Under the Enclosure with eMotors Direct

Since the invention of the AC electric motor, motor manufacturers have been innovating to make the motor more resilient, more capable, and more energy efficient. Some industries have benefitted from these innovations more than others, especially where a standard efficiency motor just doesn’t quite cut it. Heavy, harsh, contaminated, severe-duty environments need higher reliability and better efficiency from their electric motors.

Industries like Oil & Gas, Chemical, and Pulp & Paper, face the problem of excessive unplanned downtime due to early motor failures. That is, until the release of the IEEE-841 motor standards in 1986.

Who is IEEE?

The Institute of Electrical and Electronic Engineers (or IEEE) is the world’s largest technical professional society. It leads the development of industrial standards for telecommunication, electric power, and consumer electronics.

History of IEEE

Though electricity had technically been around for a while already, it wasn’t widely adopted by society until the late 1800s. And in 1884, in the state of New York, the IEEE was founded to encourage the innovation and development of electrical products and components. The early leaders of the professional organization include some major names like Thomas Edison and Alexander Graham Bell.

The membership of IEEE consists of Engineers and Scientists at its core, however, it also encompasses Computer Scientists, Software Developers, IT Professionals, Physicists, and even Medical Doctors.

Now, in 2021, the organization has a portfolio of almost 1200 electrical standards for various industries, with many more currently under development. Included in these standards is the IEEE-841 standard.

What is IEEE-841?

The IEEE-841 standard was developed in 1986 for the continuous and severe-duty operations of the Petroleum and Chemical industries. The environments and processes found within this industry place great mechanical stress on equipment and are often full of contaminants like dirt, dust, water, ice, etc. A standard efficiency electric motor will fail long before its expected lifespan due to stress and contamination, with bearing failure due to lubricant contamination being the number one cause.

The goal of the IEEE-841 motor standard was created to improve the reliability, efficiency, and performance of severe duty motors in this industry, effectively helping to prolong the life of the motors and decrease unwanted and costly downtime.

The standard has now been widely adopted by other industries, such as Pulp & Paper, and has been globally accepted for electric motors used in the most extreme conditions.

What Type of Motors Does IEEE-841 Cover?

The IEEE-841 electric motor standard covers “premium-efficiency totally enclosed fan-cooled (TEFC) and totally enclosed nonventilated (TENV), horizontal and vertical, single-speed, squirrel cage polyphase induction motors, 0.75 kW to 370 kW (1 hp to 500 hp), and up to 4000 V nominal, in National Electrical Manufacturers Association (NEMA) frame sizes 143T and larger, for petroleum, chemical, and other severe-duty applications (commonly referred to as premium-efficiency severe-duty motors).” (https://standards.ieee.org/standard/841-2021.html) However, it does exclude sleeve bearings and some additional features which are specific to explosion-proof electric motors.

No matter the manufacturer, every single motor advertised as IEEE-841 must meet the specs set out by the standard, with many of them featuring designs and testing that goes above and beyond what is set out by the standard. Additionally, there is a standardization of motor sizes across manufacturers. This allows for easy interchangeability which is convenient when you have difficulties sourcing a certain brand.

IEEE-841 Specifications

As of the most recent update published on May 28th, 2021, these are the most notable specifications set out by the IEEE-841 standard:

Service conditions must be:

-25°C to 40°C ambient temperature

A maximum altitude of up to 1000m

Humid, corrosive, or salty environments

Full voltage starting

Class I Division II hazardous locations

Standard 5-year warranty

Totally enclosed fan cooled (TEFC) or totally enclosed non ventilated (TENV) enclosure

IP55 protection rating

NEMA Design B torque and current characteristics and starting capabilities

A minimum of a Class F insulation system

Not to exceed a service factor of 1.0

Allows for long-term reliability

A short-term overload of no more than 15% is still allowed

Stainless steel nameplate

Specialized bearings

Inner bearing cap

L-10 lifespan

Cast iron frames, end shields, fan covers, and terminal boxes (corrosion resistant)

Specified efficiency ratings based on motor size/guaranteed minimum efficiency

Improved seals

Corrosion-resistant paint and internals such as stator, rotor, and shaft surfaces

Reduced system vibration (.08 ips)

Non-sparking fan

Must contact the manufacturer when pairing with a speed drive – issues with harmonics and voltage spikes

It’s important to note that even if the motor meets and exceeds these specifications, regular maintenance is required to meet the premium efficiency standards.

The Dollars and Cents of It

When searching for your IEEE-841 electric motor, you may find that the initial purchase cost is higher than that of a similar motor at standard efficiency. So, why invest? When switching to IEEE-841 motors, there is an up to 50% decrease in early motor failures. This equals cost savings due to less unplanned downtime, spoiled product, and wasted employee resources. Less maintenance budget will be directed to motor repair and replacement costs. And an increase in power efficiency equals large cost savings on power consumption over the motor’s lifetime.

Summary

So, should you consider an IEEE-841 electric motor for your application? If your electric motors will be operating in harsh and contaminated environments and placed under significant mechanical stress, then yes, you should. You’ll benefit from reduced downtime, increased reliability, low noise levels, and high efficiency, all resulting in cost savings for your business.

Whether you’ve already purchased an electric motor or are still in the planning stage, familiarizing yourself with the different electric motor controls can help you maximize the productivity and efficiency of your operation while extending the service life of your motor, electronics, and all the mechanical assets connected to your motor.

Motor control is any switch or device used to start, stop, or control the speed of an electric motor. Because each application has unique objectives and operating parameters, it is often necessary to control the motor's speed and protect it from a variety of risks specific to your usage. To select the right control for your application, the first step is to take a look at what you need the motor to do, and then select the motor control that gives you the capabilities you require.

Soft Starters

If your motor will be started under substantial load, especially if it occurs frequently, there is a high risk of damage from the electrical and mechanical shock that occurs when full power is applied to a motor at standstill. Depending on the load, a motor may experience a current surge up to five times the rated level at start-up, which can damage sensitive electronics and overheat the motor windings, drastically reducing its service life. This current surge also makes the motor accelerate suddenly, causing mechanical shock that can damage the motor bearings, gearbox and driven load. Over time, this will greatly increase maintenance, operational downtime, and parts replacement costs.

