Escolar Documentos
Profissional Documentos
Cultura Documentos
W
Afripp Projects cc
e at the CMA carry on as well, Actom (Pty) Ltd
Atlanta Manufacturing (Pty) Ltd
and even though it is still early in
Bateman Engineered Technologies Ltd
the year, committees are already Bauer a Division of Hudaco Transmission (Pty) Ltd
hard at work on behalf of our BMG (Bearing Man Group)
members, preparing for events and publications Bearings International
and, of course, some fun stuff as well! Belt Reco RSA
Bonfiglioli Power Transmissions (Pty) Ltd
The first issue of ‘The Conveyor Express’ has Bosworth A Division of Hudaco Trading (Pty) Ltd
been distributed to members. This will appear Brelko Conveyor Products (Pty) Ltd
every few months, and contains snippets on CKIT Conveyor Engineers (Pty) Ltd
just about anything that is of interest to you Continental Crushing & Conveying
all. It is also a forum for members to ‘convey Conveyor Watch (Pty) Ltd
and express’ their opinions, views, industry CMG Electric Motors South Africa (Pty) Ltd
CPM Engineering (Pty) Ltd
news etc.
CT Systems (Pty) Ltd
One of the special projects high on the agenda David Brown Gear Industries (Pty) Ltd
Simon Curry this year is to complete the CMA Handbook Delras Engineering (Pty) Ltd
on Conveyor Design. A great deal of progress DRA Mineral Projects (Pty) Ltd
Dunlop Belting Products (Pty) Ltd
has been made in the last few months, and the chapters
Dymot Engineering Company (Pty) Ltd
are taking shape nicely with much appreciated input from ELB Engineering Services (Pty) Ltd
our technical team and knowledgeable advisors, many of Facet Engineering cc
whom are familiar names in the industry. It’s a tough and Fenner Conveyor Belting (South Africa) (Pty) Ltd
often tedious job, but we’re doing it! Flexible Steel Lacing SA (Pty) Ltd
Hansen Transmissions SA (Pty) Ltd
No rest for the wicked Hosch - Fördertechnik (SA) (Pty) Ltd
As is said, there’s no rest for the wicked, and just as the M & J Engineering (Pty) Ltd
last bits of admin for Beltcon 15 have been cleared away, Martin Engineering
so we are already deep into the planning of Beltcon 16. A Melco Conveyor Equipment
call for papers is being distributed worldwide, so if you wish Moret Mining (Pty) Ltd
MS Conveyor Pulleys SA (Pty) Ltd
to participate as a speaker, let us know as soon as possible.
Nepean Conveyors (Pty) Ltd
We have set even higher standards for the 2011 Beltcon, OE Bearings (Pty) Ltd
and are determined to meet these. Osborn Engineered Products SA (Pty) Ltd
Read Swatman & Voigt (Pty) Ltd
If you wish to participate as a speaker, let us know as Rema Tip Top South Africa (Pty) Ltd
soon as possible Renold Crofts (Pty) Ltd
Roymec (Pty) Ltd
Another event to add to your calendar is the Annual Dinner RSV ENCO Consulting (Pty) Ltd
on 19 May at Bryanston Country Club, always a sociable Sandvik Materials Handling SA
and friendly evening together with wives and ‘significant oth- Schaeffler South Africa (Pty) Ltd
ers’. Space is limited, so again, book early. It’s a wonderful Secrivest (Pty) Ltd
opportunity to entertain customers and clients in a relaxed SENET
SET Agencies (Pty) Ltd
environment.
SEW Eurodrive (Pty) Ltd
Don’t forget the Members Meeting on 14 April. Shaft Engineering cc
Shaw Almex Africa (Pty) Ltd
On a sad note, we extend our condolences to the family, Siemens Southern Africa
friends and colleagues of Jan Detlof-Wismer, who passed SKF South Africa (Pty) Ltd
away unexpectedly on 20 December 2009. He will be re- Technique Avant Garde cc
membered, as was quoted at his memorial service, ‘with a ThyssenKrupp Materials Handling (Pty) Ltd
vodka and diet coke in one hand and the other outstretched Transmission Components (Pty) Ltd
in friendship’. Unitek Engineers (Pty) Ltd
Veyance Technologies Africa (Pty) Ltd
Simon Curry Voith Turbo (Pty) Ltd
Chairman Zest Electric Motors (Pty) Ltd
shock absorbing trough, is mounted underneath a “This mobile feeder system can be quickly and
conveyor belt. It is installed at transfer points where easily dismantled and relocated when necessary.
