Understanding New Generation Motor Starters’ Role In Driving Machine OEM Efficiencies

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The efficiency of building machine designs has increased as core machine parts are simple to select, wire, and install. Besides, OEM workplace simplification is on the way, due to in part fast-moving technological developments like Industry 4.0 and the Industrial Internet of Things (IIoT). For example, many machine builders would have never imagined that they would be able to link motors or other loads to the internet to immediately access data needed to make smarter design, installation and machine maintenance decisions, etc.

Manufacturers are now introducing digitized solutions aimed at enhancing OEM workplace efficiencies. Consider some of the latest advancements in the motor starter and motor load management technology. Some of the modern, fully digital, and object-oriented load management systems offer performance benefits over the machine life cycle:

• Configuring and Building

Traditionally, while configuring a motor starter/load management solution, machine builders would consult a variety of physical catalogues to determine the types of contactors needed and then write down the appropriate component numbers for ordering. When the components got delivered, they needed to be correctly assembled, connected to the PLC, and programmed. 

Whereas, innovations provide an online configurator tool based on the concept of avatars, which are digital objects with pre-programmed features inbuilt. The knowledge required to design an application is built into the avatar.

The machine builder simply selects the required avatars representing the functions he requires, and the configuration tool automatically produces the required bill of materials. When the machine builder begins programming his solution, the configuration tool’s file and all the settings indicated during the selection process are automatically imported. The time-consuming process of entering parameters twice or three times is avoided.

• Installation and Commissioning

Traditional motor starter installation and commission work were often time-consuming, tedious, requiring extensive wiring and inspection for manual mistakes. Since modular motor starters are light in weight, compact in scale, and flexible in nature, they are built for ease of installation and commissioning. The various sections (modules) snap together and are mounted onto a DIN rail inside a cabinet during assembly. To manage up to 20 starters, only one connection to the field bus is needed. 

Since the modules are interconnected by a ribbon cable, no additional wiring is needed. All of the intelligence is centralized in one of the modules, known as the bus coupler, which serves as the unit’s brain. The programming is done inside the bus coupler and through the avatars chosen via the configuration tool.

During the commissioning phase, both software tools and hardware design aid in commissioning. The system only needs two LEDs, one to show that the device is operational and the other to indicate whether the attached load is operational. Individual avatars can be reviewed easily, even without a PLC. 

• Operation

Intelligent motor starters and motor load control system components make optimizing machine output much simpler. These systems collect a wide range of machine asset data. For example, the machine builder will know exactly where a specific machine is situated at the end-user site and will be able to predict the machine’s end of life.

• Trouble Shooting and Maintenance

Intelligent motor starters free up maintenance staff who no longer need to be close to the machine to troubleshoot. If the system detects an overheating condition, such as when a predetermined threshold is exceeded, an alert is given until the machine is shut down. The collected data is combined and analyzed in order to forecast the machine’s future performance. This information is accessible from any browser, including mobile devices.

Because of their in-built open networking features, the new digitized modules ease system builder workloads. As a result, OEMs will work with several leading brands of motor starter equipment while also benefiting from efficiency gains without having to spend much time resolving interoperability problems. Therefore, it is important buy a motor starter of a credible brand after consulting an expert.