DC to AC Motor Conversion
DC to AC Motor Conversion
Tired of Repairing an older DC Powered Machine?
As a dynamic and experienced engineering solutions provider, Taylor Made Systems has developed a seamless process for the conversion of existing Direct Current (DC) equipment to the latest Alternating Current (AC) motor and AC inverter technology.In the past these two types have been used in largely differing processes due to their difference in characteristics. DC motors in the past were most often used in variable speed applications such as extrusion to meet the wide speed ranges required for different products. For this reason, previously extrusion lines brought in the past were fitted with DC motors but in the past 10 years with technological advances in AC Inverters, they have improved with the ability to more precisely control speed. New plastic extruders are generally supplied with AC motors and Inverter drives instead of the traditional DC system that were commonly used recently as the efficiency in both cost and performance is tipping to AC motors and inverters.
What are the Benefits?
Cost
AC motors are much easier to manufacture and are generally more reliable than a DC motor, Usually the cost of a single DC motor is greater than the overall cost of an equivalent AC motor and the Inverter drive combined.
If we compare two 110kw motors for example, we can see the large difference in price.
This means that if your older DC motor fails and needs to be replaced it is far more cost effective to replace with an AC motor and invertor which are cheaper, more reliable, have greater energy efficiencey and in most circumstances are more readily available on shelves so can replaced and back up and running far quicker.
Maintenance
It is not just the lower capital costs of an AC system compared to a DC system that makes conversion attractive, there are other issues too. AC technology is more efficient than DC and through greater efficiency comes lower running costs and far less annual maintenance required. There is no need for annual replacement of brushes, filters or oil, no Commutator or wear checks and no need to stock spares. Also, to carry out this maintenance further down time of the machine only increases the costs through loss of production.
Efficiency
With AC variable speed control, you will only consume the energy that the process requires. Heat loss is dramatically reduced. There are good space and noise savings too and the efficiency of your process is generally increased.
Typically, converting from DC technology to AC will save your process 20-30% in energy consumption.
Converting to AC Motors on Extrusion Lines
Why Are AC Motors Used on Extruders?
AC motors require less maintenance and have a better power factor when used with a 3 phase Inverter. It has become common practice in the industry to replace a worn out or older DC Motor and Drive on an existing Extruder with an AC motor and inverter.
Modern AC motors and drives provide several additional operating benefits that rival those traditionally available only from DC drives. For example, today's drives can now produce full torque at start-up, something that once was impossible. They also are capable of speed ranges of 1,000:1 vs. only around 10:1 with previous AC drives.
Variable-speed AC drives also can adjust to fast-changing loads and provide tight speed regulation. When operated in closed-loop systems, AC drives can regulate speeds to within 0.01 percent and less. This makes them suitable for applications requiring high dynamic response, such as web processes, material handling sorter conveyors, metering pumps, extruders and test stands.
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