General Purpose Industrial Applications
NovaTorque motors are used for a wide range of Industrial Automation applications, particularly applications that demand efficiency across a broad speed and load range. NovaTorque permanent magnet motors have high operational efficiency even at part-speed and part-load, making them ideally suited for material handling, conveyors, mixers, grinders, and feeder applications with varying speed and volume requirements. Its broad operational range also makes the NovaTorque motor a candidate for direct-drive use, eliminating the requirement for belts, pulleys or gearboxes.
The PremiumPlus+™ motor family has been designed to meet or exceed applicable standards for commercial and industrial grade motors, including a 1.15 service factor.
Among the differences between NovaTorque permanent magnet motors and the more common induction motors is that NovaTorque motors are classified as Synchronous motors. The NovaTorque motor's shaft rotates at precisely the commanded speed, synchronous to the output frequency of the VFD controlling it. In the case of an asynchronous induction motor, the shaft/rotor 'slips" behind the commanded speed. The amount of that slip (the difference between actual and commanded speed) varies unpredictably with the load. So, when precise, open loop, speed control is desired, NovaTorque is the better choice.
Also unlike induction motors, NovaTorque's permanent magnet motor delivers full torque down to 100 rpm or less without an encoder and down to zero speed with an encoder. This allows for the elimination of gearing in some applications.
Examples of Variable Speed, Constant Torque, Applications
Many belt conveyor systems operate continuously and are controlled by VFDs in order to provide soft starts/stops, save energy when reduced speed is possible, reduce mechanical wear and tear, and/or mate with other belt speed dependent processes.
NovaTorque technology provides several advantages over the conventionally applied induction motor/gearbox combination.
The first is the improved energy efficiency of the motor itself. The second is its exceptional low speed continuous torque. The latter may allow for the removal of the cost and efficiency losses associated with the gearbox.
Mixers, Grinders, Granulators, Extruders
Mixers, grinders, granulators, and extruders are used in a variety of food processing and industrial processing applications. Characteristic of these applications is a significant variation in load, the need for precise speed control, as well as providing full torque over a wide speed range. High continuous duty torque at low speeds is a common requirement. While induction motors are capable of very high peak torque, they overheat quickly if that torque is required for an extended period of time. Additionally, they are both highly inefficient and prone to stalling at low speed when applied without a position sensor.
In addition to their energy saving characteristic, NovaTorque motors are capable of providing full torque at low speed continuously without overheating, making them excellent candidates for these applications.
Web Tensioning and Control
Control of web (film, paper, woven material, etc.) tension in coating, laminating, or printing applications is a task often performed by VFD/induction motors or, when tighter control is required, by servo motors.
Given the continuous duty nature of the application, NovaTorque’s energy efficiency has a key advantage when compared to the induction motor alternative.
In those instances (which are common) where more precision is essential, NovaTorque motors, used in conjunction with a position feedback device and servodrive/controller, competes very favorably from both a cost and performance perspective with conventional brushless dc servomotors.
Lower Cost Servo for High Powered, High Inertia Load, Applications
Similar to most servo motors, NovaTorque is an electronically commutated, brushless dc, permanent magnet motor. Configured with encoder or resolver feedback, it can operate effectively in servo applications.
Unlike its conventional servo motor competition, NovaTorque motors utilize inexpensive, readily available, ferrite magnets (versus high cost rare earth magnets).
In contrast to most conventional servo motors, the rotor inertia of the NovaTorque motor is significantly higher. This can be an advantage or a disadvantage, depending on the application. For very rapid, point-to-point positioning of relatively light inertia loads, the NovaTorque motor will NOT perform as well as its low rotor inertia competition. Such applications are more typically encountered below 1kw than applications requiring motors above 1kw.
But, the ultra-low rotor inertia touted by many servomotor providers can also be a disadvantage because the motor is so responsive that the inherent mechanical time constants of other system elements make that ‘feature’ more a source of instability than performance enhancement.
So, for higher inertia loads, in higher hp applications, where the indexing/cycling is inherently slower, NovaTorque provides an extraordinarily cost-effective alternative with no sacrifice in performance -- in fact, there may even be improved performance at a lower cost.
Examples of such applications would include:
- Web Tensioning
- Indexing Tables
- Transfer Equipment
- Indexing Conveyors
- Tool Feeds