fine or caurse heavy material is being transferred It is specifically designed for no spillage. Electrical
and where there is a build-up of materials in the panels for these feeders are also available.”
transfer chute. Says Gavin in conclusion, “Our engineers are
The HIT system combines a heavy duty idler frame constantly out in the field to assist customers
with a high impact torsion arm system to absorb in making the right choices. We have so much
the impact of material which falls onto the belt.” confidence in our product range that we needn’t
even offer maintenance plans as our equipment
Skirt clamp
simply doesn’t require maintenance. But ours is
Then there’s the skirt clamp, a conveyor system’s
not a ‘now you see us, now you don’t’ relation-
spillage controller, which also uses the Neidhart
ship, we concentrate on becoming partners with
system to allow for shock load absorption. The
our customers for life.”
skirt clamp ensures that positive pressure is always
applied to the side wall. Deon Crous, OST-Africa, Bearing Man Group, Tel: (012)
803-7254, E-Mail: deon@ost-africa.co.za
It is specifically designed for no spillage
The wide variety of applications, including replacing SAG mill based flow sheets, pebble
crushing, fine crushing and heap leach preparation, is testimony to the versatility of the
Polycom HPGR. Gold, copper, platreef, platinum UG2, molybdenum and iron ore count
amongst the important “hard rock” ores which are successfully treated.
Polycom HPGR -
The key to efficient Comminution
Voorspoed
Polysius Service Centre Johannesburg South Africa
Global acceptance
Since 2007 the following significant Polycom HPGR installations have been operating
successfully:
•South Africa – Mogalakwena, Platinum
•South Africa – Khumani, Iron ore
•South Africa – Voorspoed, Diamonds
•South Africa – Northam, Platinum
•Peru – Cerro Verde, Copper
•Indonesia – Freeport, Copper
Boddington
•Canada - Snap Lake, Diamonds
•Canada – Victor, Diamonds
•Australia – Boddington, Gold
•Ghana - Tarkwa, Gold
with many more Polycom HPGR's currently being installed and commissioned in
•Australia •Brazil •Canada •China •Japan •Mauritania •Mexico
Polysius
A division of ThyssenKrupp Engineering (Pty) Ltd Visit us at
71 Nanyuki Road, Sunninghill 2191 / Republic of South Africa Electra Mining
Tel: +27 (0) 11 236-1218. Fax: +27 (0) 11 236-1301 Hall 6, Stand J3
e-mail: pia.guertler@thyssenkrupp.com 4 - 8 Oct 2010
www.polysius.co.za
BULK HANDLING TODAY Feb 2010
CRUSHERS & SCREENS
Local Impactors
Buying capital equipment
locally has distinct
advantages in terms of spares
availability and support, but the
biggest benefit is being able to
Customising
custom engineer certain aspects on
The company kicked off with the design and manu-
machinery to suit specific conditions. In facture of a horizontal shaft impactor (HSI) and
rock crushing this is particularly convenient as so far have completed several installations with
the same raw material often differs from one region this machine as the primary crusher. Their vertical
to the next and a customised crusher can make a huge shaft impacter (VSI) has now been designed and
difference on the throughput. the company expects sales to take off this year.
“Most impact crushers in South Africa come from
B
ulk Handling Today” speaks to Shane Be- overseas but ours are entirely manufactured here
attie of Crushrite about the niche market in our workshop from locally sourced materials,”
this engineering company has created in says Shane. “Because we design ourselves, we
the local industry. “There’s always been have the flexibility to modify machines to very
this debate about choosing between a horizontal specific customer requirements.”
or a vertical impact crusher, but there is a place Turnkey
for both and therefore we decided to manufacture Although Crushrite sells their own series, they also
both,” he says. “From experience we know the make spares, service, maintain and upgrade other
advantages and shortcomings of impactors, so we makes of impact crushers for a broad spectrum of
decided to design our own series for both types existing customers in the lime, chrome and cement
of crushers.” processing industries. “We can supply anything from
Ours are entirely manufactured here in our workshop an impactor to full turnkey systems that include
from locally sourced materials conveyors, chutes and screens,” says Shane.
