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Better Motor Alternatives for Variable Speed Pumps
"What type of motors do you use for your pumps? For variable speed pump applications, which often utilize 3-phase AC induction motors paired with variable frequency drives (VFDs), there exists an alternative motor option that can ensure more consistent fluid transfer while also reducing the overall footprint.
Let’s explore two common challenges encountered in pump applications:
**Challenge 1: Achieving Consistent Fluid Transfer**
In many pump operations, like fluid control, maintaining consistent speed is crucial. You’ll want to have a certain level of control over the rate of fluid transfer to ensure predictable outcomes.
VFDs regulate the motor speed by controlling the frequency of the supplied voltage. The most commonly used control method in basic applications, such as pumps and fans, is the open loop scalar volts-per-Hertz (V/f) control method, which offers a speed regulation of approximately ±2~3%. If more precise control is required, encoders can be added to close the loop, or vector control can be employed. However, encoders are costly, and vector control demands a more advanced CPU on the VFD.
It’s also worth noting that in both open loop scalar (V/f) and vector control, motor response isn’t always guaranteed due to the lack of physical feedback. Load fluctuations, which can arise from differences in fluid type or viscosity, can cause the motor to slow down, leading to inconsistencies in the volume of fluid transferred.
**Solution 1: BMU Series Speed Regulation**
The built-in hall-effect sensor feedback in brushless motors, combined with the speed regulation capabilities of the dedicated driver, presents a cost-effective alternative to VFDs.
Oriental Motor's BMU Series brushless motor systems boast a speed regulation of up to ±0.2% maximum. As a comparison, the BX II Series brushless motors equipped with encoders have a speed regulation specification of ±0.05% maximum (at rated speed). This ensures consistent performance regardless of load, voltage, or temperature changes.
In certain cases, the effective speed range can be extended with brushless motors compared to VFD-driven AC motors. Standard brushless motors offer an 80~4,000 RPM speed range (50:1 speed ratio), while VFD-driven AC motors typically offer 90~3,600 RPM (40:1 speed ratio). The constant torque output of brushless motors ensures reliable performance across the entire speed range, and the limited duty torque boosts motor torque for dynamic acceleration or deceleration.
[Insert image comparing brushless motor vs. AC motor]
**Challenge 2: Reducing Energy Consumption**
For applications where mass and energy consumption are not significant concerns, using AC motors with VFDs may suffice. However, brushless motors are more efficient than AC motors, making them a more compact and energy-saving solution.
Brushless motors significantly reduce power consumption because the use of permanent magnets in the rotor eliminates secondary losses from the rotor. This results in a substantial reduction in power consumption (approximately 27%) compared to AC motors.
Additionally, brushless motors are smaller and lighter than three-phase induction motors of the same output specifications. For instance, when comparing 200 W (1/4 HP) motors, the brushless motor is 83 mm shorter in overall length and 3.2 kg lighter in weight.
**Solution 2: BMU Reducing Size and Energy Consumption**
With higher efficiency, brushless motors are more compact, consume less power, and do not require built-in cooling fans for continuous duty operation. The absence of a fan also helps prevent dust dispersion or contamination of products like food, cosmetics, or resin.
[Insert video demonstrating easy operation of BMU Series motor]
[Insert table showing alternative motor options]
Are you looking for something different? Perhaps one of these alternatives could work for your application.
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