How to effectively control electric drives?
Electric drives are one of the most important components of modern industrial facilities. They account for as much as 70% of total electricity consumption in the manufacturing sector. A key element of their efficient operation is control systems, which enable the optimization of motor parameters and entire drive systems. The implementation of modern solutions in this area allows for significant energy savings, improved process quality, and increased reliability. In this article, we will explain what electric drive control systems are, how they are used in industry, what benefits and limitations they present, and how they can effectively support the optimization of production processes.
Definition and functions of electric drive control systems
Electric drive control systems are based on advanced electronic circuits that are responsible for controlling the operation of electric motors and other components of the drive system. Their main task is to regulate the rotational speed, allowing the performance of the installation to be adapted to the requirements of a specific technological process. Additionally, these systems enable precise torque control, which ensures the appropriate dynamics and drive force depending on the load. Monitoring operating parameters such as temperature, vibrations, or energy consumption allows for increased safety and efficiency of the equipment. In their structure, control systems often use inverters, PLC controllers, and SCADA systems, which together enable precise management of drive operating parameters.
Application areas of drive control systems
Electric drive control systems can be found in many sectors of industry, construction, and transport. In the manufacturing industry, such solutions support the operation of production lines, enabling precise control of speed and torque, which translates into better production quality and waste reduction. In HVAC systems used in office and industrial buildings, drive control systems allow for efficient management of fan and pump operation, leading to significant energy savings. In transport, they can be found in electric vehicles, elevators, or rail systems, where they support the safety and efficiency of equipment operation. In the energy sector, such solutions are used in power plants and energy processing facilities, where precise control of machine movement affects their durability and operational efficiency.
Electric drive control systems offer many benefits, ranging from better process and production quality control to significant energy and cost savings. At the same time, they come with challenges such as the need for specialized knowledge of available solutions, capabilities, and understanding of the controlled process to implement such a project, as well as, in some cases, high initial costs. Choosing these solutions requires careful analysis to ensure that their application will deliver the expected results.
Electric drive control –
what can you gain?
Implementing drive control systems brings a range of benefits, including:
- energy efficiency – precise adjustment of motor speed and torque to the requirements of technological processes allows for significant energy savings. In variable load applications such as pumps or fans, savings can reach up to 60%,
- optimization of production processes – thanks to precise control of drive operating parameters, it is possible to improve product quality and production line efficiency,
- extended equipment lifespan – monitoring motor operating parameters allows for early fault detection and avoidance of costly failures,
- improved safety – control systems offer protection functions against overloads, overheating, or 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 numerous advantages, drive control systems also have some limitations:
- initial costs – investing in advanced control systems can be expensive, making implementation difficult for companies with smaller budgets,
- technological complexity – implementation and operation of the systems require specialized knowledge and appropriate staff training,
- maintenance – advanced control systems may require regular maintenance and software updates.
Thanks to cooperation with DB Energy, it is possible to effectively overcome these challenges and maximize the potential of the technology. For example, an investment designed and financed by us in the ESCO model included the modernization of a 160 kW drive throttled to 30%, where:
- we reduced energy consumption by about 100 kW with continuous operation of 6,000 h per year,
- the savings generated amounted to approximately 60%, i.e. 600 MWh, with a total electricity supply price of 350 PLN/MWh, totaling 210,000 PLN annually,
- the investment repaid from the savings achieved under the Client 25% / DBE 75% split will pay off in 5 years.
Electric drive control systems play a key role in improving energy efficiency, production process quality, and industrial safety. Despite higher initial costs, the benefits of their implementation outweigh the potential limitations, making them one of the most cost-effective solutions for modern industrial facilities. Their application enables companies to achieve significant savings, improve efficiency, and extend the durability of their equipment.
