Hydraulic test rig benefits from energy efficiency as standard across WEG electric motor range

30/09/2016 10:21:17
 
 
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ImagesClick Image for 300dpi jpg fileHydraulic test rig benefits from energy efficiency as standard across WEG electric motor rangeHydraulic test rig benefits from energy efficiency as standard across WEG electric motor rangeHydraulic test rig benefits from energy efficiency as standard across WEG electric motor rangeHydraulic test rig benefits from energy efficiency as standard across WEG electric motor rangeHydraulic test rig benefits from energy efficiency as standard across WEG electric motor rangeHydraulic test rig benefits from energy efficiency as standard across WEG electric motor range
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For Oilgear, a prominent UK based manufacturer of hydraulic pumps and power systems, designing and building a new test rig has been made easier thanks to the wide selection of electric motors on offer from WEG in the UK. The design process led to four WEG motors being selected for a variety of reasons, from cost effectiveness to efficiency rating, availability and quality reputation.

Whilst most of the media discussion about electric motors is focussed on efficiency there are times when this is not the top priority; recent EU directives have established a minimum efficiency standard for new equipment and these will help to significantly reduce running costs. However, not all applications run for thousands of hours per year, some may be used very infrequently and so other factors become more important to the customer.

Oilgear is one of the world’s leading suppliers of electro-hydraulic packages for a wide variety of industrial, marine, oil & gas, military, plant and mobile applications. The company has over 100 years’ experience in pump and valve design and manufacture as well as considerable experience in delivering complete hydraulic power systems that include the associated controls and software solutions.

As part of a project to expand the range of fluids that could be used with their equipment, Oilgear has developed a test rig that is designed to validate the performance of each product with a new fluid. In this way a pump that was originally designed to operate with hydraulic oil can be modified and tested for use with less forgiving fluids, such as water-based glycol mixtures, biodegradable fluids and fire resistant fluids.

The primary power source for driving the pump under test is a 132 kW WEG W22 motor that is operated via a variable speed drive (VSD). In many applications a VSD is used to improve the efficiency of the motor under varying loads as well as providing a soft-start facility for high inertia loads. For this particular application, the variable speed feature was the more important one in order to allow a wide range of hydraulic pumps to be run at a specific speed and with different flow rates and pressures, based on the test schedule required.

Mike Harding, UK Design and Product Development Manager at Oilgear, comments:

“This project called for a cost effective range of motors without any compromise on quality or reliability. The WEG motors were selected because they met a number of our criteria including suitability for VSD applications and availability for immediate delivery. The test rigs we build typically have a very long lifespan so we also wanted a motor that would last.”

For more specialist applications, the W22 range can be supplied with increased levels of ingress protection, up to IP66, as well as being specified for the UK water industry and for operation in potentially explosive atmospheres.

“In this particular application, where operation of the motors would be limited to short periods of time, overall efficiency was not the main driver. The ability to control the speed of the pump under test is crucial and so the drive motor must be constructed in such a way that it can withstand the increased voltages of VSD control without affecting the durability of the motor.”

For applications such as this where a VSD is used, WEG has created an exclusive insulation system - WISE® (WEG Insulation System Evolution). WISE® offers the key benefit of increasing the dielectric resistance of the motor windings, enabling operation with variable speed drives at voltages up to 575 V, without modification – a facility that helps to extend motor lifetime.

“Having stated that efficiency wasn’t the main consideration, it was a pleasant surprise to learn that with WEG we could source all the motors from one supplier, direct from stock and also benefit from an IE3 efficiency classification as standard. This meant that even though a lower efficiency motor would have been OK from a practical point of view, from an environmental and general efficiency principle point of view we have achieved the best of both worlds, with no cost penalty.”

By using improved insulating designs and cooling systems, the W22 range operates more efficiently and at a lower temperature, which improves the overall reliability of the motor as well as reducing running costs. Furthermore, the W22 range of motors are robust and built to last; the motor housings, end-shields, terminal boxes and fan covers are produced in WEG’s own foundries using high quality (FC-200) cast iron, ensuring maximum durability and high performance in aggressive environmental conditions.

WEG can supply the motor / generator, gearbox, switchgear and inverter package required to deliver a complete solution.

Captions:
Image 1:
Hydraulic test rig benefits from energy efficiency as standard across WEG electric motor range

Image 2: The company has over 100 years’ experience in pump and valve design and manufacture as well as considerable experience in delivering complete hydraulic power systems that include the associated controls and software solutions.

Image 3: Customers looking for an electric motor usually have a wish list of attributes that will help in making the final decision on which make and model will best suit their application. In this instance they could all be sourced from one brand, WEG.

Image 4: In addition to the main drive motor, two mid-sized motors provide power to the circulation pump and the boost pump while the smallest motor provides an initial pilot pressure to the test bed system. All four motors are from WEG’s W22, IE3 motor range which offers a number of features that satisfied the requirements of this project.

Image 5: The off-the-shelf availability of the W22 range covers frame sizes from IEC 63 to 355A/B and can deliver between 0.12 and 500 kW; offering high levels of productivity and reliability for industrial applications that require minimal downtime, and providing maximum convenience to the machine builder.

Image 6: WEG can supply the motor / generator, gearbox, switchgear and inverter package required to deliver a complete solution.

About WEG

A global major in the power distribution, automation and control sectors, WEG has just celebrated its 50th birthday. The company’s global sales now exceed the US$3-billion mark, representing increasing global success across a wide range of product groups, including the latest generation of transformers, LV control gear, generators, inverter drive systems, soft starters, LV and HV motors, ATEX- compliant explosion proof motors, smoke extraction motors and full turnkey systems. In addition, WEG has recently made a significant strategic expansion of its product portfolio, following the establishment of a joint venture for the manufacturing of wind turbines and the purchase of an Austrian gearbox manufacture, WATT Drive.

The image(s) distributed with this press release may only be used to accompany this copy, and are subject to copyright. Please contact DMA Europa if you wish to license the image for further use.

Editor Contact

DMA Europa Ltd. : Anne-Marie Howe
Tel: +44 (0)1562 751436 Fax: +44 (0)1562 748315
Web: www.dmaeuropa.com
Email: anne-marie@dmaeuropa.com

Company Contact

WEG Electric Motors (UK) Ltd : Marek Lukaszczyk
Tel: +44(0)1527 596748 Fax: +44(0)1527 68726
Web: www.weg.net
Email: wegsales@wegelectricmotors.co.uk

 
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