“We’ve just supplied the entire plant for a rubble
recycling operation and also a whole plant for a
lime processing application where our installation
functions as the primary processing machine.
Most recently we supplied a new Crushrite HSI
machine as a tertiary crusher in a cement pro-
cessing plant.”
Semi mobile
The system on both impactors is modular and can
be adapted to each individual situation while being
either semi-mobile or fixed. The semi-mobile unit
comes complete with VSD drive, control systems, modifications have been made to make the ma-
conveyors, impactor and screens. “Clients who are chine uncomplicated. “From the start our objec-
using our design have been impressed with the tive was to make our machines more user-friendly
reduction rates they’re getting,” says Shane. in general,” says Shane. “As we do a lot of the
maintenance ourselves, we paid a lot of attention
We’re reducing lump sizes of 450 down to 60 with a to ease of access, not only for servicing, but also
99% pass rate to replace parts.”
“At the lime installation, for example, we’re reducing Impact
lump sizes of 450 down to 60 with a 99% pass Although Crushrite’s two types of impactors work
rate. Lime stone is easy to work with though, but on completely different principles, the choice
in our chrome processing installation, which is a between the two depends mostly on the material
much more abrasive material, we’re also getting being processed and the reduction rate required.
feedback of above average reduction rates. Impact crushers involve the use of impact rather
Lump sizes than pressure to crush material.
“The rubble recycling company which is using our As an HSI crusher breaks rock by impacting the
semi-mobile unit says they can do lump sizes of rock with Blow Bars that are fixed on the outer
600 even with pieces of metal and rebar going edge of a spinning rotor, the particle size can be
through without damage to the machine.” controlled by the gap setting between the outer
Although the design of the Crushrite series is edges of the blow bar to the face of an impact
not unique in terms of the principle of operation, plate. The practical use of HSI crushers is limited
to medium to soft materials and non abrasive
materials, such as limestone, phosphate,
gypsum, and weathered shales.
Velocity
VSI crushers, on the other hand, use a different
approach involving a high speed rotor with
wear resistant tips and a crushing chamber.
This impactor predominantly utilises autog-
enous crushing (rock on rock) rather than
surface force to break rock. Final particle
size is controlled by the velocity at which
the rock is thrown against a Rock Box.
The product resulting from VSI crushing is
generally of a consistent cubical shape such
as that required by modern highway asphalt
applications. Using this method also allows
materials with much higher abrasiveness to
be crushed compared with an HSI and most
other crushing methods.
VSD drives are used on the impactors
Coal
“We’re targeting the coal industry as our
machine will show very low wear costs while
easily coping with the required tonnages as-
sociated with coal processing,” says Shane.
“Compared with cone and other crushing
methods, our machine is also about 30%
lower in capital costs. Because we manufac-
ture locally we’ve been able to offer a good
pricing structure and are able to make the
impactor a bit more affordable, especially
on the primary side.
In the aggregate industry the good product
shape and high percentage of sand makes the
impactors attractive while the high reduction
ratio of the H.S.I is a bonus.”
Shane Beattie, Crushrite, Tel: (011) 826-662, Email:
shane@crushrite.co.za
O
definitely a matter of individual choice, but there
ver the past 12 years the level of skills is a common element, being able to discern the
requirements versus available skills has optimal manner in which to increase productivity
influenced mining houses to re-evaluate and reduce downtime in each specific applica-
their business strategies and consider tion,” he says.
sourcing skills externally. “This is an ability which stems from skills, com-
Why a specific panel has to be replaced after a shorter mitment and experience gathered over many years
of industry exposure.”
period than planned
Flexible approach
Multotec was one of the first companies in the This flexibility in approach is evident in the structure
industry to actively embrace this trend and has of each branch of the business and the variety of
built up a strategic branch network to cater for the packages available to customers. “Although we offer
demand and to learn more. “Bulk Handling Today” the same basic elements to customers such as 24/7
speaks to Derrick Alston, service, preventative maintenance programmes,
managing director of Mul- service teams, strategic parts availability and so
totec Manufacturing. forth, each customer liaises with the branch man-
“In the past, the branches agers and the field service teams to determine the
we had in place served best fit for their particular operation.”
