According to Kes Beech, technical manager at Invertek Drives, in the realm of electric motors and drives technology, the overarching trend right now is for maximising energy efficiency. “This drive for efficiency is fuelled by both economic and environmental considerations, and variable frequency drive (VFD) technology is at the heart of enabling this shift,” Beech states.
He reports that Invertek is witnessing a surge in demand for VFDs with advanced features such as regenerative braking (which captures and reuses energy that would otherwise be wasted). Additionally, Beech says he’s noticed growing interest in drives that are capable of seamless integration with smart energy management systems, allowing for real-time monitoring and optimisation of energy use. “We’re also seeing increasing adoption of VFDs in sectors traditionally reliant on fixed-speed motors, such as HVAC and water or wastewater treatment. This reflects a growing recognition of the substantial energy and cost savings that VFDs can deliver,” he explains.
Invertek is actively responding to and enabling these trends through continuous innovation, says Beech. “Our latest Optidrive models boast improved efficiency levels, enhanced communication capabilities and smarter control algorithms – all contributing to greater energy savings and a reduced carbon footprint,” he explains. “Additionally, we’re investing considerably in our future capabilities. A planned new innovation centre, coupled with an expanding team of talented engineers, highlights our commitment to staying at the peak of VFD technology development.”
SAVINGS PLAN
Discussing the benefits of his firm’s approach for end users, Beech says he believes that Invertek is at the forefront of demonstrating how VFD technology is pivotal in achieving cost savings and supporting environmental sustainability across industrial applications globally. More tangibly, what these benefits translate to in real-world applications is potential energy savings of up to 50% in certain applications, such as pumping and fans/ventilation – a benefit that directly impacts the bottom line for businesses.
“Furthermore, the smoother starts and stops facilitated by VFDs minimise mechanical stress on the equipment, leading to reduced wear and tear. This results in extended equipment lifespans and decreased maintenance costs, adding another layer of financial benefit,” Beech notes.
An additional advantage is the precise speed control through VFDs enables process optimisation, leading to increased productivity and potential cost reductions across various industrial operations.
Beech is also keen to point out that the merits of VFDs go beyond financial savings. “The environmental sustainability aspect of VFDs is equally important,” he emphasises. “The reduced energy consumption resulting from optimised motor control directly contributes to lower greenhouse gas emissions, playing a vital role in combating climate change.
“By enhancing the efficiency of motor-driven systems, VFDs empower industries to decrease their overall carbon footprint and advance towards a greener future,” he adds.
In terms of specific products, Beech says that the company’s Optidrive VFD range “embodies these principles of efficiency and sustainability”. Its advanced algorithms and power electronics ensure optimal energy utilisation across diverse applications.“Easy integration features simplify installation and operation, making energy savings readily achievable,” he explains. “The robust design and comprehensive protection mechanisms ensure long-term, reliable performance, minimising waste and resource consumption.”
RANGE REFRESH
The Optidrive range relies on continual R&D inputs on both the hardware and software sides to ensure that each generation delivers greater energy efficiency in the systems it controls. “Our current range – particularly the Optidrive Eco VFD – has been meticulously designed to maximise efficiencies in applications such as pump control,” explains Beech.
Beyond solutions for the precise control of electric pumps, Invertek has also developed the Optiflow system. “Optiflow enables multiple Optidrive Eco drives to work together seamlessly, optimising flow and energy use across an entire system,” Beech details. “Imagine four pumps working in concert – the first Optidrive Eco acts as the master, intelligently controlling and commanding the other three drives, adjusting their speeds and run times based on real-time demand. This is crucial in scenarios with fluctuating water requirements. Instead of a system of constantly running pumps, Optiflow allows for dynamic adjustments, ensuring energy is only used when and where it’s truly needed.
“A key advantage of Optiflow is its self-contained nature,” he continues. “There’s no need for external PLCs or additional control devices. The entire programme resides within the Eco drives themselves, requiring minimal setup from the user. The system leverages the internal PID function of the Eco drives for intelligent control based on consumer demand. The result is a continuous, optimised output flow with no overshoot, reducing mechanical stress and ensuring savings on wear and tear and downtime.”
CASE IN POINT
When asked for examples of real-world applications of Invertek’s drive technology, Beech says that two recent case studies showcase how much of a difference VFDs can make. “The first project involved T.A. Handte Ibérica, a leading provider of industrial smoke, dust and gas extraction and filtration solutions. The company aimed to create a versatile and adaptable control solution for its diverse range of filtration systems, including wet scrubbers and cartridge filters,” he explains. “Invertek Drives Ibérica, proposed the Optidrive Eco VFD with integrated PLC functionality as the ideal solution. The VFD offered a combination of precise motor control, customisable logic programming and diverse I/O capabilities, addressing the company’s key challenges.”
Beech says that, according to the happy customer, the implementation of the Optidrive Eco VFD with integrated PLC “revolutionised and enhanced” the filtration systems, delivering numerous benefits in terms of performance, operation, safety and cost savings.
The second success story involved the application of VFD technology at a coffee roaster in Indonesia. “Coffee roasting hinges on meticulous control of temperature and airflow. Accurate control of gear motors enables consistent and high-quality coffee roasting across cafes, roasteries and industrial settings,” says Beech. In this project, Optidrive E3 VFDs stepped in to precisely control the speed of the gear motors powering the rotating bean drum, motor blower and cooling agitator. “They ensure each batch achieves the desired roast profile with consistency. This creates exceptional drink quality, roast after roast, ensuring the roaster’s reputation for excellence,” reveals Beech.
THE BIGGER PICTURE
An interesting knock-on effect of deploying Invertek’s drives is that they can extend their energy-saving capabilities to other applications as well. Beech explains: “For instance, they can precisely adjust the electric motor control of fans or HVAC systems, ensuring accurate airflow for temperature and humidity regulation. Again, this translates to energy usage only when necessary, rather than constant full-speed operation.
“Overall, the trend towards energy efficiency is clear and compelling across diverse applications in almost all industry sectors,” summarises Beech. “At Invertek, we’re dedicated to not only keeping pace but also driving this trend forward through innovative VFD technology and a steadfast focus on sustainability.”
BOX: A GOOD EXAMPLE
Discussing environmental considerations, Beech says that Invertek Drives’ commitment to sustainability goes beyond product innovation. “The company leads by example, implementing initiatives such as the installation of photovoltaic cells at our global headquarters in Welshpool, UK and the use of electric vehicles throughout our fleet,” he details. “Additionally, the global assembly cells (GACs) used in the assembly and testing of our Optidrive VFDs, use a regenerative braking system. This allows each GAC to capture and recycle energy that would otherwise be lost. This proactive approach to reducing our own energy consumption and environmental impact reinforces our dedication to a sustainable future.”