Motor Controllers

To be efficient, A/C motors need to be sized to their typical duty cycle, operating as close to their rated capacity as possible.  In a lot of applications, motors must be sized to peak load capacity regardless of their typical duty cycle.

Constant speed, variable load motors, like those installed on escalators, elevators, balers, etc., are sized according to peak loads.  In many cases, these peak loads are rarely realized.  For example, an escalator has a motor sized according to the maximum capacity of the escalator. This is done for obvious reasons, but in a normal day the escalator will likely not be carrying anywhere near its rated capacity the entire time it is running.  When the escalator is not loaded to full capacity, opportunities exist to improve the motor’s efficiency.

 FMSI offers a very effective solution to improve the efficiency of constant speed/variable load motors.  Our Motor Controller constantly monitors the motor’s power factor and adjusts the voltage supplied to it to keep the motor’s power factor high while maintaining the speed and torque at the level required by the load at that time. The resulting decrease in volts, amps and watts significantly reduces the overall cost of operating the system.  In fact, if we use this technology on applications that run lightly loaded most of the time, we can generally achieve 20% to 40% savings.

Our system includes a soft-start circuit that reduces starting inrush current by as much as 70%. Reduced inrush current reduces contactor wear, mechanical starting stresses on bearings and the associated drive train, insulation damage and overheating, particularly when the motor is stopped and started frequently. When running continuously, the energy-saving feature further extends the life of the motor by lowering its operating temperature by 10-40 F (6-22 C). An 18 F (10 C) reduction in temperature can double the motor’s expected life.
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