Drive & motor solutions energy benefits lauded in Sweden.

The energy-saving benefits of using Emerson drive and motor solutions have been highlighted in a test report on electric motors by Energimyndigheten (Swedish Energy Agency).

The agency commissioned the test to investigate claims made by manufacturers of electric motors in various efficiency classes, when used in conjunction with a series of different variable speed drives.

The investigation (Swedish) showed savings of around 5,700 kW hours per year can be achieved from a single Leroy-Somer Dyneo® LSRPM 15kW electric motor from Emerson, equivalent to the entire annual household electricity consumption for a four person household.

The independent tests, the first of their kind in Sweden, follow amended EU legislation which concerns the efficiency of electric motors in industry. Since January 2015, all new electric motors of powers from 7.5kW up to 375kW covered by the Ecodesign directive must meet minimum EU efficiency requirements of IE2 class when supplied by an inverter and IE3 when supplied DOL.

Energimyndigheten subsequently analysed the motor’s performance in conjunction with four variable speed drives, which adjusted the output according to need by controlling the speed of the electric motor.

If one efficiency class was defined as 20 per cent less losses between two measures, the results showed how Dyneo® improves efficiency by an equivalent of one entire class better than Emerson’s competitors’ products, and close to three efficiency classes above IE3 induction motors in the pump example.

Compressor applications would give even higher differences as Dyneo® keeps its superior efficiency across the full speed and load ranges.

The Dyneo® LSRPM motor from Emerson, using HPM technology (hybrid permanent magnet) was tested both with a Unidrive M600 drive from Emerson, and a model from one of Emerson’s competitors. The optimized motor and drive package from Emerson clearly showed an improved efficiency, as a result of both drive and motor being engineered specifically to work together.

The first example assumed a situation where an electric motor is supplied by a drive and used to drive a pump. The electric motor with the pump was installed in a system where there is constant pressure, but where the pump flow ranges from idling operation to the peak load. Under these conditions, the results show that in a year, this solution can save up to six per cent of the cost of electricity with a Leroy-Somer Dyneo® permanent magnet motor from Emerson Industrial Automation.

Electric motor systems are estimated to account for around 65 to 70 per cent of the total electricity used in industry, and almost 40 per cent of total global electricity use. They often run round the clock, throughout the year, and can be used to drive fans, pumps and compressors, or power systems such as elevators, escalators and large air conditioning or refrigeration units.

It is estimated that more efficient electric motors could save around 135 terawatt hours (TWh) of electricity annually in the EU by 2020, more than Sweden's current total annual electricity use.

Eric Coupart, from Leroy-Somer, said: “We wholly welcome the findings of the investigation, which confirms how Emerson drives and motor solutions, purchased as packages, deliver not only proven reliability but also the best return and life-cycle cost on the market.”

• The Swedish Energy Agency, which has been in operation since 1998, is the country’s national authority for energy policy issues. Its aim is a sustainable Swedish energy system, through the support of renewable energy, improved technologies, climate measures, and a smarter use of energy.

Camshaft gauge!

An upgraded camshaft measuring machine that has been engineered to handle longer camshafts for large diesel engines, and provides submicron accuracy is being introduced by ADCOLE Corporation.

Their Model 911 Camshaft Gauge for diesel engines handles parts up to 105” long and features a video monitor to assure the center hole is lined up and engaged and employs a footswitch operated open-close of the tailstock. Capable of automatically measuring 360° around the part, including all cam lobes, reference journals, timing features, and keyways, this gage provides submicron accuracy and can detect material buildup and other irregularities.

Featuring precision carriage ways to assure ±0.25 micron radial accuracy, this Camshaft Gauge measures each cam lobe’s axial profile from edge-to-edge and creates a 3D image that illustrates the shape and identifies irregularities. This gage has become the world standard for milling and grinding machine tool users to assure there is product conformance among suppliers and OEMs, claims the firm.

Climate control

Climate control applications vary in many different ways, from control to air routing. Rittal offer a range of accessories that may be tailored to satisfy specific requirements.

Energy-saving philosophy that has resulted in many motors being controlled by inverter drives may also be applied to Rittal’s fan-and-filter unit; a speed control device may be used to vary the fan speed in response to the cooling demand, ultimately switching the fan off when not required.

