How to maximize the life of your motors and drive?

The reliability of your production equipment depends largely on the reliability of the motors, gear and coupling driving the different loads.

Mechanical breakdowns are often caused by inadequate sizing or selection  or overload of equipment.
To make a good selection it is necessary to evaluate all the forces applied to the equipment, often forces are forgotten. Under sizing or misunderstanding of the manufacturer’s selection guidelines or the lack of protection against mechanical overload is often the basis for premature breakage.

For example, the servo and gear manufacturer Stober offers a very efficient engineering service that offers free sizing assistance. Several options are available to increase the capacity of the gears without increasing their size, For example in the case of axial load roller type bearings are available or (Peak Torque Booster) which allow to increase the shock resistance of the reducer.

Stober also offers Video tutorials that help democratize the application of Gearbox and servos motor to help you better apply the equipment

Below are some episodes of Stober’s Power Tip focusing on the important points when designing a machine and their links with reliability

For more video of the Power Tip series visit stober’s website

There is also the manufacturer R+W who manufacture couplings with overload protection that will protect your gears against momentary overload or blockages. The load will then be decoupled and breakage avoided.So our 1st recommendation would be to use the services of your manufacturer, distributor or manufacturing agent to validate your product selection. The minimum information required is: Torque Maximum, Torque Nominal, axial load, speed, application type and motor model and engine manufacturer. The 2nd would be to use a mechanical overload protection when there is a risk of blockage or overload.

Here is a video about R+W’s technology

The other source of breakage is electric, when motor is not controlled by a dimmer the motors are subjected to voltage variation without any protection. Modern three-phase motors have a lower heat capacity and are more susceptible to breakage during phase loss or under-voltage situations. The manufacturer Macromatic offers voltage detectors that protect against single-phase. A nice option to avoid this kind of breakage.

Watch the following Macromatic Video

When the motors are controlled by a variable speed drive, these are the ones that are at risk during voltage variation. The manufacturer Bonitron manufactures filtration and voltage conditioning equipment to eliminate breakage and untimely triggering of your drives. So our two tips to avoid breakage related to the power supply will be to see to install phase loss detectors on your motors on your full voltage starters and to see to evaluate the conditioning needs of the AC power supply and the DC Bus of your drives.

Attached is an overview of Bonitron’s offer at an event organized by a Rockwell distributor in the USA

Hoping who you found the above information interesting

We are available if you need help selecting equipment for a new project or improving the reliability of your equipment

Looking for ways to reduce the carbon footprint of your machines?

It is quite possible to reconcile, two things that seemed opposite not so long ago, thanks to the new technology. Reduce energy consumption and increase the performance of a machine. Pneumatic technologies for example are very inefficient, in some cases there is only 10% of the energy consumed that is used by the cylinders the rest is lost in heat and other losses in the system. In addition to generating more noise they require a compressor,  an imposing amount of air preparation device (lubricator, regulator, accumulator, valve and silencer). The maintenance of these devices is intensive and in some cases the adjustment of the regulators is more witchcraft than technique. A change in temperature or humidity can result in a complete adjustment. Not to mention the replacement of the cylinders because the cousin at the end of the stroke no longer does its job or that the operator has changed the pressure of the system. LinMot has developed a linear motor that has the shape of a cylinder but the properties of a servo motor.

Stainless steel Servo Motor Guided LinMot

So complete control over speed and position. In addition, the technology does not include wear parts and requires very little maintenance. You will be able to increase the pace without breaking the equipment, in addition to an  increase of  efficiency ( 95% to 98%)  , the solution is also not influenced by moisture. Once adjusted the actions will be repetitive and will not change over time. This results in a reduction in startup time and reduction of service calls on the machine.

Another technology that consumes quite a lot of energy is hydraulics. The efficiency of this technology is about 50% and also uses several more or less complex devices to make everything work 🙁 Pump, Regulator, Piping, Cooler, Valve and Oil Tank). Oil is increasingly becoming an environmental concern especially in food processes. There are vegetable oils but it is less durable and requires more maintenance. Oil changes generate waste that can be potentially mismanaged

There are linear positioning technologies in the form of cylinder, belt or rack and pinion that are powered by a Servo motor that have an efficiency of more than 90%.

Exlar GSX actuator with integrated servo motor

Their accuracy is better and so is their durability. For the most part maintenance-free other than lubrication of their bearings they present less risk to the environment and are much greener and more efficient technologies.

Another source to improve your energy efficiency is to favour high-efficiency speed reducers. Worm Gear type gearboxes generally have a low efficiency VS Planetary or helical gearbox. So pay attention to the choices of your gearboxes and try to choose products in the 90% efficiency. There is up to 40% energy saving possible. Especially in large gear ratio  .

There also other benefit with lower friction comes lower heat dispassion , so your gearbox run cooler and you will need less BTU to cool down your plant. Your Oil and Seals will also last longer.

Here are some reference articles for you



In summary it is possible to improve productivity and reduce operating costs if you go electric . New technologies are more expensive but if we take into account the total cost of ownership they become more competitive than traditional linear fluid power option.

In addition the servo drive technologies are already ready for Industry 4.0, You will have a more efficient process in addition of having more data on the process.

For example your drive know in all time : Position and Speed

We are available to work with you on your energy saving program or your machine conversion program

Feel free to contact us