Motors & Motor Control
Electrical Motors are electro-mechanical devices that convert electrical energy to mechanical energy by producing a rotating force. These motors are used to power equipment and machinery in all industries.
Variable Frequency Drives (VFDs) are similar to soft starters in that they reduce the torque and start more gradually. A VFD allows control of the motor speed at all times. By lowering the inrush current and running the motor at lower speeds, the motor and the equipment will last longer and can result in energy cost savings.
Soft Starters limit the voltage to the motor when starting This reduces the inrush current and torque, which provides a more gradual ramp up to full speed. This can help protect the motor and equipment from uncontrolled shock and damage over time.
Motor Starters are electro-magnetic switches that contain a contactor and an overload relay. This allows motors to start and stop in a safe manner. Starters protect the motor from drawing too much current and overheating.
Starter contactors are switches that supply and interrupt power to the circuit in a motor starter, but do not provide overload protection.
Overload relays monitor electrical current flow in the motor circuit and interrupt the circuit when an electrical overload is detected.
Motor starters safely start and stop a motor in industrial applications. They are designed with a contactor, overload and circuit protection. They are used when basic motor control is required, where torque on the motor is not a concern and speed control is not needed. The advantages of motor starters include: lower cost, allows for remote operation, allows for monitoring of motor state (with the use of auxiliary contacts) and they are safe and efficient. The disadvantages include: high inrush current that can cause fuses to blow and breakers to trip if the inrush is too high, and the starter will allow a full torque to start the motor which can cause the motor to ramp up to full speed very quickly potentially causing the motor to wear and degrade prematurely.
Soft starters protect motors from inrush current by gently ramping up the motor to full speed. They provide all of the same functions as a traditional motor starter. The advantages of soft starters include: they are less expensive than a VFD when only startup control is needed, they are a smaller system than a VFD where space is a concern and they prevent unwanted torque upon startup, prolonging the life of the motor. The disadvantages include: they are more expensive than a traditional motor starter and they do not allow for full speed control.
Variable Frequency Drives (VFDs) allow for the slow ramp up of a motor during startup and the slowing down of the motor during shutdown. They also allow for full speed control during the entire run cycle of the motor. VFDs provide the same functions as both the traditional motor starters and soft starters. The advantages of VFDs include: full speed control (start, stop and in-between), more custom control and monitoring, energy savings due to efficient motor usage and less wear and tear on the motors. The disadvantages include: they are more expensive and larger than other motor control options and they generate heat that may require fans or AC units.