Industrial Motor

Industrial Motor | The Complete FAQ Guide

The purpose of electrical motors is to transfer electrical energy into mechanical energy, and industrial motors are not different. Industries are dependent on industrial motors to manufacture power and produce their products.

Industrial motors are of two types – AC motors and DC motors. DC motors are powered by DC current, which is generated from batteries, and that’s why they are not widely used for industrial purposes.

Xinnuo motors is one of the leading industrial motor manufacturers in China. We receive lots of questions from our clients and people planning to purchase an industrial motor. That prompted us to create a detailed guide on the industrial motor.

1. What is an Industrial Motor? 

An industrial motor is a high-grade motor used for industrial purposes. It converts electrical energy into mechanical energy. You can create a linear or rotary force with an industrial motor and you can use both AC and DC motors for this purpose.

Figure 1 – Industrial motor

There are two types of  Industrial motors – DC motor and AC motor. DC motors use direct current and AC motors use alternate current. With DC motors you will get precise controls.

For industrial purposes, you will mostly see AC motors.

2. What Are The Components of an Industrial Motor? 

Industrial motors are machines that convert electric energy into mechanical energy. You can use AC or DC current to power up your industrial motors. Though you can use direct current such as batteries for an industrial motor, you will see AC sources such as power grids, generators for industrial motors.

Here are the components of industrial motors:

Armature Or Rotor 

The armature or rotor is the moving part of an industrial motor. The armature turns the shaft to convert electrical energy into a mechanical one.

Figure 2 – Rotor

Typically, the rotor is placed in the middle part of the engine and rotates when the poles are attracted, and the stator poles repel.

Stator

Stator’s electromagnet’s wire length is the key to the strength of your industrial motor.

Figure 3 – Stator and Rotor

The stator is the central part of the electromagnetic circuit. It contains thin metal sheets reducing energy use. You can use windings or a permanent magnet in the stator of your industrial motor.

Air Gap

Air gap is the physical gap between the stator and rotor and plays a vital role to increase the reluctance in the magnetic circuit.  Therefore, for optimum performance the air gap is crucial.

Figure 4 – Air Gap in induction motor

Less air gaps make the industrial motors more efficient.

Coil or Windings 

These are the wires wound around the core.

Figure 5 – Stator winding

Typically, insulated copper and aluminium are used as winding

Commutator

Commutators periodically reverse the electricity direction in a Industrial motor. This is a very important operation because, without this, the industrial motor will stop.

Figure 6 – Commutator

In most cases, the commutator is insulated from the shaft and each other and made of slip ring segments. However, brushes are another way to employ this mechanism, and you will see those in DC industrial motors.

3. What is an AC motor? 

Alternate current or AC runs an AC motor and the motor converts the electric energy into mechanical energy. Alternate current reverses direction and changes its magnitude periodically.

In contrast, the DC current does not change its direction or amplitude at any time. And that is why manufacturing AC industrial motors is a more sophisticated task.

Types of AC motors

You will find various types of AC motors. Here are some of the types:

• Single Phase AC motors
• Polyphase AC Motor
• Synchronous AC Motor
• Reluctance Motors
• Hysteresis AC Motor
• Repulsion Motor
• Asynchronous Motor

Industrial Applications of AC motors 

AC motors are low-cost and are used in various applications. From household works to heavy industrial applications, AC motors are used everywhere.

• Appliances
• Hydraulic and irrigation pumps
• Compressor drives and systems
• Conveyor systems
• Computers
• Transportation equipment
• Fans and air conditioners,
• And many more.

5. What are Basic Factors to Consider before Selecting an Industrial motor?

Choosing an industrial motor is not that tough if you know the application type. We will discuss that later in this article. Let’s discuss the properties you should take care of when you purchase an industrial motor:

Horsepower: It describes the power of a motor. Determine the horsepower you would need and purchase according to that. Do not go for too much horsepower if you don’t need that. Conveyors, cranes are some examples where you will need variable horsepower industrial motors. So, with the horsepower, you should also consider the speed type.