solely as sales outlets for “It would therefore be true to say that while some
our product range,” he says. of our branches are still in their infancy, all of the
“However, we identified a branches have the same work ethos and strive to
need to service our custom- find the most cost effective and workable solutions
ers more comprehensively to customers’ production and maintenance require-
by being located in close ments,” Derrick adds.
proximity to their opera-
tions and thus the branch Software
network was expanded for The company uses its in-house developed Hawkeye
this purpose.” software programme to monitor screen maintenance
processes. “This Web-based application, accessible
Common element anywhere in the world, offers both our people and
Derrick points out that be- our customers an easy-to-use interface which allows
cause each customer has accurate and efficient recording of maintenance
Derrick Alston, managing director of Multotec different needs, the ability
Manufacturing
activities,” says Derrick. “These entries are stored
in a database, and can be called up as required
in a number of ways so as to zoom in on what is
actually happening on the screen.”
“This is important information for us to have from
a costing perspective since it provides accurate
data on average usage and the cost implications
involved,” he adds. “In addition, the benefit to both
the customer and our maintenance team is that
Hawkeye provides us with accurate trends. For
example, it may indicate an inferior chute design
which is resulting in excessive wear and tear with
associated downtime. This then allows us to make
recommendations to customers to improve critical
elements within their plants.”
Correct stock
This also allows maintenance teams to be directed
to a specific problem area with the correct stock
Training is paramount at Multotec on hand. “Variance reporting records show why a
Pinpointing potential problem areas branch develops, to extend the full preventative
Success breed success, especially when the ser- maintenance package to other customers in the
vice offered to customers is of such a level that surrounding areas.”
downtime is consistently minimised. “We provide
Future hotspots
preventative maintenance services to a number of
“We have the capacity to customise products to
mines in the Northern Cape region including iron ore
customer specifications which means that the prod-
and diamonds,” Mark Mannel of Multotec’s Sishen
uct is the best fit from the outset, resulting in both
Branch says. “At this branch supply maintenance
increased productivity and decreased downtime,”
packages depend on the application demands, and
Derrick says in conclusion.
offer a high degree of flexibility to the customer. For
instance, we have a fixed rate with a permanent We have the capacity to customise products to customer
team on site or a variable rate, calculated in ton- specifications which means that the product is the best
nage of product passing over the panels. fit from the outset
“In the first case, a predetermined portion of the
“What is apparent throughout our branches is a
plant is shut down on a daily basis to allow inspec-
credo of reducing production costs for our cus-
tion and replacement of screen panels, sideliners
tomers through analysing their specific needs,
and nozzles to ensure the seamless running of the
monitoring their operations to proactively pinpoint
process. The other option is to dovetail mainte-
future hotspots, planning for maintenance that will
nance requirements with the customer’s shutdown
have the least negative effect on the production
schedule, again minimising plant disruption or
process, and retaining adequate and appropriate
shutdown.”
stock levels in order to facilitate maximised uptime
Shipshape for our customers’ operations.”
Unlike its counterparts which deal with land-based Bernadette Wilson, Multotec Group, Tel: (011) 923-6193
customers, Multotec’s Cape Town branch is actively Email: marketing@multotec.co.za, Website: www.mul-
involved in maintaining the screens, mills, cyclone, totec.com
magnetic separators and other process related
equipment such as chutes on vessel-based diamond
processing plants. “Our maintenance periods are
also governed by statutory regulations of maritime
law and very specific wear patterns related to
mining at sea. In other words, we often wait until
we are informed by our customer that a ship is
coming into port and then we encamp ourselves
on the ship for the duration of the running repairs
and replacements,” Vivian Rocher, Multotec’s Cape
Town branch manager, says.
“In other instances, a ship may be forced into port
because it has lost an anchor or some similar mishap
has occurred and then we seize the opportunity to
conduct required maintenance. In cooperation with
the customer, breakdowns and other emergencies
are also dealt with at sea.”
Building on a concept
Such has been the success of Multotec’s philosophy
of providing a total support solution through the
establishment of branch offices in close proximity
to its customers that new locations are constantly
being investigated and developed.
