Nowadays, competition in the industrial world has increased and is continuously going up. One of the major reasons is a significant rise in the number of MSMEs by 2.4 times since 2020, and this is where maximising efficiency and cost-effectiveness becomes essential. In this pursuit of a smooth industrial process, ensuring optimal motor performance is of the utmost importance.
Traditional on-off control methods for electric motors result in a surge in current during startup, which leads to various drawbacks. This is where a soft starter comes in handy. These starters are motor control devices designed to provide a gradual increase in power during motor startup and a controlled decrease during shutdown. Let’s understand better how soft starters add significant long-term value and future-proof your motor operations.
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The Advantages of Using Soft Starters
A soft starter acts as a buffer between the power supply and the motor. It gradually ramps up the voltage and frequency during startup. This gradual acceleration helps streamline industrial operations and paves the way for several other advantages. Some of them are:
1. Reduced Mechanical Stress on Motors
Traditional across-the-line starting subjects motors to a significant current surge, causing mechanical stress on components like belts, bearings, and couplings. This, in turn, can lead to premature wear and tear, frequent maintenance needs, and, ultimately, motor failure.
A soft starter eliminates this issue by gradually increasing the starting torque, significantly reducing the strain on mechanical components. This translates to extended equipment lifespan, lower maintenance costs, and improved overall reliability.
2.Enhanced Power Quality
The current surge during conventional motor startup can cause voltage dips in the electrical supply. This can affect the starting motor and disrupt the operation of other sensitive equipment on the same power grid.
Soft starters help overcome this issue by controlling the inrush current, minimising voltage fluctuations, and ensuring a cleaner, more stable power supply. This improved power quality benefits all equipment on the network and contributes to a more efficient overall operation.
3. Energy Savings and Reduced Demand Charges
The surge in current during motor startup also increases energy consumption. A soft starter, by controlling the starting current, can significantly reduce energy usage during this critical phase.
In addition, many utilities impose demand charges based on peak energy consumption. Here, these starters can help lower these charges by minimizing the peak current drawn during motor startup.
Additional Advantages of Using a Soft Starter
While reduced stress, improved power quality, and energy savings are the core benefits of soft starters, they offer additional advantages that contribute to long-term value.
- Improved Process Control: A soft starter provides more precise control over motor acceleration and deceleration. This is crucial for applications requiring consistent speed control or those sensitive to sudden jolts.
- Reduced Water Hammer Effect: In pump applications, the sudden on-off operation can create a water hammer effect, causing damage to pipes and valves. Here, a soft starter helps to mitigate this effect, ensuring smoother operation and protecting the entire pump system.
- Extended Motor Life: A soft starter contributes to a longer lifespan for your valuable motors by minimising mechanical stress and thermal heating during startup and shutdown.
Leveraging Soft Starters for Industrial Success
The benefits of soft starters are undeniable. However, to maximise the value proposition, it is crucial to partner with a reputable partner that offers a comprehensive range of soft starter solutions.
Look for a company with a proven track record, a strong commitment to innovation, and reliable after-sales support. This will ensure you receive the right soft starter solution for your specific needs and technical expertise.
Partner with the right energy and automation solutions provider to future-proof your industry’s motor operations for long-term success today!
Sources: https://www.cnbctv18.com/economy/udyam-registered-micro-businesses-double-fy22-fy20-18981721.htm
https://www.researchgate.net/publication/288480915_Essentials_of_Mechanical_Stress_Analysis