It is highly recommended to install a soft starter to safely manage your motor's start-up process if your motor is started under a substantial load. The soft starter ramps up the power to the motor slowly, alleviating current surges and preventing overheating in the windings. This means that your motor will accelerate slowly and smoothly, protecting the motor, gearbox and load. You can also customize the soft starter's start-up parameters, including the time it takes to reach full speed, to suit your project needs.

When your electric motor is required to run at full speed all the time, a soft starter may be sufficient. However, to precisely control and manage your motor's speed during all phases of operation and respond to changes in operational conditions, speed control is necessary.

Speed Controls

Speed controls enable your electric motor's speed to be continuously adjusted to meet the requirements of your operation, giving you the ability to maximize efficiency and performance at all times. Speed controls can replace soft starters to safely bring an electric motor up to speed, maintain a specific speed or adjust to changing circumstances. They are often capable of providing dynamic braking, which is useful for quickly and smoothly bringing a heavy load to a stop. AC and DC speed controls operate on different principles, but they are designed to achieve the same result.

AC motor speed controls are commonly divided into two categories: Variable Frequency Drives (VFDs), and Vector Controls, also known as Field Oriented Controls (FOC). VFDs manage the speed of the motor by modifying the frequency of the power supply and are the most common and cost-effective way to control the speed of an AC motor. However, they lose precision at lower speeds and are unable to create holding torque in a motor.

Vector Control drives enable the speed of an AC motor to be precisely controlled over the entire speed range, even giving a motor capability to provide full torque at zero speed (holding torque). They achieve this by managing the motor's speed and torque separately, using a sophisticated control algorithm to produce the desired output. This enables servo-like control of an AC motor, a capability that was previously only available with DC motors. Vector Control drives are generally more expensive than VFDs, but their precise speed-control capability is essential for many finely-tuned, responsive electric motor applications. A special Vector Duty or Servo motor is needed for this type of drive.

DC motor speed control is much simpler, as it only requires management of the input voltage, which is usually achieved using a PWM voltage regulator. DC speed controls also provide good precision over the entire speed range of the motor.

Magnetic Starters

A magnetic starter is a device that enables an electric motor to be started and stopped safely, especially when operating a heavy load. Magnetic starters offer controls for the operator and safety protections to prevent damage to the motor in case of overload.

Magnetic starters consist of an electromagnetic contactor or switch and a thermal overload relay. The relay is usually closed manually by the operator pushing the start button. It is then held in a closed position by an electromagnetic force that can be automatically cut off when a hazardous situation is detected. The relay opens when excessive current passes through or overheating occurs, opening the switch and cutting off power to the motor to protect it from damage.

If you start your motor with a heavy load, or it experiences intermittent high load during operation, it is recommended to use a magnetic starter to protect your motor from damaging surge currents.

Summary

Selecting the right motor controls gives you the capability to fine-tune the productivity of your application and protect valuable assets from electrical and mechanical damage.

Here at eMotors Direct, we offer a comprehensive range of electric motors, gearboxes, and motor controls, giving you the components you need to build a complete package that meets all your performance objectives.

Regardless of industry, modern businesses are moving from an outdated linear supply chain model to a new paradigm that leverages technological tools to improve visibility, forecasting, and stock management. Let us introduce you to the key technologies and practices driving this shift and what they can offer for you and your business.

The Evolution

Traditionally, supply chains have operated in a linear network made up of parts that operate largely independently. This structure suffers from several issues that prevent optimization and reduce efficiency.

Linear supply chains often employ an outdated silo approach that involves each link in the chain operating either independently or with limited collaboration with its immediate neighbours. Instead of freely sharing information to build a clear understanding of the company’s needs from one end of the supply chain to the other, each link in the chain works with incomplete information that often changes, interfering with efficiency and increasing operating costs.

This approach misses the fundamental understanding that different parts of the supply chain are dependent on each other in complex ways. Each link contains knowledge, expertise, and information that could greatly improve the ability of other parts of the chain to operate effectively.

To combat this problem, modern supply chain management has recently evolved toward a much more collaborative model that prioritizes information sharing, driven in part by the development of smart technology that allows rapid recording and processing large datasets.

A New Supply Chain Paradigm

In the last few years, industries have shifted towards using advanced digital tools and technology to develop a deeply connected and highly resilient supply chain. This approach leverages data-gathering across the entire network to create predictive models that drive strategy development and use automation and optimization tools to streamline performance.

Analytics

Recently, many businesses have benefited from data-driven software tools used to gather large amounts of performance data in different areas of the business and harvest them for insights into risk and opportunity. This creates a rich source of information that can be used to drive strategic planning.

To get this data, industrial automation tools are being deployed that use IoT (Internet of Things) technology to continuously record data on equipment health and process performance, storing it in cloud-based servers that can be securely accessed from any geographical location.

Machine Learning

This decentralized data can then be operated on by advanced machine learning algorithms that look for ways to optimize the business's performance and spot opportunities for improvement. When both data and machine learning algorithms are deployed on the cloud, parallel computing power can be leveraged to massively speed up data processing and generate useful insights extremely fast.

Having this type of aid enables managers to react to important signals in data gathered from all over their businesses, compare these signals to historical data and predicatively model future outcomes based on different actions they take right now.

Real-timeVisibility

With the advent of data-driven analytics and modelling tools, managers and operators are being provided with real-time visibility into key performance and health indicators, no matter where on the planet they are located. With the recent availability of 5G networks, massive amounts of low-latency data can be recorded and processed in record time, powering live dashboards that update on a moment-to-moment basis.

Warnings about equipment health and performance can be broadcast to off-site personnel or even generate automatic orders for parts replacement, and information about potential opportunities sent directly to travelling business managers on their personal laptop or phone.