Dawie van Eeden, who was responsible for setting up
and developing the Sishen and Kimberley branches,
is now in the process of establishing an office in
the Lephalale area, previously known as Ellisras.
“In addition to Lephalale, this area extends from
Thabazimbi into Botswana and northern Limpopo
where we currently provide a full time maintenance
programme to one of the largest diamond mines
in South Africa as well as an ad hoc maintenance
service to other mines in the area,” he says. “The
aim is to develop this service offering and, as the Trommel aperture panel replacement underway
T
his dust is generally not released intention-
ally, but more often than not comes from
leaking dust conveying and dust collecting
systems that have not been maintained
properly or worse, not installed correctly from the
start. “Bulk Handling Today” speaks to Jeremy
Kirsch, executive director of Clyde Materials Han-
dling Africa, an expert in pneumatic conveying and
dust collection systems.
New developments
Continuous dense conveying has always been a chal-
lenge but the engineering team at Clyde Materials
Handling in South Africa has now found a solution.
“We have come up with a technology whereby we
can go from the traditional dense phase conveying,
which is a batch-wise process, to true continu-
ous dense phase conveying,” Jeremy says. “The
continuous dense phase conveying system we’ve
developed shows a reduction in energy consumption
The CD-Pump system from Clyde Materials Handling of at least 15% and greater, which is a quantum
leap in terms of savings in industry.
Clyde Materials Handling Africa has the technol-
ogy to prevent dust pollution while saving energy “In addition, we have paid attention to mechani-
at the same time. “Several institutions have begun cal problems in order reduce maintenance to the
installing our systems, because of the air pollution minimum. Better, longer lasting sealing arrange-
and energy saving benefits,” says Jeremy, “but ments, new valve systems and injector technology
mostly from a maintenance perspective. In our for furnace feeding are some of the improvements
experience, the only companies that are prepared that are now standard on our products.”
to make dramatic changes away from traditional Jeremy Kirsch, Clyde Materials Handling Africa, Tel: (011)
technologies are those that have experienced im- 704-0580, Email: jeremyk@cbz.co.za
mense pain.
Unworkable
“Let’s say there is something in a plant that is
not working very well, but due to high production
pressure, nothing is done about it. Quick fixes are
When the business world lights up again, and
the order of the day until the issue gets to manage-
the clarion call for skills is heard once more,
ment level where they realise they’re losing money,”
will you be on our database for us to contact
explains Jeremy. “This is when they will open up
you?
and start looking at other technologies to try and
www.engineerplacements.com
solve their problems.
or email us at:
“Situations like these, where maintenance prob- admin@engineerplacements.com
lems have become unworkable, have given us the
Understanding Electric
Motors
T
here are two
main types of
electrical mo-
tors found in
industry: AC motors
and DC motors. For
the purposes of this
paper, we will deal
only with AC motors
as DC motors are used
very infrequently and
are only be applied in
very specialised ap-
plications. AC motors
are available in three
types: Asynchronous
AC induction motors,
synchronous AC in-
duction motors and
slipring AC induction
motors.
Of these three types
Figure 1: “Squirrel Cage” Motor only the asynchronous
AC induction motor
needs to be considered
for conveyor applications. This type of motor is also known
as a “squirrel cage” motor or even just as an AC motor.
IP Rating Definition Prime mover
First Numeral Second Numeral Due to its construction and
Protection against solids Protection against liquids
electrical characteristics, this
motor has become the prime
0 No Protection 0 No Protection
mover in all industries. These
1 Protection against solid objects > 50 mm 1 Protected against vertically falling drops of water motors are simple to operate,
(hands) (condensation)
very robust and adaptable to
2 Protection against solid objects > 12 mm 2 Protected against sprays of water up to 15º from most applications. Because
(fingers) vertical
there is no physical connec-
3 Protection against solid objects > 2.5 mm 3 Protected against sprays of water up to 60º from tion from the rotor to any
(tools / wires) vertical
external electrical power
4 Protection against solid objects > 1.0 mm 4 Protected against water sprayed from all directions
(small tools / wires) (outdoor rain)Limited ingress permitted supply, the standard AC motor
can be designed to an IP55
5 Protection against dustLimited ingress per- 5 Protected against low pressure jets of water sprayed
mittedNo harmful deposits from all directions (hosepipe)Limited ingress per- or even an IP66 degree of
mitted protection. Different electri-
6 Totally protected against dust 6 Protected against strong jets of water sprayed from cal designs are also possible,
all directionsLimited ingress permitted for example, such as motors
7 Protected against immersion between 15cm and that need either a high or low
1m torque to start.
