How to effectively control electric drives?

Electric drives are among the most important elements of modern industrial plants. They account for as much as 70% of the total electricity consumption in the production sector. A key aspect of their effective operation is controlling systems that optimize the operating parameters of motors and entire drive systems. Implementing modern solutions in this field enables significant energy savings, improved process quality, and increased reliability. This article explains what electric drive control systems are, their uses in industry, their benefits and limitations, and how they can effectively support the optimization of production processes.

Definition and functions of electric drive control systems

Electric drive control systems rely on advanced electronic mechanisms that control the operation of electric motors and other drive system components. Their main task is to regulate rotational speed, allowing for the adjustment of an installation’s efficiency to the specific requirements of a technological process. Additionally, these systems enable precise torque control, ensuring appropriate dynamics and drive force depending on the load. Monitoring parameters such as temperature, vibrations, and energy consumption enhances the safety and efficiency of equipment operation. Control systems often incorporate inverters, PLC controllers, and SCADA systems, which together allow precise management of drive operating parameters.

Areas of application for drive control systems

Electric drive control systems are widely used across industries, construction, and transportation. In the manufacturing sector, these systems enhance production line operations, allowing precise speed and torque control, which improves production quality and reduces losses. In HVAC systems, commonly found in office and industrial buildings, drive control systems manage fan and pump operations, leading to significant energy savings. In transportation, they are applied in electric vehicles, elevators, and railway systems, improving the safety and efficiency of equipment. In the energy sector, such solutions are used in power plants and energy processing facilities, where precise machine movement management enhances durability and operational efficiency.

"Electric drive control systems offer numerous benefits, ranging from better control over the production process and quality to significant energy and cost savings. However, they also come with challenges, such as the need for specialist knowledge of available solutions and the controlled processes, as well as potentially high initial costs. Careful analysis is essential to ensure these solutions deliver the expected results." says Przemysław Kurylas, Operations Director at DB Energy. 

Control of electric drives – what can you gain?

Implementing drive control systems provides several benefits, including:

  • Energy efficiency - precise adjustment of motor speed and torque to meet process requirements enables substantial energy savings. In variable-load applications such as pumps or fans, savings can reach up to 60%.
  • Optimization of production processes - accurate control of drive parameters improves product quality and production line efficiency.
  • Extended equipment lifespan - monitoring motor parameters facilitates early fault detection, preventing costly failures.
  • Enhanced safety - control systems include protections against overloads, overheating, and short circuits, reducing the risk of damage and accidents.
  • Automation and flexibility - integration with SCADA and PLC systems enables remote control and process automation.

Challenges and limitations of drive control systems

Despite their many advantages, drive control systems have certain limitations:

  • Initial costs - advanced control systems require a significant investment, which can be challenging for companies with smaller budgets.
  • Technological complexity - implementing and operating these systems demands specialist knowledge and staff training.
  • Maintenance - regular maintenance and software updates may be necessary for advanced systems.

Collaborating with DB Energy can help companies overcome these challenges and maximize the potential of this technology. For instance, a project designed and financed by DB Energy under the ESCO model included modernizing a 30%-throttled drive with a power of 160 kW. This initiative resulted in:

  • Energy consumption reduction by approximately 100 kW during continuous operation for 6,000 hours per year.
  • Savings of around 60%, equating to 600 MWh annually. With electricity priced at EUR 82.3/MWh, this translates to EUR 49,367 in yearly savings.
  • A 5-year payback period for the investment, with savings shared between the customer (25%) and DB Energy (75%).

Electric drive control systems are vital for enhancing energy efficiency, production quality, and safety in industrial settings. While their initial costs may be higher, the benefits far outweigh the limitations, making them one of the most cost-effective solutions for modern industrial plants. By implementing these systems, companies can achieve significant savings, improve efficiency, and increase the lifespan of their equipment.