Robotics and Automation

Recent advancements in robotics and industrial automation tools provide an unprecedented opportunity for predicting and mitigating risk and optimizing process performance. Automation tools can react incredibly fast to shut down expensive equipment when they are put at risk by a developing fault or human error and can even manage the switch to backup equipment or alternative production pipelines when something goes wrong. This can enable production to continue uninterrupted in circumstances that would previously have resulted in a temporary shutdown.

That’s only the beginning. Robotics and automation can assist across the entire supply chain, including inventory management, data distribution, spotting errors and trends in all kinds of datasets, and notifying relevant personnel with clear, concise information when events occur.

The Human Element

With advanced technology changing the way businesses operate, many people are worried that robots will take over their jobs and they will be made redundant. While this fear is sometimes overblown, many types of dangerous, repetitive, and mundane tasks will indeed be transferred to automation in the coming years.

But what will not change is the requirement for the human element in virtually every part of industrial plants and businesses. Computers and robots are best at doing jobs that have clear boundaries and consistent parameters. Most jobs are never completely routine since unexpected events can necessitate a different course of action to what a robot or automation software is programmed to do. This means that people will continue to be needed to make the final decision in many areas, and robotics will aid their creativity and thought processes.

Regardless, the modern workforce is not the same as it was decades ago. For many different reasons, the days of a person working at a single job for an entire career have been dwindling for some time. Modern workers in both blue-collar and white-collar jobs are well-advised to continually update their knowledge and diversify their skills, not just because of the risk of technology taking jobs, but also to continually increase the value they provide to the company and improve their career prospects.

Summary

Advanced technologies are revolutionizing how businesses and supply chains operate, providing new opportunities for reducing risk and optimizing productivity. Implementing modern supply chain management will position your business well to take advantage of the opportunities and meet future challenges.

Service factor plays a crucial role in a long-lasting, reliable gearbox. Service factor is a way to measure how well a gearbox or a gearbox motor will handle specific demands and operating conditions, depending on the application. Let's take a look at why the gearbox service factor is essential, what it means, and how to optimize it for your requirements.

Why Is Gearbox Service Factor Important?

When choosing an industrial gearbox, it's essential to account for typical usage and operating demands. Doing this will enable you to select a gearbox that won't experience rapid wear and tear or premature failure, costing your business lost productivity and parts replacement.

Two electric motor drives of the same size doing the same primary function may be subject to entirely different stress levels when operated in other conditions. Especially in harsh industrial environments, it can be challenging to predict the maximum stress levels that a gearbox will experience. Gearboxes that start and frequently stop, cyclic loads, high peak loads, vibration, high duty cycles (i.e. running 24 hours/day), and high ambient temperatures will experience a shorter lifespan. High-stress environments greatly accelerate the average rate of wear and tear.

This massive usage results in a service life that is much shorter than expected. Typically, choosing the correct gearbox designed for higher horsepower applications extends its life span exponentially. But higher horsepower gearboxes are more expensive, so you may be wondering how much oversizing you need for your application. To answer this question, let's first examine what gearbox service factor is.

What Is Gearbox Service Factor?

The gearbox service factor is the ratio between the horsepower that a gearbox is rated to handle and the horsepower required for the application. In practical terms, it defines a performance safety margin that may be required by incredibly demanding tasks to help ensure long-lasting and trouble-free operation.

For example, a service factor of 1.0 means that a gearbox only meets the application's design horsepower requirements, without any safety margin. A service factor of 2.0 indicates a gearbox that can handle double the required application horsepower and is highly oversized for the task.

The gearbox's service factor directly impacts the durability and resistance to pitting and bending fatigue of the gear teeth. As a general rule, the gears' longevity is proportional to the increase in service factor raised to the 8.78th power. For example, a 30% additional service factor will result in a 10x increase in the gears' lifetime.

But how exactly is the service factor calculated for different types of gearbox applications?

How Do I Calculate My Gearbox Service Factor?

To choose the right gearbox, calculate the service factor you require and then match it to the rating on the gearbox to determine if it will be suitable.

Calculating the service factor required of a gearbox is not an exact science. Numerous operating conditions have different impacts on how well the gearbox will perform. The gearbox properties, including gearing, the construction materials, bearing quality and design characteristics, affect its ability to withstand its demands. Calculating the service factor is based on practical experience guidelines rather than empirical formulas.

The American Gearbox Manufacturers Association (AGMA) provides widely used standards for determining a gearbox's service factor. These are guidelines that primarily consider the type of application and the duty cycle to provide a good value based on gearbox manufacturers' extensive experience supplying different industries. Manufacturers use these guidelines to determine the service factor rating for a gearbox used in a specific application.

For example, for typical industrial tasks, a value of 1.4 is adequate. However, this rating can increase depending on how long the gearbox is in use and load characteristics.

Suppose your gearbox will be operating in exceptionally stressful circumstances, or you're unsure of the operating conditions. In that case, select a higher service factor, or consult with a trusted gearbox supplier to determine whether it can handle the demands you'll put on it.

What Is Gearbox Service Class?

Many manufacturers use the concept of service class rather than a service factor value to simplify matching a gearbox to an application.

A service class essentially corresponds to a range of service factor values, and each service class is around a commonly used service factor. Because calculating service factor isn't precise, using a service class instead can be more useful than a numerical value and provide a small margin of safety when selecting the right gearbox for the task.

There are three main service classes in common usage. Service class I corresponds to a minimum service factor of 1.25. Service Class II corresponds to a minimum service factor of 1.40, and Service Class III corresponds to a minimum service factor of 2.0.

Class I gearboxes would be used in typical industrial tasks, while Class III gearboxes uses would be in a very heavy-duty application that requires exceptional resilience.

Summary

Determining a gearbox's service factor is a crucial step in selecting one that will perform reliably and help ensure your application's lasting productivity. To get started building your perfect gearbox, visit our Gear Reducer Builder, or get in touch with us today to speak with our experienced team who will help you find the right gearbox for your needs.