8 Protected against long periods of immersion under
pressure (> 1 m) The IP rating of a motor is a
specification of it’s degree of
Table 1: IP rating definition
protection against the ingress of external contaminants ie, wound around a part of the stator core. Each phase produces
solids and liquids. “IP” is the abbreviation for “Increased a magnetic field. As the AC voltage fluctuates, the magnetic
Protection”. The higher the IP rating the higher degree of field changes and rotates. The movement of the magnetic
protection. Table 1 details the meaning of the various IP field in the stator magnetically induces a voltage and current
ratings. in the rotor. (Hence the term induction motor).
The higher the degree of protection, the more The current flowing in the rotor also produces a magnetic field.
The stator and rotor magnetic field interact. The stator field
robust the item must be
attracts the rotor field causing the rotor to rotate following
the stator field. Except for VSD applications, the stator field
Practical implications always rotates at a speed that corresponds exactly with the
It would seem then that the best you can do is to specify
frequency of the supply. In South Africa this is 50Hz. When
that all motors and VSD panels be IP68 or IP66. Unfortu-
a motor has 2-poles the speed of rotation is 3000 RPM,
nately, there are practical implications to achieving the above
4-poles is 1500 RPM and 6 poles is 1000 RPM. This can
protections. The higher the degree of protection, the more
be calculated as follows:
robust the item must be. Due to the simplicity of construc-
tion an AC motor can easily and practically be manufactured
to a high degree of protection. Guidelines for IP ratings for
standard AC motors as per figure 1 on previous page are
given below.
This is known as “synchronous speed”. It is synchronized
• Cast iron totally enclosed – IP66
with the mains supply frequency.
• Large AC motor of fabricated steel construction – IP55
• Large AC motor terminal box – IP65 The rotor and hence the motor shaft never turns at the same
• VSD panel for indoor use – IP42 speed as the stator field. The difference in rotational speed
• VSD panel for outdoor use – IP54 is termed the motor “slip”. Typical slip values are between
0.3% and 4% of stator speed. The actual value of the slip
Magnetic field differs from motor to motor and is dependant on many de-
A three-phase alternating current (AC) voltage is applied to sign factors. A 4-pole motor can thus run at 1450 RPM or
such a motor. Each phase is connected to a winding, which is perhaps 1460 RPM or even 1490 RPM. This is the motor’s
4. Locked rotor time – This defines the length of time for ambient temperature of 40°C the hottest spot in the motor
which a motor can draw starting current without overheating. would reach 130°C, while the motor insulation system is
Starting current is drawn during acceleration; therefore the capable of operating at 155°C. This gave a margin of safety
motor locked rotor time must exceed the time required for of 25°C. In recent times, and especially in the 525 V mining
acceleration. Motor manufacturers may provide either a hot industry, this has changed so that the motors have a Class
or cold locked rotor time. The locked rotor time considered H insulation system. This then gives a safety margin of
should be the hot locked rotor time so that the load can be 50°C. In addition, it is seldom that motors are run at 100%
started without undue delay after a trip. A high inertia load of nominal power.
such as a fan will require a long locked rotor time. Conveyors These temperature classes have nothing to do with dielec-
have a low inertia and do not require a long locked rotor tric strength or voltage insulating strength or capability to
time. It is desirable for a conveyor to have a very gradual withstand peak voltage capability.
acceleration over a fairly lengthy period.
