A variable frequency drive often called VFD is a kind of motor controller that has the ability to drive an electric motor by changing its power supply of frequency and voltage. It has the ability for controlling motor ramp-up and ramp-down during beginning or end, correspondingly.
Although the drive controls the motor power supply's frequency and voltage, we often called it to speed control as it comes out as an adjustment of motor speed.
VFD saves energy and increase the efficiency of the system
In hybridization applications, VFD converts power
Match the drive speed to the process needs
Match the drive's torque or power to the process needs
Enhance the working environment
Reduces noise levels
Lower mechanical stress on machines to enhance their lifetime
Cut off-peak use to avoid peak-demand costs and reduce the essential motor size
Additionally, drives manufactured today integrate networking and diagnostic capacity to enhance control performance and boost productivity. Often, VFD is chosen as the controller in every motor-driven system because of its features such as intelligent motor control, energy savings, and cut down of peak-current drawn.
VFDs are commonly used for controlling fans, pumps, and compressors. 75% of all drives functioning globally all account for these applications.
Less complicated kinds of motor controllers are soft starters and across-the-line contactors. A soft starter refers to a solid-state device and offers a tender ramp-up to full speed during the setup of an electric motor.
An across-the-line contactor refers to a kind of motor controller generally applying the full line voltage to an electric motor.
What is the key benefit of using a VFD?
A VFD can change the power supplied to meet the energy necessity of the driven equipment, and thus it saves energy or optimizes energy use.
The drive can considerably cut down energy consumption as compared to DOL (direct-on-line) operation, in which the motor works at full speed irrespective of the demand. Drive can save power or fuel up to 40%.
Are VFDs useful for power conversion?
Yes, VFDs are useful in power conversion for hybrid systems utilizing battery storage.
How you will distinguish a VFD, a variable speed drive (VSD), and an AC drive?
There is no difference between a VFD, a variable speed drive (VSD), and an AC Drive, all are the same.
What are the types of VFDs?
There are different types of drives available as you can check out at CM Industry Supply Automation. VFDs are extensively used in industry. Single-phase VFDs and three-phase VFDs are available to match the requirement of the different applications. The only differences we can observe in drive types are the methods to control frequency and voltage; along with the harmonic mitigation technique.
Current source inverter, pulse-width modulation (PWM), and voltage source inverter are the three main variable frequency designs utilized in drives. However, the PWM technique is highly common. It just needs switching the power devices of AC drive inverter such as transistors or IGBTs (insulated-gate bipolar transistors) – start and stop many times, to make the suitable RMS (root-mean-square) voltage levels. Controlling and changing the pulses width is how PWM changes the frequency and voltage of the output.
Gears are mechanical components that have been used by mankind for a long time. These toothed elements have mechanical properties that are used to convey motion and power among machine components. From bicycles and cars to modern industrial machines, instrumentation, and equipment, gears find a wide range of applications in aircraft, automobiles, power plants, marine systems, and more! Earlier, these tools were a bit complex to manufacture. Thanks to the advanced CAD system and CNC machine system, the production of gears is more precise and faster than before!
Here, we’ll get you through the entire gear manufacturing process and the role of CNC machining.
What Goes into Gear Manufacturing Process?
Gears come in many configurations, i.e., spur, bevel, or helical gears. All these types of gear are generally found in aerospace, automotive, or other motor industries. They have applications in almost every modern machinery. Thus, gears should have robust construction and offer high efficiency, great performance, and durability. Based on these unique requirements, manufacturers use different materials to manufacture gears. Some gears are made of steel, while others are of non-ferrous materials.
Furthermore, gears are manufactured through many different processes, like Forging, Casting, Powder Metallurgy, or Blanking. Amongst these, Gear Machining is the most common manufacturing method.
Gear Machining: The Most Common Gear Manufacturing Process
Gear machining is a set of processes by which gears of different shapes are manufactured from raw materials. In this process, the material is filed and sculpted until the required shape and characteristics are obtained. Gear machining is divided into two categories-
Generally, cut gears are manufactured via a gear-generating method. In this method, gear cutting is done via a relative motion of a rotating cutting tool and rotational motion of the workpiece. Hobbing and Shaping are the two common gear generating processes.
Hobbing refers to a continuous machining process on a hobbing machine. A cutting tool called a hob is used to make a series of cuts into a workpiece. This method offers good precision when it comes to cutting gears, splines, etc. However, this process is limited to creating external gear teeth only.
Gear shaping uses a reciprocating tool called ‘shaper cutter’ to create a part. This process can be used to cut both internal and external gears. Moreover, it requires a small clearance; thus, it can be used to cut gears that hobbing can’t. This process is slow as compared to hobbing, though.