Ingress protection of Rittal’s fan-and-filter unit may be improved by installing an additional fine filter mat or an IP56 hose-proof hood fitted with the same blue sealing material that is used in Rittal’s Hygienic Design enclosures, a proven success, particularly in the food and beverage industry.

To direct cooled air towards the bottom of an enclosure, Rittal’s air diverter may be used, or an internal fan may be fitted to optimise air distribution, as natural convection currents and the flow of air through wall-mounted cooling products will pull it upwards immediately upon entry.

Rittal’s roof-mounted cooling products have multiple supply air spigots to offer a great degree of flexibility when air distribution is being considered. Rittal’s air duct systems, duct extensions, angled deflectors and stoppers provide the ability to target those areas in the enclosure in which cooled air is required. This particular range of accessories has recently been extended to include an adaptor that allows the shallow air duct system to be used with Rittal’s smallest roof-mounted cooling units.

Piston inspection system prevents engine failures

An automatic vision inspection system to read the alphanumeric product identifiers cast into pistons has been developed by Olmec-UK Ltd for an automotive engine manufacturer. The pistons must be checked immediately prior to engine testing to ensure that the correct ones are used. Starting an engine with incorrect pistons fitted results in catastrophic failure with the entire engine having to be scrapped.

Automatic reading of the alphanumeric identifiers posed a huge challenge for the vision system because the characters were never intended for machine reading. Although the characters stand raised from the background material, there is very little contrast between them and the background and this is made even worse because the material is very reflective. In addition, pistons are produced from a variety of different moulds, so there is significant variation in the quality of the characters from batch to batch.

The vision solution featured the use of 4 individual cameras, each equipped with their own ringlights to image each of the pistons simultaneously. Using red illumination optimises contrast and minimises noise in the resultant images. The system is controlled using Olmec’s VP2-CR system which features character recognition software that takes into account different fonts, quality, scale, skew and slant of the characters. The system features a simple, graphical user interface using a touch screen controller, and is also configured to allow for the different working distances that occur when different engine types are inspected.

The engines arrive at the vision inspection station on a conveyor. The conveyor is stopped and the vision system inspects all 4 pistons. If any piston fails the inspection, the process is stopped to allow an operator to make an additional visual assessment. Since the vision system has been introduced, there have been no engine failures due to fitting of incorrect pistons, saving the manufacturer a considerable amount of money.

Reduce emissions while saving fuel costs

With the price of petrol and diesel rising again and against a backdrop of global warming, it is no wonder that close attention is focused on driving, which according to the USA’s Environmental Protection Agency (EPA) is the largest contributor to ground level ozone affecting global warming and acid rain. Most vehicles generate three major pollutants: hydrocarbons, carbon monoxide and nitrogen oxide. Vehicles also emit large quantities of carbon dioxide, the biggest contributor to global warming.

While car manufacturers strive to produce ever more efficient cars and engines it is a simple fact it will take many years before there are a sufficient proportion of newer vehicles on the road to have a significant impact. With the world still on an economy drive, older, less efficient vehicles are going be around for many more years to come.

But therein lies the solution. One of the quickest and surest ways to effect change is by offering immediate and realistic cost savings. That is where Forever Freedom International (FFI) can help with its amazing fuel pill, the MPG-CAP™. Used in a ratio of just 1 gram per 300 – 380 (More or less may be required for different engine types, driving styles, and fuels) litres of EU petrol – or EU on-road diesel - this inexpensive little caplet decreases emissions by up to 75% and fuel consumption by 7 to 14%.

How does it work?
The MPG-CAP™ gradually puts a catalytic coating on the face of the engine piston making fuel burn more efficiently while still in the combustion chamber, as opposed to continuing to burn on its way out the exhaust. Evaporative emissions decrease as fuel efficiency increases. In effect, the combustion chamber is enabled to burn more of the air/fuel mixture thus reducing wasted fuel that is expelled in the exhaust cycle of the engine.

The product has been thoroughly tested by tier one testing facilities and has been demonstrated in both laboratory and on road studies to improve octane (petrol) and cetane (diesel) values, reduce combustion chamber carbon deposits and exhaust particulate emissions, lower CO, NOx, and unburned hydrocarbon emissions, and improve mileage 7-14%.

Made of the purest of active ingredients and with no end of life disposal issues, these little capsules are even supplied with a money back guarantee. This product, properly registered with the EPA, is very inexpensive and easy to use. It and associated products can be ordered online where it is also possible to sign up to become a distributor of the products.