The second consideration in terms of motor insulation is
This is normally achieved by using an electronic variable dielectric strength or peak voltage rating of the motor insu-
speed drive or a mechanical fluid drive coupling. In both lation. When a motor is used with 525 V, it does not have
cases the motor is not subjected to starting current during 525 V insulation because the peak values of the sine wave
the acceleration time. and other voltage peaks present are much higher. When
These are not the only considerations. A complete design used in DOL applications, the voltage rating is not a major
would consider the mechanical mounting arrangement, concern. This is because most insulation systems can cater
type of bearings, type of coupling, ambient and altitude for voltage peak values >1000 V. This far exceeds any volt-
de-rating, etc. age peak that occurs on a DOL system. In resent years, the
percentage of motors used on AC variable speed drives has
Specific motor features for conveyor applications
increased greatly. On VSD applications the motor insulation
From a motor electrical design perspective, conveyor applica-
dielectric strength is very important. The requirements for
tions do not require any specific features. Selection should
VSD applications are dealt with later in this article.
be as described in the previous section. Often conveyors are
in locations where the ambient conditions and mounting VSD motor applications
arrangement must be taken into account. There are many benefits to using VSD driven motors on
conveyor applications:
Not a pure smooth sine wave such as Eskom 1. The conveyor start-up can be controlled optimally and
supplies thereby the stress to the belt and structure is minimised
2. The conveyor speed can be varied to cater for differing
Different types of motor insulation product or process delivery requirements
In terms of motor insulation, the main consideration is ther-
3. At times when full production is not required, the conveyor
mal characteristics. This defines the maximum temperature
can be slowed down resulting in reduced electrical power
that the motor can reach before the insulation material is
consumption and also reduced mechanical wear
damaged. For practical purposes, there are three tempera-
ture classes to consider: Class B, Class F and Class H. The There are many concerns as to AC motor compatibility for
temperature class is determined as follows: VSD applications. In principle, any normal AC motor can be
used in conjunction with any AC VSD. The VSD will start and
Motor insulation Thermal Classes in °C control the motor speed. The issue of compatibility affects
medium and long term durability and reliability. So, while
Insulation Class: B F H
any AC motor can be driven by any AC VSD, this does not
Ambient 40 40 40 necessarily guarantee compatibility. Fortunately, this is not
Heat rise 80 100 125 difficult to achieve. Compatibility can be considered from
Hot spot allowance 10 15 15 four perspectives:
Total maximum temperature 130 155 180 1. The motor thermal capability
Table 3: Summary of thermal class values 2. The motor insulation suitability
3. Mechanical adaptations required on the motor
Total maximum temperature = Ambient + heat rise + hot 4. Mechanical speed limitations
spot allowance The voltage and current that an AC VSD supplies to a motor
Ambient temperature is 40°C is not a pure smooth sine wave such as Eskom supplies. The
distortion is known as harmonic distortion. This distortion
Heat rise is the motor rise in temperature when it supplies
creates additional heat losses of 1 – 5% in the motor. The
nominal power. Hot spot allowance makes allowance for the
motor thermal capability and hence it’s torque delivery is
reality of a non-uniform heat rise resulting in certain points
reduced by this amount. An AC VSD driven motor current
within the motor being hotter than others.
is illustrated in graph 3.
Table 3 gives a summary of the thermal class values.
Loss of cooling
Until recently almost all motors were designed and specified An AC motor is dependant on a shaft-mounted cooling fan on
with a Class B heat rise and a Class F insulation system. the non-drive end for cooling air flow. When a VSD is used
This meant that when operated at 100% full load in an to slow the motor down, this air flow is reduced. As a result,
permissible current
at which the motor
can run is reduced.
Current and torque are
roughly proportional,
therefore the motor
capability to deliver
torque on its output
shaft is reduced. The
relationship between
speed and torque is il-
lustrated in Graph 4.
For example, a motor
may be rated at 100
A and 200 Nm. When
used in a VSD ap-
plication, this motor
can only deliver 95
A and 190 Nm for
an extended period
Graph 3
of time. If this same
motor runs at 25%
the motor thermal capability is reduced. This means that at speed it can only deliver 75 A and 150 Nm at that speed.
speeds below 100%, the motor can no longer run at 100% This is a purely thermal consideration and this limitation only
nominal current. To compensate for the loss of cooling, the applies to constant operation. The motor may be overloaded
Equation 2
Photograph 1
to apply. This standard deals with ≤500 V and then ≥600 fit an insulated non-drive end bearing and a shaft grounding
V. This leaves a gap exactly for the South African 525 V device on the drive end.
market. Furthermore, the IEC standard links the voltage The final consideration is the mechanical speed limitation.
rating requirement to the rise time of the VSD pulses. This The motor bearings are limited to a certain maximum speed.
value is very seldom known and therefore not a practical On small motors, this is in the region of 6000 RPM, but on
and useful specification. larger machines the limit is lower.
