Motor, Drives & Control System | Supplier & Contractor Malaysia

February 29, 2020

Although motors and drives may sound familiar and mistakenly associated with similar devices, it is not to be confused that they both are entirely different electrical devices with independent functions in accordance to motor drive supplier in Malaysia. A motor can be described as a mechanical and electrical device that generates the rotational or linear force used to power a machine; while a drive is the electronic device that harnesses and controls the power source transmitted to the motor. Unbeknownst to the general public, most tend to think that the speed of rotation of motors is solely controlled by the applied voltage and frequency of the source current, but the advent of electrical drives allowed the precise control and optimization of the motion and speed of an electrical machine. In short, the function of drives is to modify the power input to the motor in order to achieve the desired output for various kinds of process controls. Motors controllers and drives work collectively as an electrical control system to regulate motor speed, torque and position outputs with motor drive supplier Malaysia. The controller circuits are commonly integrated with the drives as a stand-alone unit in most applications, as such the terms motor drives and controllers are often used interchangeably. As a whole, a motor and drive form a drive system, whereby the electric motor is assembled together with a sophisticated control system that controls the rotation speed of the motor shaft. Modern technology has made the usage of these drives even easier with the help of a software interface. As drive systems consist of many intricate parts and components of varying specifications, it is best to consult a professional electrical contractor or drive specialist, such as Aathaworld for your power requirements.

Brief Introduction to Motor Types

The most common type of motors can be classified into AC and DC motors, and can be further branched down according to the power requirements. Direct current motors are relatively more expensive as they require a direct current source, meaning it needs to be connected to a converting device to convert normal alternating current into direct current. Their advantage is that they are capable of operating at adjustable speeds over a wide range and are ideally suited for accurate and flexible speed control, that being said, they are usually restricted to special applications to compensate for the much higher installation and maintenance cost. Alternating current motors, on the other hand, are the more common type as it can be easily fed by the AC power supply offered from motor drive supplier in Malaysia. Synchronous motors are three-phase AC motors which run at a fixed speed and are normally applied for larger outputs due to their relatively high cost. A rather more popular type of AC motor is the induction motor as it combines many advantages such as low cost, ease of supply and distribution, simple handling and controls; it is, therefore, versatile and suitable for almost all types of machines. To summarize AC motors are generally preferred for compressor power drives, air conditioning repressors, hydraulic and irrigation pumps; while DC motors are ideal for applications requiring stable speeds torques and operations such as steel mill rolling equipment and paper machines.

Understanding Electronic Drives and Their Types

It is important to understand the basic functionalities and how-to’s of a drive system as matching drives to motor requires a specific selection and motor drive supplier Malaysia says that it is essential to gain the best combination of torque, speed, and efficiency. A drive provides many different frequency outputs which produce a unique torque curve. In detail, the drive’s control board signals control circuits to turn on the waveform during the positive or negative half of the power device; this alternating positive and negative switches recreates the three-phase output, providing constant magnitude voltage pulses. As aforementioned, selecting the right drive is critical to achieve the best performance, to draw a case in point, replacing a three-phase motor starter driving a fan with a variable frequency drive (VFD) permits the fan to operate at variable speeds and this allows energy savings as the system varies airflow without the need of an air outlet damper. Industrial drive supplier in Malaysia says that the system is used in many different applications across the factory floor, combining a suitable motor with a drive, sensors, switches and communication links as part of the Internet of Things (IoT). To simplify the complexity of your drive systems, consider hiring an electrical specialist, such as Aathaworld to provide you a one-stop solution to install your drive system.

AC motor drives, referred to as controllers in some cases, control the speed of an AC motor and are used primarily in process applications including the speed control of pumps, fans and blowers; more recent applications include conveyors, cranes and hoist, machine tools, extruders, film lines and textile-fiber spinning machines. A standard AC driver consists of three basic parts, the rectifier that converts AC into DC, an inverter to switch the DC voltage back to an adjustable frequency AC output voltage and a DC link that connects the two. The double conversion process offered by Industrial drive supplier Malaysia plays an important role in increasing the output current tens to hundred folds in order to keep up with modern, sophisticated drives without burning up the motor coil. Key specifications of AC motors to take note of is their drive operating mode, motor and inverter type, loop system voltage classification, power rating, communication interface, as well as input and output electrical requirements. A variable frequency drive (VFD) is a particular kind of adjustable-speed drive that is used to control an AC motor’s rotational speed by controlling the frequency of the electrical power supplied to it, allowing the motor speed to be adjusted in accordance with the load. Due to this energy-saving property, VFDs are often found in ventilation systems, pumps and machine tool drives. Contrary to how a complete voltage is applied, from the advice of Industrial drive supplier in Malaysia to an AC motor where the current is kept especially high initially until the motor reaches full speed, VFDs operate differently by eliminating excessive current, increasing voltage and frequency in a controlled manner as the motor starts. By doing so, the AC motor is typically able to generate up to 150% of its rated torque. VFD systems are often utilized in motors that are designed for fix-speed operations, having an operator interface to allow users to switch and reverse between automatic control or manual speed adjustments.