Torque – It is the rotational equivalent of linear force. Some machines need constant torque with variable horsepower. So, the application type is also essential here.

Position Control – Precise positioning is mandatory where a machine must be placed in multiple positions sequentially and accurately. For example, paper and still mills need this advantage.

Speed – An industrial Motor works most efficiently when running at its top or near top speed. Therefore, you should know the optimum speed you will need for your application. Besides, if you need variable speed settings, you should also tell your industrial motor supplier about this requirement.

Current – You will need predictable torque to complete your task. The operating current of a motor describes how much current it must draw to produce the desired torque.

Voltage – High voltage motors manufacture high torque. And to produce the desired voltage, you will need to set up a specific environment. Remember, any flaw with this environment will not produce the desired outcome, and in the worst case, you can damage your AC industrial motor.

In Xinnio motors, we have a dedicated team to assist new clients. Just send us a message, and we will suggest the exact motor you need for your industrial application.

3. What are The Types of Industrial Motor?

Industrial motors are the driving force of industries. As a leading industrial motor manufacturer, we can say that more and more new industrial motors are being added every day. Let’s look at the type of motors you will find in the market:

DC Series Motor

DC series motors have variable speed and a high starting torque. You can use them in heavy-duty applications such as steel rolling mills, lifts, hoists, cranes, and electric locomotives.

DC Shunt Motor

DC shunt motors have a nearly constant speed and medium starting torque. You will see DC shunt motors in a lathe, woodworking machines, elevators, laundry washing machines, conveyors, small printing machines, and grinders.

Cumulative Compound Motor

These industrial motors have high starting speeds with different speed settings. You will see these motors driving variable head centrifugal pumps, compressors, rotary presses, sharing machines, saws, and continuous conveyors, etc.

Three-phase Asynchronous Motor

Three-phase induction motors are widely used in various industrial applications. You can see them in pressing machines, pumps, lathe and grinding machines, flour mills, conveyors, and many other industrial applications.

In Xinnuo motors, we manufacture a wide range of three-phase asynchronous motors for various industrial applications. Our motors are highly efficient, and we follow the best manufacturing practices to maintain the quality.

Squirrel Cage Induction Motor

These industrial motors are simple in design but come with high overload capacity. It comes with poor starting speed and operates at a constant speed.

If your application type is medium and doesn’t need speed control, you can use a squirrel cage induction motor.

Double Squirrel Cage Motor

These motors have high starting torque, nearly constant speed, and colossal overload capacity. You should use these industrial motors where you need high starting torque, such as reciprocating pumps, compressor pumps—crushers, large refrigerators, textile machinery, boring mills, punches, lathes, and cranes, etc.

Slip Ring Induction Motor

These motors have a large overload capacity and high starting torque. You can change the speed of the slip ring induction motor up to 50% of its regular rate. You can use a slip ring induction motor where high starting torque and speed control are mandatory.

Single Phase Synchronous Motor

Single-phase synchronous motors come with constant speed, and you can use them in clocks, teleprints, recording instruments, reproducing systems, sound recordings, etc.

Single Phase Series Motor

Single-phase series motors have high starting torque and a wide range of speed controlling options. They are not ideal for industrial application, though. Instead, you can use single-phase series motors in domestic applications such as vacuum cleaners, refrigerators.

Capacitor Start Induction Run Motor

These motors have a moderately good starting torque and constant speed. You can not control the pace here. These motors are typically used in refrigerators, compressors, and small portable hoists.

4. What is a single-phase Induction Motor?

We are talking about the industrial motor, and the single-phase induction motor has some industrial uses. These motors use a single-phase AC current to produce mechanical energy. Single-phase AC supply uses two-wire systems. One wire powers the phase wire, and current flows between the power wire and the neutral wire.

