Total drive train optimization of industrial fans and pumps consider-ing VFD driven motor, transmission and load

Standards and mandatory legislations concerning minimum efficiencies of electric motors have entered our world of electromechanical drive trains over the last years. It was a logical step to consider these elements as they account for the largest amount of energy consumption in the European industry. The European ecodesign measures count for 40% of total estimated savings in electric motors by 2020. However, not only the driving motor has to be considered when it comes to optimizing the drive train efficiency. This paper shows the saving potential in other drive train components based on measurement campaigns during several research projects at Ghent University Campus Kortrijk

Energy efficiency measurement procedure for gearboxes in their entire operating range

Over the last decade, forced regulations and a growing social awareness with respect to energy efficiency have resulted in a renewed interest in the research for high efficient electrical machines. When an electrical motor is coupled to a machine, in many cases a gearbox or belt transmission is used. Research shows a lack of information on energy efficiency of these components. In comparison to electrical motors and drives, there is very few regulation and if efficiency values can be found in catalogues, there is no regulated test procedure available to validate the data. As a result, the reliability of these efficiency values is unknown and comparison between manufacturers and technologies is impossible. In this paper a test bench is proposed to measure the energy efficiency of a gearbox with an accuracy up to 0.4%. The test bench is used to measure the efficiency of gearboxes in their entire speed and torque range. Contour maps are used to visualize these measurement results. Moreover, a measurement campaign using different gearboxes is carried out to compare the energy efficiency in the manufacturers catalogue and the measured efficiency

Efficiency measurement campaign on gearboxes

The last decade, new concepts of electrical motors with promising efficiency have entered the market. Such an electric motor is connected to the load machine often by means of a transmission system. Considering the energy efficiency of transmission systems, there is a lack of available information on the market. In contrast to electrical motors and drives, there are very few mandatory regulations imposed on these components. Information on efficiency can be occasionally found in catalogs but accepted test procedures are not available. As a result, the reliability of these efficiency values is low and comparison between brands and technologies is impossible. Regulation on energy efficiency on the other hand evolves towards a total system approach. The new European fan directive 327/2011 is an example of such an approach where overall efficiency is considered. Information on the efficiency of mechanical transmission components such as gearboxes and belt drives will be required to assess and optimize the overall system efficiency. Due to the lack of reliable information on energy efficiency of these components, a measurement campaign was set up to test a series of gearboxes. This paper discusses the results of this measurement campaign. Because of the wide variation in types and sizing, the measurements where done on a flexible designed input-output gearbox test bench [1]

Energy efficiency optimization of a dust extractor: an industrial case study

The Eco-design directive published by the European Union aims at 34TWh of annual savings with industrial fans by the year 2020. This is about 10% of the total saving aim of 366TWh. Electric motors are still responsible for over 40% of the planned savings with 135TWh of annual savings by 2020. These aims are translated into European directives to guide the market towards more energy efficient systems. An evolution within those regulations is the fact that directives are not only focusing on one particular part in the drive system (e.g. the induction motor), but consider the entire system with all its parts to rise the overall system energy efficiency. Examples of this total system approach are the latest EU directives on circulator pumps [1] [2], air conditioning systems [3], domestic comfort fans [3] and industrial fans [4]. This system approach demands a thorough analysis of all the different parts of the drive system in order to make a sound technical and economical choice on which part to invest to rise the overall system efficiency. This paper describes a practical case study carried out on an industrial dust extractor in preparation of a new research project proposal in which o.a. the EU-directive 327/2011 [4] will be investigated. The different drive parts were analyzed based on their efficiency and replaced if technically and economically feasible. Research and test bench results of previous and on-going research projects on energy efficiency were used to predict the potential savings. At each step energy consumption measurements were carried out before and after to validate the estimated savings