The American Nema MG1 Part 31 has a more practical
Motor standards
specification. Nema requires insulation that is ≥ 3.1 x the
There are three standards for general industrial use AC
supply voltage and inverter output rise time > 0.1 µsec.
motors.
This rise time requirement is generally met and therefore not
of concern. Both Nema and IEC refer to “General Purpose” SANS / IEC 60034
motors and “Definite Purpose” or VSD motors. SANS / IEC 60072
SABS 1804
Differentiate
How does the user differentiate between a general purpose These standards cover all the specifications and require-
and a VSD purpose motor? Which of these motors are stocked ments. They are well known and applied by the South African
and supplied by the motor suppliers? While this may seem motor industry.
problematic, the situation is really simple. In South Africa Maintenance
nobody stocks and supplies “VSD Purpose” motors as a One of the benefits of standard AC motors is that they re-
standard. These motors are always specially labeled and quire very little maintenance. The requirements are listed
identified. below:
Differences are so small that they are negligible 1. Visual inspection – weekly.
2. Bearing vibration check – monthly.
There are however, local suppliers that stock and supply 3. Greasing of bearings – according to the motor greasing
“General Purpose” motors that are also designed and manu- plate requirements. This is normally every 2 – 4 months.
factured to be suitable for VSD use. These motors have an 4. Check and clean terminal box – annually.
insulation rating that is ≥3.1 VAC supply in accordance 5. Complete overhaul, i.e. dismantle, clean, re-paint, replace
with the Nema MG1 Part 31 mentioned above. So for 525V bearings, replace any parts that are damaged, re-assemble
systems the motor insulation must be ≥ 525 x 3.1 = 1627 and re-grease – 3 year intervals.
V and on 400 V systems the motor insulation must be ≥
400 x 3.1 = 1240 V. The above proposed maintenance schedule may be varied
according to individual end-user or site requirements. Some
Individual pulses motors are small and drive unimportant items. The user may
If motors of this standard are used then the user does not elect to do no maintenance and simply replace them as and
have to be concerned about the suitability of either new or when required. Some motors drive very critical applications
spare motors for either DOL or VSD use. This means that and should be inspected on a daily basis.
motor selection on this basis is easy and that these motors
If a motor has been inspected regularly, the bearings have
are readily available.
received grease according to the stipulated intervals and
The normal 3-phase voltage that a DOL motor would be vibration monitoring does not indicate any problem, then
connected to when started DOL is a balanced sinusoidal the suggested complete overhaul may be ignored.
waveform. At any point in time, the three phases are bal-
In terms of maintenance, the single most important con-
anced and their vector sum is zero. In reality, the balance
sideration is alignment. The majority of motor failures can
is not perfect but the differences are so small that they are
be attributed to misalignment. The initial installation must
negligible. When supplied from a VSD, the motor voltage
ensure correct alignment. Once in operation ongoing bear-
consists of many individual pulses that add to produce a
ing vibration analysis will show if there is any problem with
near sinusoidal voltage waveform. (See figure 3) The three
alignment.
voltages are not balanced.
This results in voltage being induced into the metal frame Conclusion
of the motor and in the motor rotor. This voltage will Some of the issues related to motors are complicated at a
cause a current to flow from the motor down to earth. The design level. However, the solutions and application thereof
current flowing from the rotor can only pass through the for the user are simple and clearly defined. This paper has
bearings to go down to earth. The result is pitting, which aimed to present this. When the various issues as dealt with
damages the bearing and leads to failure, as illustrated in in this paper are properly considered the user or designer
photograph 1. can have confidence of a successful installation that will
operate correctly and efficiently for many years
Frame size This paper has been condensed due to space constraints. The author
It is a rather complex phenomenon. The solution however is Johan van Niekerk of Zest Electric Motors & Drives.
is simple. This phenomenon can only build up sufficient This paper was first presented at Beltcon 15 held in Johannesburg
electrical field in motors with a frame size greater than a on September 2 and 3, 2009 and copyright is vested with the IMHC.
280 frame. On all VSD application motors of frame size Enquiries can be made through the website; www.beltcon.org.za
>280, the vendor must be informed. The vendor will then
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40 BULK HANDLING TODAY Feb 2010