Below are the types of Single Phase induction motors:

1) Split phase motors.

• Two-value capacitor motor.
• Capacitance-start motors.
• Permanent split capacitor motor.
• Resistance-start motors.

2)Reluctance-start induction motor.

3)Shaded-pole induction motors.

4)Repulsion –start induction motor.

In Xinnuo motors we have Aluminum shell Single phase with capacitor motor (MY/ML series), Aluminum shell Single phase with capacitor B35 motor (MY/ML series), Single Phase dual value capacitor motor (YL series) Single phase capacitors asynchronous motors .

Applications of Single phase induction motors 

You will find these motors in Air conditioners, refrigerators, vacuum cleaners, centrifugal pumps, small firming appliances, washing machines, blowers, etc.

Single-phase motors are mainly used in those applications that need low power but constant speed. Single-phase AC is supplied in standard electricity connection. On the other hand, three-phase AC is used as an industrial current.

Therefore, single-phase induction motors are not widely used in industrial applications. Instead, they are mainly used in home applications.

Are you looking for an industry-grade single-phase industrial motor? Tell us in brief, and we will assist you in choosing the best one that suits your needs.

If you want to learn more on induction motor please watch the video

https://youtu.be/AQqyGNOP_3o

5. What is a Three-phase Induction Motor?

When you are talking about industrial motors, three-phase industrial motors are the most important ones. A Three-phase industrial motor is a kind of machine that uses a three-phase alternate current to produce mechanical energy.

A three-phase AC or alternate current is three wires and produces a stable voltage all over the circuit. They are also called asynchronous motors.

Constructions of Three Phases Asynchronous motor 

A three-phase asynchronous induction motor consists of a rotor and stator with no electric connection between them.

You can use rolled steel, aluminum, cast iron to construct the stator frame providing support and mechanical protection for windings and other arrangements.

There are three-phase windings in the stator overlapped at an angle of 120 degrees shaft installed into slotted laminations.

Figure 10 – 3-phase induction motor construction

The winding material is copper wire. Those wires are insulated with varnish, and the impregnated varnish remains rigid in any working environment. As a result, those windings of three-phase induction motors have high insulation resistance. Moreover, they are resistant against the atmosphere, alkaline fumes, moisture, grease, and oil.

In Xinnuo motors we manufacture high quality three phase induction motors and our three phase induction motors are used all over the world.

6. What is an Asynchronous Motor? 

Asynchronous Motors are also known as induction motors. When we are talking about the industrial motor, we are mainly referring to asynchronous motors. They are used in 90% of the industrial applications. They are cheap compared to other motors, durable, and sustain many years. Besides, the maintenance is also straightforward.

These motors operate at less than synchronous speed.

7. How to Choose an Industrial Motor? 

Before choosing an industrial motor, you should ask yourself the following questions:

Does the Application need Constant Speed or Multiple Speeds? 

If the application needs constant speed select a motor without variable speed settings. These motors deliver mechanical energy at a constant speed.

AC motors are an excellent choice for constant speed industrial applications. AC motors need very little maintenance and come with a high power factor. Furthermore, they are less expensive and require minimal installation space. To know more about single-speed AC industrial motors, please send us a message.

Do you need a Variable Speed Industrial Motor? 

Variable speed applications need a motor that comes with variable speed settings. Some industrial applications such as centrifugal pumps, fans need variable speed to improve the motor’s efficiency. Furthermore, for conveying applications, this is a very crucial option.

Though DC motors were the first choice for variable speed industry motors, now you can use AC motors for these applications. DC motors are still popular for these types of applications, but they are expensive and have a high maintenance cost. Therefore, AC motors are becoming more and more popular day by day.

In Xinnuo motors, we manufacture some of the best quality variable speed industrial motors. We launched our permanent magnet industrial ceiling fan in 2019, which is one of our best-selling products.

Learn more on speed control in Induction motor from the video below

https://youtu.be/UfiNbIUN7G0

Do you need Position Control? 