Maintaining a safe work environment is paramount in industrial settings that involve high-voltage infrastructure and rapidly moving components. Proper electric motor safety is an essential step toward achieving trouble-free operation. Safety practices span across motor installation, everyday operation, and maintenance. It is necessary to develop and consistently follow proper safety procedures during each phase to achieve the best outcomes for your company and personnel. With the right approach, the risk of accident can be minimized, and a safe and productive working environment maintained.

Motor Installation Safety

Before installing a motor or developing electric motor safety procedures for your application, it is essential to become familiar with local and national safety codes related to your industry, as well as risk factors specific to the type of motor you have purchased. Please read the information provided by the manufacturer and always follow their recommendations. After developing comprehensive safety procedures for your operation, ensure that all operators and technicians involved are familiar with the procedures and apply them consistently.

Find manufacturer technical specifications, data packages, warranty policies, features sheets and dimensional drawings to inform your safety procedures for motors on our product pages.

Following the right steps during the installation of the motor helps prevent accidents that can cause injury and damage to infrastructure. Before installing the motor, inspect it thoroughly for defects or damage. If any issues are found, contact the seller before commencing installation. To reduce the risk of accident, check that the motor characteristics are adequate for the requirements of the application and that the voltage and connections on the motor match the power supply.

When installing the motor, ensure that it is properly grounded and all connections are tight. This helps protect against electrical shock if the motor connects with the skin. Install all necessary safety measures such as thermal protection and electrical fuses, which protect the motor and prevent potential accidents such as fires caused by overheating. Ensure that the motor is securely mounted and properly aligned and connected to the load.

Before start-up, it is advisable to run the motor in-place without a load to ensure that it has been installed correctly. This is a good time to review safety procedures for the operator and relevant personnel, including start-up, shutdown and emergency stop procedures. During normal operation of the motor, including start-up and shutdown, it is essential to develop consistent procedures that protect the safety of not just the motor but any personnel in the area. When starting a motor, make sure that all personnel in the area are alert and aware of it.

Motor Operation Safety

One of the best ways to spot problems with a motor in advance is for operators to use sight, smell and temperature to detect abnormal circumstances. However, this can be dangerous unless operators are properly informed. A motor's surface can be extremely hot during normal operation, especially after sudden changes in the load that draw unusually high current, and this temperature can persist well after the motor has been stopped.

Correct safety gear should be used around running motors, and fingers and other objects kept away from ventilation ports and other points of entry into the motor. Everyone should keep a safe distance from moving or rotating components of the motor or driven load. When power outages occur, make sure that the motor power is cut off so that it does not start unexpectedly when power returns.

Motor Maintenance Safety

Whether routine or not, electric motor maintenance involves repeatedly handling and testing the motor. Maintenance personnel work near hot and rapidly moving components. Besides being qualified to disassemble and service the motor, maintenance personnel should be trained in proper power lockout procedures, safety gear, first aid and any relevant safety codes. This ensures that maintenance is a low-risk operation and productivity can be restored as quickly and safely as possible when a fault occurs.

Locking out power before working on the motor is extremely important, and it is not enough to simply switch it off. Power can be suddenly and unexpectedly restored if the motor was stopped by a thermal protector, which can automatically re-connect power when the motor has cooled down. The motor may also be inadvertently switched on by someone unaware. Proper power lockout involves physically locking the main power switch in the off position, for example, by enabling each technician to apply their own padlock before working on the motor. The main power switch should also be clearly labelled with a warning to ensure that operators know that maintenance is being performed.

Before handling the motor, ensure that the work environment is safe and that the motor has been fully de-energized. Capacitors can store a lethal charge and must be properly drained if they are to be handled. Ensure that the motor has cooled down sufficiently so that it does not present a risk of burn. Check the work area for pools of liquid or leaked lubricant, increasing the risk of an accident.

Summary

Prioritizing personnel safety by developing and adhering to strict electric motor safety procedures helps ensure that operators and technicians carry out their jobs smoothly and effectively, maximizing productivity and reducing the impact of maintenance schedules on your business.

Electric motors are often required at potentially explosive or flammable sites, such as chemical plants, coal mines, or petrochemical plants. Accidents could result in damage, injury, or loss of life. This makes it vitally important to select a motor that won't create an ignition source. Let’s take a look at the four key criteria used to classify different types of hazardous locations and how electric motors are designed and rated to operate safely within them.

Understand The Hazard

When selecting a motor for a hazardous location, the first step is to classify the site according to the standards that apply in your local area. In the US, hazardous location classification is determined by the National Electrical Code (NEC), while the Canadian Electrical Code (CEC) applies in Canada.

In practice, site classification is complex and requires a thorough inspection and analysis of every aspect of the motor's environment. Consult the relevant safety authorities in your local area for detailed guidance. The following sections will give you a broad overview of the four main criteria used.

1. Class

The Class of a hazardous location describes the form that the principal hazardous material takes within it. There are three Classes, in order of highest to lowest risk of ignition.

Class I locations contain highly flammable gases and vapours in the atmosphere, which could be explosive when ignited. Examples include petroleum refining plants, gas plants, spray painting facilities and refuelling areas.

Class II locations contain combustible or electrically conductive dust particles in the air. Materials such as coal dust or flour and conductive particles such as aluminum and magnesium dust can become highly explosive when dispersed in the air at sufficient concentrations.

Class III locations describe environments where combustible material is present in a larger particulate form, such as filings and shavings, usually settled on surfaces. Examples include industries where the processing of wood or textiles takes place.

2.Division

The Division of a hazardous location describes the conditions under which the principal hazardous material is present, and there are two divisions.

Division I locations designate areas where the material is present under normal operating conditions, either as part of the process itself or during a scheduled activity such as maintenance.

Division II locations are those where the material is exposed only under abnormal conditions. The material will usually be present in a contained volume such as inside sealed pipes or tanks, potentially coming into contact with the motor only during an accident such as a rupture or leak.

3. Group

The Group that a hazardous location belongs to represents the behaviour of the principal combustible material after ignition. There are seven Groups labelled from A to G.

