Technical Articles
Nowadays, industries are developing at a pace never imagined before. Machines are now expected to be smarter than ever, function with more efficiency, and be highly responsive. Consequently, to meet the growing demand for automation systems, AC drives are now widely used in most industries
AC drives control motor speed, which helps minimize power consumption and improve system performance. They are a great addition to any plant, regardless of its size.
Let’s explore how AC drives work and the top five benefits they offer in industrial automation.
A variable frequency drive (also called an AC drive, VFD, or inverter drive) is a type of AC motor controller that regulates the speed of an AC motor and also controls the torque of the motor by varying the electrical frequency of power supplied to the motor. Simply put, it assists in machines operating at precise speeds required in the task, thus saving energy and eliminating wear and tear.
AC drives are predominant in industries where the usage of the electric motor is an integral part of the operation. These include manufacturing, food processing, packaging, HVAC, and others.
In industrial processes, electric motors place a high level of demand on power. Motors are likely to run at a faster speed than required when the speed is not controlled adequately, wasting energy and increasing the bills. This is where the AC drive comes in big. In addition to offering speed control, it also enhances performance and improves industrial energy efficiency.
Here are the top 5 benefits of using AC drives in industrial automation:
One of the biggest benefits of using AC drives is their ability to improve industrial energy efficiency. Traditional motor systems run at full speed even when they are not needed. With this drive, the motor speed becomes adjustable, and you can match it to the actual load.
For example, in a pumping system, reducing the motor speed by just 20% can cut energy use by nearly 50%. Over time, this leads to significant cost savings. Here’s an overview of the energy-saving table:
| Motor Speed Reduction | Approximate Energy Savings |
| 10% | 27% |
| 20% | 50% |
| 30% | 66% |
Older motors are difficult to start because they jerk (which can overload gears, belts, and other mechanisms). AC drives enable soft starts, and this makes it possible to start the motors at a gradually increasing speed. Such a gradual change alleviates machinery shock.
When it comes to smooth braking, it is also valuable for delicate procedures. The mechanical parts will last longer, resulting in fewer breakdowns due to reduced stress.
In any industrial automation system, control is everything. The ability to precisely control the speed of any machine—be it conveyor belts, mixers, fans, etc.—is the key to a good output.
With AC drives, it is possible to achieve that level of control and modify it at any time. As a result, product quality enhancement is observed along with decreased waste production and reliable functioning.
Consider the example of a conveyor belt here to understand how these drives promote industrial energy efficiency. Now, with functional accuracy at high speed, it can be ensured that the packing of the items will be proper, without deformation.
AC drives reduce the strain on motors and other components, which means the entire system works more efficiently. This lessens wear and tear, extends the lifespan of your equipment, and significantly reduces downtime. As a result, you'll see fewer service calls and lower repair costs.
By running the motor at an appropriate speed, AC drives also prevent sudden failures and breakdowns caused by excessive vibration and stress
Flexibility is a major benefit of AC drives, yet it's often one of the most overlooked advantages. They can be easily integrated into both new and existing systems, and they are compatible with a wide range of motors and a diverse set of programmable tasks.
Industrial energy efficiency is no longer just a buzzword. It is a requirement for industries to remain profitable and environmentally responsible. Governments and industry bodies are encouraging the use of efficient systems. By making efforts in such a direction, it reflect your dedication toward fulfilling environmental responsibilities.
AC drives help reduce carbon emissions, which are often due to high energy use. They also reduce peak power demands, helping industries avoid penalties for high consumption. Here are some common areas where these drives are making a difference:
A good-quality drive should offer long-term reliability, ease of use, and support for remote monitoring if needed. When it comes to choosing the right AC drive, it depends on your specific needs. Here are some tips to help:
The industrial world is growth-driven, and it always has been. Therefore, improving efficiency is not a choice but a necessity. Using AC drives in an automation system gives you better control, lower costs, and long-lasting equipment. More importantly, it helps you meet your energy goals and reduce waste. However, to ensure the final output matches the expectations, these drives must be sourced from reliable sources.
At Lauritz Knudsen Electrical & Automation, we believe in providing application-led automation tailored to solve real-world industry challenges. With a presence in over 500 cities across the country, our 70-year legacy speaks for itself. Our services, which offer benefits like precision control, improved efficiency, and longer machinery life, extend to diverse segments including industry, buildings, homes, infrastructure, and agriculture.
To explore such smart investments, let’s connect today.
Read Also: Common Switchgear Mistakes That Compromise Safety
Assistance Required?
Select an option to Contact Us
Contact Us 