Some applications require a position control feature from your industrial motor. You can use a servo motor or a stepper motor to accomplish the position control feature.

As a leading industrial motor supplier in China, we always help our customers to choose the best industrial motor for their applications.

8. What is the Standard LifeSpan of an Industrial Motor?

The lifespan of industrial motors depends on the type of the motor and the application type. For example, AC induction motors can sustain 15 years if you use them under standard conditions.

Figure 11- Maintain properly to increase industrial motor’s lifespan

Different manufacturers estimate different life duration for their industrial motors. On average, the lifespan is between 30,000 hours to 40,000 hours.

9. What are Common Causes of Industrial Motor Failure? 

There are various reasons that can cause industrial motor failure or reduce their lifespan. These factors can include improper mechanical installations, input power problems, environmental factors, malfunctions in the load, among others.

Besides, a thermal breakdown can damage the windings, and in that case, you have to rewind your industrial motor.

11. How to Maintain an Industrial Motor? 

Maintenance is crucial for industrial motors. Please follow the following and your electric motor will perform well and last many years.

Visual Inspection 

You can find out some vital details about your industrial motor by performing a visual inspection. Check the physical condition and take the records. You will see corrosion if your industrial motor is working under a rugged environment.

Check the winding and find any hint confirming overheating. Make sure contacts and relays are ot rusted and are dust free. Your industrial motor can face an internal problem for any of those reasons and the performance efficiency can degrade.

Commutator and Brush Inspection 

An excessive wear can create commutation issues in your industrial motor. Therefore, regular maintenance checks are necessary for maintaining the proper health of your industrial motor. Changing the brush in regular intervals regains the integrity of equipment functions.

Also look for any scratches or dents on the commutator. If you find any, that is an indication of brush sparking. Furthermore, you should check the stator, rotor, and belts and replace them if any part is worn.

In Xinnuo motors we also manufacture individual items. You can contact us if you need to replace any part of your industrial motor.

Widing Test

After running the previous checks you should check the winding of your motor to find out any failure. Conduct a mandatory winding test if you find any cracks or burn marks. If you smell a burning odor you should immediately perform a winding test. To run the test you have to disassemble the motor and find out abnormalities.

In case the winding is overheated you can face some serious damage.

Bearings Check 

Vibration or noise in the bearings is an indication of potential problems. The problems include, wear and tear, poor lubrication, etc. If you can not touch the bearing house as it is too hot then there is a high chance that the industrial motor has insufficient grease or  is overheated.

Vibration Test 

Excessive vibration can reduce the lifespan of your industrial motor. But performing vibration tests manually is very tough and most of the times do not provide accurate results. Many factors can induce too much vibrations such as faulty ball bearings or sleeve, improper balance or excessive belt tension. You can remove the belts or disconnect the load to perform the vibration check.

Sometimes, electricity itself can lead to excessive vibration. In that case, we suggest performing a field vibration analysis to identify the exact value of vibration.

Infrared Thermography 

This is a more modern method and many users are using this method these days. Here an infrared camera captures thermal images without disturbing your industrial motor. You can see the temperature profile in the various parts of the motor from this image.

If you have any complicated issues such as insulation failure, insufficient air flow, etc the thermal image will distinguish the problem and you will be able to take action in advance.

Keep Record 

This is the key to a well organized maintenance procedure. Always keep records in a structured way. Document all the test results and replacement, repair records. Thus you can track all the records of your industrial motors and also tell the manufacturer if you are facing similar problems with many of your motors.

Final Words  

Xinnuo motors is one of the best industrial motor manufacturers in China. We have over 20 years of experience and thousands of clients all over the world. We hope this guide on the industrial motor has provided you with sufficient information.

But, in case you did not find the answer to your question or are not satisfied with the answers, please send a message. Our team members are always awake to answer your question.

Or, Do you have any project in mind? Ask for a quotation.