Groups A, B, C, and D describe flammable or explosive gases, vapours, and liquids, in order of highest to lowest risk. For example, acetylene, a particularly volatile gas that burns intensely, belongs to Group A, while Group D contains the less dangerous ethanol.

Groups E, F and G contain combustible dust that would create a Class II hazard in order of higher to lower risk. Materials range from aluminum dust in Group Eto corn, sugar and wheat flour in Group G.

4. Auto-Ignition Temperature

It is important to obtain the Auto-Ignition Temperature (AIT) of the hazardous materials in the vicinity of a motor. This is the minimum temperature at which a material will ignite independently, without any other ignition source. As you will see in the following sections, this is a key part of determining whether a motor is suitable for the site.

In practice, the AIT value is not simple to obtain, as it depends on environmental factors such as oxygen concentration and environmental pressure. Mixtures of several different materials can complicate this step further, and a conservative estimate may be required.

Choosing A Motor

Once a site has been classified, it is time to choose a suitable motor. Let’s look at the types and ratings of electric motors designed for hazardous locations.

Motor Ratings

Hazardous location motors usually come with a rating for the Class, Division, and Group for which they are suitable. For a long time, only Division I motors were rated, so many motors do not have a Division rating as they were rated for Division I locations by default. Division I motors can operate in Division II locations but may be over-engineered and unnecessarily costly compared to Division II rated motors.

Electric motors also come with a T-code rating, which specifies the maximum temperature that any part of the motor surface that might become exposed to a hazardous material will reach, including in the event of burnout, power overload or locked rotor. This temperature rating must be compared to the AIT of hazardous materials at a site to determine if the motor surfaces pose a risk of ignition.

Motor ratings must be authorized by safety authorities such as the Underwriters Laboratories (UL) in North America or the Canadian Standards Association (CSA).

Explosion-Proof Motors

Explosion-proof motors, which are a requirement for Class I, Division I locations, must be able to contain an internal explosion of a specified hazardous material without creating an ignition source for the environment around them. This is based on the assumption that over some time, the gases and vapours in the atmosphere around the motor could make their way inside, coming into contact with internal elements that could produce a spark or generate excessive heat, especially during a fault.

Explosion-proof motors are designed with thick, hardened cases to contain the pressure of an initial explosion, and they must allow hot gases to escape in a controlled way that does not create an ignition source. To do this, they use flame paths, which are long, narrow corridors through which burning gases can escape while being cooled to a safe temperature. Flame paths are usually built into the shaft or body of the motor.

Division II Motors

These can often be regular TEFC motors that have been CSA approved for use in Division II areas. They must include a secondary nameplate with the CSA rating, Class/Division/Group rating and a Temperature Code.

Dust-Ignition Proof Motors

In Class II locations, where the hazardous material is present in the form of airborne dust, a dust-ignition proof motor is required. This type of motor features dust-proof seals and bearings that prevent dust from entering the motor altogether.

It is important to determine the T-code rating of dust-ignition proof motors properly. They often accumulate a layer of dust on the outside of the motor body that inhibits cooling and increases the surface temperature.

Using VFDs In Hazardous Locations

Variable Frequency Drives (VFDs) modify the frequency of an AC power supply, enabling speed control of AC electric motors. However, they often create extra heat inside the motor due to the creation of harmonic frequencies in the motor windings. Additionally, when VFDs are used to run a motor slower than the motor’s base speed, it can greatly affect a shaft-mounted fan's ability to provide cooling.

Explosion Proof Inverter duty motors designed to work with VFDs while mitigating these heating effects are available. It is important to keep in mind that these motors must meet the Division, Class, Group and T-code ratings of the area and be rated for VFD use.

Summary

Now that you are familiar with the key concepts used in hazardous location classification, as well as the motors designed for different types of hazards, you have taken the first step toward selecting the right electric motor for your needs.

https://www.emotorsdirect.ca/motors/explosion-proof

Regardless of the application, you and your team need to depend on your electric motor to operate consistently. Not all industrial applications are the same, but you can determine which motor will be best suited for your job by using this checklist. Consider these six factors when selecting your next industrial motor:

1. Size and Power

2. Reliability

3. Durability

4. Cost-Effectiveness

5. Precision

6. Safety

By understanding these characteristics and why they are required, you can select a motor that will offer cost-effective performance over its full-service lifetime. From food processing to chemical manufacturing, this checklist applies.

1. Size and Power

Industrial applications often require large, powerful motors capable of delivering high productivity over many hours. In these conditions, an electric motor that isn’t adequately sized will quickly deteriorate and wear out, causing downtime and loss of productivity while incurring a replacement cost.

When choosing an industrial motor, confirm it’s rated for the power required during the most intensive part of its operation, typically during acceleration and peak load times. If the required speed is lower than the motor’s base speed, a gearbox solution allows for a smaller, more cost-effective motor operating at a higher efficiency.

Industrial motors' duty cycle can be very high, especially when they’re the primary component in an operation. Ensure the rated duty cycle of the motor can be operated for its condition, or the motor will experience overheating and shorter service life.

2. Reliability

Industrial motors are often utilized in high-use applications that depend on consistent performance and productivity. By selecting industrial motors that are reliable and require minimal maintenance, plants can save on unplanned maintenance costs.

The use of brushes in the commutator of a motor can become problematic in these conditions, as the brushes quickly wear down and require periodic replacement that causes significant downtime. Because of this, brushed DC motors can be less reliable and potentially unsuited to high duty-cycle operations. As an alternative, AC induction motors have a simpler, brushless, low-maintenance design that is well suited for intensive industrial use.

Please look at our AC & DC Motor Speed Control to learn about the difference in controls for both motors.

If a motor requires regular maintenance, ensure it’s easy to dismount to reduce the downtime of the application.

3. Durability

Motor environments often contain pollutants such as moisture, dust, oil, and corrosive chemicals. To maintain performance, the motor must be able to operate effectively in this environment without becoming damaged.

