some motors do not have multiple reverse or rotation capabilities, so be sure to choose a motor that can do everything your tasks require.
Electric motor capacity and size will impact operational efficiency. An electric motor must offer sufficient torque for your application’s load without generating more heat than the insulation present can handle.
A key factor in selecting motor size is whether you will be installing it permanently or in a system you plan to move often. You can get a bigger motor for equipment that will remain in one place, like a large lathe in an industrial building. Anything you need to transport often will call for careful consideration.
Whether noise is a concern will depend on where you’re using the motor. You might select a model geared for noise reduction if the installation will be in a public area like a hospital.
Motors have different maintenance requirements. Consider the motor type and if you can maintain and repair it yourself or need professional services. DC motors tend to be more challenging to maintain and require expert knowledge.
Having a way to collect data on motor performance can enhance your applications. With encoders or sensors, you can get feedback on how well the motor works and adjust speed and other settings for better performance. Data components offer diagnostic capabilities to indicate wear or damage so you can schedule maintenance, preventing breakdowns and downtime.
A motor’s operating costs depend on its life span, maintenance requirements and initial price. You’ll need to decide which model will offer the best value for your money or return on investment. Weighing potential costs is necessary before selecting an electric motor for your commercial facility.
Deciding on an electric motor for your industrial or commercial facility requires you to look at many complex factors. If you want to ensure you select the best model based on your unique circumstances, it’s best to consult a professional. Industrial Electrical Company specializes in various electric motor services, including installations, preventive maintenance and repairs.
Our certified technicians are experts in their craft. We’re also committed to delivering exceptional customer service, and we’ll answer your calls 24 hours a day. Whether you want us to evaluate trouble signs with an existing motor or assess your requirements and help you choose a new model, our team will make sure you have everything you need.
Contact us to learn more about our electric motor services.