DC motor drives modify the fixed input AC voltage by adjusting the constant power source to a pulsed, direct current output of varying pulse frequency. The principle operation of a DC drive is more simplistic than that of an AC drive as it does not undergo a double conversion but directly delivers the converted DC current to the motor, in accordance to industrial drive supplier Malaysia. A typical DC drive normally leverage several thyristors to create a half cycle or full cycle of DC output from a single or 3-phase AC input. In the last couple of years, DC drives have fallen out of favor as they are regarded as lacking in durability and consistency, and as such, they take up a higher operational cost over their lifespan. In contrast, AC drives are a much more popular choice in a wider range of motion control applications as they have greater performance benefits, in particular, being more energy-efficient. However, DC drives are still regarded as a common option in low speed, high torque applications such as in construction equipment based on the experience of industrial drive supplier in Malaysia. Servo drives may be AC or DC driven and functions to adjust the voltage and current applied to the servo motor based on closed-loop feedback. They are primarily used in motion control applications in manufacturing and construction environments such as micro-positioning, robotics, conveyors or spindle drive systems. Stepper motor drives, also known as motor indexers, are specifically designed for stepper motors, which, as its name suggests, do not rotate in a traditional manner, but instead make repeated movements of small fixed increments. A stepper driver offers adjustable current control and multiple-step resolutions, accordingly to industrial drive supplier Malaysia.

Applications and Industries of Motors & Drives

Automating industrial processes and connecting drives to the appropriate motor is the key to step up to the next generation of factory automation in accordance with Industry 4.0. Drives being the heart of all industrial processes is a vital component to keep the system as power-efficient as possible. To begin, fans widely used for ventilation, cooling and fume extraction, have a complex mechanical configuration such as the axial, centrifugal and tangential airflow, size and shape of the blades. As a result, it requires a careful selection of a particular motor depending on the size of the blades and the speed at which they rotate, for example, a brushed or brushless DC motor and a single- or three-phase AC induction motor. Electric forklifts are also a prime example produced by industrial drive supplier Malaysia of construction equipment that utilizes industrial drives in several areas, from the driving wheels to the hydraulic pumps that lift the heavy cargo. These industrial-grade machines require the use of a permanent-magnet DC motor (PMDC) controlled by high-power low-voltage inverters in the powertrain and the hydraulic actuators. Alongside mobile machinery, industrial servo drives are especially important in providing the maximum accuracy for a motor’s acceleration, speed and position; as such they are reserved for specialized needs in robotics applications where accuracy is prioritized such as lens autofocus control or antenna positioning. These also make use of sophisticated feedback control loops for a three-phase induction motor.

Unlike servomotors and steppers, AC and DC motors only require simple motor starters and protective devices, and most do not demand the need for motor controllers or drives to motor drive supplier in Malaysia. However, the use of motor drives is significantly beneficial to vary the speed control of an AC motor to a desirable output as opposed to having a standard specified operating speed which is considerably waste a substantial amount of energy. AC motor drives increase the efficiency of the industrial operation or system by setting the pump or speed to match the bare minimum requirements need. On the other spectrum, brushed DC motors are fundamentally speed controllable using a simple rheostat and hence do not need a drive. However, newer brushless DC motor models offered by motor drive supplier Malaysia are not mechanically commutated, and the use of drives are therefore necessary to commutate the magnetic field electronically. Before the commercial use of electronic DC motor drives, DC motors are commonly coupled as motor-generator sets such that AC induction motors are employed to produce direct current. Having a very good low-speed torque, DC motors are especially suited to winches, cranes and heavy machinery where loads are required to be lifted without a “running start.” To gain further insights into your drive and motor system installation, work with Aathaworld to provide you an easy solution and comprehensive service for your industrial needs.

Consideration and Important Attributes When Purchasing Motors and Drives

Unsurprisingly shared by motor drive supplier in Malaysia, drives tend to vary in complexity according to the requirements of different industries, with today’s rapid-growing technology, newer generations of electrical drives are available in the market, offering better performance and improved efficiency adding to smaller packages. Drives have become increasingl