The crucial factor in a motor's durability is its enclosure, which protects the vulnerable windings from encountering harmful pollutants. Open Drip-Proof (ODP) motors should only be used in clean, dry climate-controlled environments, as they provide little protection against airborne contaminants. For highly polluted environments, Totally Enclosed Fan Cooled (TEFC) motors are a great option, as they prevent the free exchange of air from the interior to the exterior motor body. Washdown duty motors use TEFC enclosure to protect the motor from regular washing.

To gauge whether an enclosure provides enough protection, its IP (Ingress Protection) rating should match or exceed the conditions that the motor is subjected to.

4. Cost-Effectiveness

In many motor applications, the cost of the motor is not the only consideration. Depending on the job, the costs may include the electric motor, gearbox (if required), and any other peripherals such as speed control, which are required for the motor to perform its function.

The AC induction motor is the most cost-effective solution for medium to large applications that do not require precise speed control. If a speed control is required, consider incorporating this as part of your project budget and timeline, as speed controls can be complex to set-up with AC motors. For medium to large applications, the speed controller pricing is usually offset by the savings on the cost of the motor.

DC motors are relatively expensive for their complex designs in medium to large applications. Speed control is simpler compared to AC motors, especially for smaller applications. They can effectively compete in terms of the total cost of the motor solution.

5. Precision

Many industrial applications such as robotics, actuation, and manufacturing automation require a different kind of motor solution that performs complex tasks consistently at high precision. The two main types of motors used in these applications are stepper motors and servo motors.

Stepper motors rotate a fixed amount known as a ‘step,’ providing holding torque when that step is reached. This makes them ideal for situations where the motor will rotate a specified amount and then come to a stop, such as in manufacturing and machine tools applications.

Servo motors are motor packages with precise speed and torque control capable of precise complex-motion performance. DC motors can be effectively controlled over a wide speed range with a simple circuit, as they dominated the servo motor industry for many years. However, improved AC motor speed controllers, such as Vector Control drives, have made it possible for cost-effective AC motors to provide servo-like precision and holding torque. They are a great option for medium to large applications.

6. Safety

Depending on your industry, a higher level of safety may be required for the motor environment.

In the chemical and petroleum industry, where the atmosphere is volatile, an explosion-proof motor may be required by law. These motors can contain an internal explosion of a specified substance without igniting the surrounding atmosphere, providing much-needed protection to personnel and infrastructure in the vicinity.

In food manufacture and processing, minimizing the risk of pathogens is a high priority. All the equipment, including motors, need to be regularly washed down and thoroughly cleaned. A fully enclosed washdown-duty motor would be ideal for this environment, with the physical exterior using approved paint or a paint-free stainless-steel body.

Check out our Electric Motor Safetyarticle for additional tips on maintaining motor safety.

Summary

Industrial motors often face exceptionally tough operating conditions, and downtime can be very costly for the operating company and those dependent on the productivity of the application. When selecting an industrial motor, it is important to prioritize the key characteristics required for the conditions that it will operate in to ensure it provides long-lasting performance.

So, you’ve input the ratings you need your new motor to meet, and your choices are down to two motors. Seemingly identical, the ratings on the product data sheet match your requirements precisely. The only difference? One motor is a Baldor motor, and the other a Leeson.

How do you make your selection between these two top brands? Below, we’ll cover the history of these manufacturers and how to choose the correct motor for the job.

History of Baldor

Two employees at St. Louis Electric Company saw a chance to upgrade the design of the electric motors their company manufactured. The two friends were Emil Doerr, the plant supervisor, and Edwin Ballman, a talented electrical engineer with an affinity for inventing. In 1920, they pooled their savings and leaped into entrepreneurship. Baldor motors was born.

Baldor’s brand mission to “make a better motor” served them well as they grew bigger and bigger over the decades. The company only faced two years of losses in its century-long history. Coming off of one of those years (1960 due to the impending “Energy Crisis”), the company’s leadership looked at their product offering and knew it was time for a change. Baldor began to focus on offering services rather than just motors; instead of a small line of standard motors, they began to manufacture custom motors for various industrial purposes. By 1965, they had the widest range of motors on the market.

The company always embraced change; they brought the electric motor industry to new heights and dominated the motor efficiency race.

In 2011, Baldor was acquired by ABB Ltd. Their motors are still sold as Baldor-reliance, and the brand is held under the ABB umbrella. They are now headquartered in Fort Smith, Arkansas, with 15 manufacturing locations across eight states.

History of Leeson

A lot of people don’t know that the history of Baldor is also the history of Leeson. In fact, the two companies share family ties. In 1939, three of Emil Doerr’s sons created Doerr Electric, which was brought under the Emerson umbrella and eventually sold to Nidec.

One of the sons who created Doerr electric was named Lee Doerr. Lee also had three sons, all just as passionate about motors as their father and grandfather. To continue the familial tradition, Lee’s three sons created Leeson Motors in 1972.

Throughout the decades, Leeson Motors acquired four industrial manufacturing companies, and were eventually acquired themselves in 2000 by Regal-Beloit Corp. Leeson motors are still Leeson branded but are now manufactured and sold under the Regal-Beloit umbrella.

Best Uses for Baldor

Baldor motors are best known for their (link to energy efficiency post). Their line of Super-E® motors meets and exceeds the NEMA Premium® efficiency standards. The standard industrial motor sits around 88% efficiency, while the Baldor•Reliance® Super-E® motors are upwards of 94.5% efficient.

Best Uses for Leeson

Leeson motors have developed a reputation for handling the harshest conditions found in industrial applications. And you’ll also find that their warranty period can be almost double that of their competitors.

Summary

When it comes down to it, you can’t go wrong with either brand. Both are top manufacturers in North America, utilizing the latest in electric motor technologies. With decades of design evolution under their belts, either brand is a top choice if the motor has the ratings required for the application. Your choice comes down to brand preference and loyalty.

Keep in mind that it’s a good idea to select one brand and stick with it. You can reduce your spares inventory and ensure you always have the right motor on hand by standardizing your brand selection.