In this process, cutting tools with actual shapes (desired in the final product) are used. Broaching and Milling are the two most common form-cutting methods.
Broaching is the fastest method of machining gears. It is extensively used to fashion the gears into levelled structures by removing excess material from them. It redefines the odd shapes of gears.
The gear milling process involves the use of a milling machine for creating almost any type of gear. Traditionally, manufacturers used a form cutter for producing gears. This method is now outdated due to its low precision. However, recent CNC modeling improvements have empowered gear milling, resulting in the use of standard milling tools with sophisticated CAD programs.
What Is the Role of CNC Machining in Gear Manufacture?
Manual methods of the gear manufacturing process, like cutting or hobbing, have been relied on for years. In fact, knowledgeable and skilled operators were able to achieve fantastic results. But CNC precision machining has revolutionized the gear and spline business. Below is what makes custom machining ideal for gear part fabrication-
Improved Speed and Quality
With CNC machining, you get the same result as specified, at a faster speed. Unlike manual methods, the speed of production is high, streamlining the production process. Further, CNC machining offers a lucrative option for a larger production. Though a skilled operator can replicate the same quality, CNC machining lets you assess the production rates and quality better.
No Need for Prototype
With CNC machining software, one can visualize the finished products before they are made. A finished product designed on a computer eliminates the need for a prototype.
CNC machining, Machine tools control panel offers ways for monitoring the progress of gear manufacture remotely. Thus, manufacturers can keep track of their projects and keep an eye on every detail. Though it requires experience, the level of skills and overall user involvement is still less compared to the traditional gear cutting methods.
Precision is a paramount consideration when it comes to gear manufacturing. Factors like gear variations, high accuracy, etc., make the process a bit complex. However, by picking the right solution, the quality and productivity can be improved while saving a lot of time and effort.
Motor drives are the spine of a new global industry. They are often hidden but play a vital role in industries and our way to live a more sustainable life. Nowadays, the most frequent usage of drives is for the controlling of fans, pumps, and compressors. About 75% of all drives work globally on these applications.
Sourav (CEO of CM Industry Supply Automation) says Motor drives are also referred to as AC drives, VFD (variable frequency drives), adjustable speed drives, VSD (variable speed drives), and adjustable frequency drives, inverters, frequency converters, and power converters. By changing the voltage and the frequency of the power supply to an electrical motor, drives are able to control their speed and improve process control, cut down energy usage and make energy-efficient. In addition, industrial drives optimize the working of various applications that relies on electric motors.
Drives have the capability to control ramp-up and ramp-down of a motor while set up or discontinuing respectively. This reduces automatic stress on motor control applications and enhances ride quality in, such as elevators.
Motor drives are also useful for converting energy from natural and renewable resources such as the wind, sun, and tides, and spreading it to the electrical network or utilizing it for limited consumption. Industrial motor drives are also utilized to merge conventional energy sources and energy storage for creating total energy management solutions, in hybrid technologies.
Drives are a vital part of various industrial processes. They provide good energy efficiency, enhance productivity, and great performance for electric motors in various applications. However, when an industrial drive breaks down suddenly, it can bring working to a halt and cause many problems.
The best way is to prevent a breakdown before it takes place. During the life cycle of the product, this usually means usual preventive maintenance. However, for an industrial drive at the end of its life cycle, repair or replacement is a good solution to minimize the risk of breakage and accidental production shutdowns.
How old is your Industrial drive?
When you are thinking about whether to repair or replace the industrial drive, it is crucial to consider the drive's age and what's it phase right now. Lenze drive lifecycle falls into various phases. Since your drive passes on through each phase, parts become complex or not easy to obtain. Moreover, the advancement in drive technologies results in your application not having the latest features and functionality.
Do you want to know where your drives are within their lifecycle? CM Industry Supply Automation has access to the complete drive database of many brands such as Lenze, KEB, Siemens, Rexroth, Elau, ABB, Allen-Bradley, and more.
All you have to do is share the serial numbers of your drive population with us, so we will register them and tell you precisely where they are within their lifecycle.
How significant is your application?
Downtime of a significant application will cost you thousands of bucks in lost production and we know how crucial it is for you to get back up and operate as quickly as possible. The replacement may seem to be the easiest option, but it is always costly. VFD repair and Lenze Drive repair can save you lots of money.
Frequent Maintenance Prevent Frequent Breakdowns!
CM Industry Supply Automation recommends performance regular maintenance on industrial drives to prevent frequent breakdowns and keep them operating efficiently. Ask us about the Servo Drive Repair option that we have designed for your critical applications.
Get all industrial automation products sales & repair services. Call us for Lenze Drive, Keb Drive, Siemens, Allen-Bradley equipment sales and repair services.
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