To choose the right gearbox for your electric motor drive application, it’s important to understand the fundamentals of gearboxes, the key differences between gear designs, and how to match a gearbox with your application's requirements.

A gearbox is a gear train designed to modify the speed and torque characteristics of a motor. When gearboxes reduce speed, they simultaneously increase the torque (turning force) at the output. When they increase speed, they reduce torque.

Speed reducers are a popular term for gearboxes that reduce an electric motor's speed and increase the torque. Because almost every application of gearboxes involves reducing speed and increasing torque, these terms are often used interchangeably. However, speed reducers are really a subcategory of gearboxes, and it is possible to use a gearbox to increase the speed of the output at the cost of torque.

Types of Gearboxes

The two main types of gearboxes are in-line gearboxes and right-angled gearboxes, each using specific types of gears.

In-Line Gearboxes

In-line gearboxes transmit the RPM of the motor to an output shaft that is parallel to the motor shaft. Depending on the gear train, the output shaft can be coaxial (aligned) with the motor shaft or offset by a small distance. In-line gearboxes typically use the following types of gears:

Spur gears

Helical gears

Herringbone gears

Planetary gears

1. Spur Gears

Spur gears are the most common gear design and are relatively economical due to the standardization of their design. However, they don’t offer as much torque capability as some other gear designs.

2. Helical Gears

Helical gears have better meshing characteristics than spur gears, making them quieter in operation and able to handle more torque. However, due to their design, they produce axial forces that make them unsuitable for some very high torque applications.

3. Herringbone Gears

Herringbone gears are essentially composed of two opposite-hand helical gears mounted side-by-side. This retains the benefits of helical gears while removing axial forces, making them useful for very high torque applications such as heavy-duty power transmission.

4. Planetary Gears

Planetary gears typically provide the greatest speed reduction in the smallest volume and are very efficient. They also have a very low backlash, making them especially suited to applications with frequent stops and starts.

Right-Angle Gearboxes

Right-angle gearboxes transmit the RPM of a motor to an output shaft that is at right-angles (90 degrees from) the motor shaft axis. Right angle gearboxes typically use the following types of gears:

Bevel gears

Worm gears

1. Bevel Gears

Bevel gears are essentially spur or helical gears that are tapered. They can mesh with another gear oriented at a different angle, making them suitable for creating a right-angle turn in the drive system. They offer similar characteristics to standard spur and helical gears.

2. Worm gears

Worm gears are essentially a screw with a single tooth that spirals the length of the shaft, meshing with the teeth of a second gear mounted at right angles to the worm. Because the teeth interact in a sliding motion, they are usually quieter than other gear types. However, due to the friction produced, they have an overall lower efficiency, with a sharp drop in efficiency once the lead angle of the screw approaches 15 degrees. The friction also generates a significant amount of heat within the gearbox, and the correct maintenance of the lubrication system is important.

Selecting a Gearbox

Selecting a gearbox for your motor depends on the following gearbox characteristics:

Torque output

Speed output

Efficiency

Service factor

Mounting and connection characteristics

Backlash

Radial load

Moment of inertia

Torque Output

The gearbox must output enough torque to run the machinery that the gearbox is connected to. This includes the torque required to start and accelerate the machinery – which may be substantially higher than the normal operational torque – and the torque that is created during jams and load shocks.

Speed Output

If the application requires a specific speed output, the gearbox must maintain that speed while providing sufficient torque to the driven load.

Efficiency

If the motor output power closely matches the driven load's power requirements, the gearbox must convert that power efficiently. Efficiency is also important when one goal is to reduce the motor's operational costs, such as power costs.

Service Factor

The gearbox's service factor is the percentage of its rated torque that it can sustain for short periods of time. A substantial service factor is required if the gearbox will experience frequent fast accelerations or occasional load spikes on the output. As gear reducers do not have a cooling fan, the service factor is also based on how many hours a day it is used. The longer the production shift, the larger the case needs to be to dissipate the produced heat.

Mounting and Connection Characteristics

If the gearbox mounting area has space and profile restrictions, the gearbox size, shape, and configuration are important in determining which option is suitable. Different types of gears have different size efficiencies, with planetary gear trains generally the most compact and spur gears requiring a larger volume. Also, in smaller applications, it may be possible to utilize a gearbox that provides the mounting for the motor. In contrast, in larger applications, it is usually necessary to mount them separately to a chassis.

Backlash

Backlash is the amount of error or plays in the meshing of the gears in the gearbox, which results in the gearbox experiencing mechanical shock when started or stopped. For applications where the motor is run intermittently, it may be advisable to utilize a gearbox with a low amount of backlash, such as a planetary gearbox, to avoid premature mechanical failure.

Radial Load

Radial load refers to the force on the gearbox output shaft that occurs at right angles, such as when a belt pulley or sprocket is used to connect the gearbox to the driven load. Gearboxes have different radial load tolerances, so it’s important to make sure that a gearbox can withstand your application's operational conditions.

Moment of Inertia

The moment of inertia of the gearbox is essentially the resistance of the gearbox to sudden acceleration. In applications that require responsive speed control, such as robotic servosystems, it is important to choose a gearbox that features a low moment of inertia.

Gearbox Installation and Maintenance

The most common cause of premature gearbox failure is not the gearbox's quality and workmanship but the conditions in which it is run and the service factor it was designed for. The most important factor is maintaining the gearbox properly – ensuring adequate lubricant is always present in every part of the gearbox and replacing the lubricant when it wears down from mechanical pressure and heat. Also, it is essential to properly install the gearbox to reduce vibration and stress. Always ensure that the alignment error between the motor and the gearbox and between the gearbox and the driven load is within the gearbox's acceptable limits.

Summary

Gearboxes have a variety of characteristics that affect their suitability for different applications. When choosing a gearbox, it is important to carefully analyze your specific application to select an option that efficiently meets all the design criteria. When you have chosen a gearbox, it is essential to install and maintain it properly to ensure the longest possible service life.

Our Business Development Manager, Cory, sat down for an interview on "Talk to the Experts" on 650CKOM - a Saskatchewan NewsTalk radio station.

This podcast is a recording of the second half of the interview, providing an overview of eMotors Direct's offering to our Agriculture clients.

The following transcript was automatically generated:

Welcome back, you're listening to talk to the experts this half hour presentation of e eMotors. Direct their website eMotors direct.ca. And the name really says it all electric motors over 20,000 different items in their inventory Brent Loucks with you joined by Corey Soetaert, who is their business development manager. And when I look over some of the items that you've got, man, just about every kind of electric motor, no one demand and no one to industry. We've got DC motors, we've got pumps, we've got general purpose, we've got oil, well. We've got two speed motors, and the list goes on and on. There's furnace motors, there's farm duty motors, you need an electric motor. It's as simple as getting online and checking out their selection, checking out their prices. And again, this is a great Canadian company. eMotors, Corey home base where Edmonton?

So, head office is out of Edmonton, Alberta. But we do again service the entire country via drop ship from manufacturers warehouses across the country, I should say.

And you were saying earlier, over 20,000 different items that I can search through on your online directory correct.

From industrial motors to agricultural motors. We have it all.

So, let's talk ag. Of course ag is the heart of our industry here in Saskatchewan along with mining and oil and gas. Talk to me a little bit about the motors and for your farm listeners out there, what you can provide for them from eMotors Direct.

So the most popular products in the ag industry would be aeration, fan motors, motors and gearboxes for crop drying equipment. barn fans, as well as feed auger drives and gearing gearboxes as well as motors. And then we also do get into the control systems for that we have a specialty line called the sinus m VFD. And what that does for customers is it accepts single phase power in and produces three phase power out so they can actually control the speed of their motors. Not something that ag customers had good access to in the past.

Interesting and a pretty broad selection of brands in that field of motors for ag.

Correct. We carry Baldor nidec, TECO Westinghouse weg AGI, grainguard aeration fans, so a good selection of the products that they would require.

I'm just curious the size of some of these motors what they get to when you think about going online to E motors direct.ca finding the motor you want, be it on the farmer at the mind, How big does some of these get in and when it comes to delivery, you think about an electric motor for the farm is that something that is required the more than just my half done truck to bring it home.

For sure most ag industry customers wouldn't. The motors aren't overly large, because most ag customers only have a certain amount of power to their property. So most agricultural customers would stop at a 50 horse motor, which is probably in the 500 pound range. Obviously industry, they can get extremely large, a you know, eight to 10,000 pounds.

You know when you think about these motors and the investment that farmers put into their operations each and every year. And they maybe don't have the expertise, they know that they need these electric motors to move grain whatever it may be. They're doing from eMotors direct.ca. You've got people who will help me basically put this project together?

Correct. I think one of the legs that we have from an online marketplace, is we actually offer technical support. One of my pet peeves was always going to an online marketplace, I can find the thing I need but if I have a question, it's very difficult to get an answer. So one of our one of our claims to fame is we do list our phone number and when you phone in, you can talk to a technical expert to help you through that process.

Boy, that's a big part of it, isn't it? That's what we all do. Your right it's easy often to find a part but then you try to think how am I going to make this work in my system. So you've got a team of experts who who specialize in agriculture and they're ready to help our farmers take on that next motor project when they order their motors and controls and gearing systems from eMotors e eMotors. direct.ca. free delivery involved for the farm folks?

We some products are for sure free delivery.

Boy, that's good to know. So any of our farmer folks who are listening right now that say We're in the need of some of these products, the electric motors, the motor controls, whatever it may be from eMotors Direct, make that order online eMotors direct.ca. And some other stuff you wanted to mention relating to farmer folks who may be ordering items from eMotors Direct at eMotors direct.ca. When it comes to delivery of these items, as you mentioned earlier, a lot of the stuff the farmer could simply throw on his half ton truck. What about the bigger items though Corey?

So larger items, over 60 pounds, we typically send with an LTL carrier, so less than truckload, semi tractor trailer type of delivery, a lot of those are quite heavy, you can't just pick them off the back of the truck. So we actually offer free power tailgate delivery. So when that comes to your farm, the truck already has a power tailgate, they roll it onto the power tailgate, drop it on the ground for you. So you don't have to have a forklift on site to get your product.

Oh, what a great idea that is. And I think the average person if you're not working on the farm, may not fully understand just how many applications there are at a particular farm for electric motors. And you cover the gamut here, all this different equipment as far as where these motors would be applied.

For sure, and I think one of the real changes in industry, the family farm is less prominent, and the farms are getting bigger and bigger. So their applications for meeting larger equipment or specialized products for their system is is growing at a rapid rate.

As you say you've got over 20,000 products. I think people will be quite impressed when they get online to your website just to see the variety of electric motors and fixtures that you guys provide.

For sure the industry is a very wide industry with tons of applications. And we do our best to provide service for all those customers.

We're talking about eMotors Direct. They are Canada's industrial motor supplier, based out of Edmonton, but it doesn't matter. It's all online. You can shop online right now seven days a week, 24 hours a day at E motors direct.ca. Cory Soetaert is our guest, Corey is business development manager with eMotors Direct.

I think the biggest message we always want to get across is just the product selection and the availability information for our customers. We we do our very best to supply as much information, data packs, drawings, all of that stuff for the customers so they don't have to go searching, they look for the product, the information comes up. And if they have any technical questions or further information you require, we're easy to access, email, phone chat, just trying to be that real good resource for customers. When they're in a bind, well, motors break down and it's a panic. It's not Can I get one in two weeks?

You definitely revolutionize the way businesses and farms are able to purchase electric motors all done online. You can see for yourself when you go to eMotors direct.ca Cory Soetaert. Thanks so much for your time today. Corey, thank you very much.

Have a good day.

You've been listening to our experts show for eMotors Direct on news talk radio.

https://www.emotorsdirect.ca/industry/Agriculture