Modernizing Motor Control for a Building Materials Manufacturer

BUSINESS SITUATION

In addition to mechanical obsolescence, the machinery no longer performs reliably enough to meet current production demands. Rebuild options from motor suppliers that could support the original system have become prohibitively expensive. The machine’s design further complicates matters, as it utilizes a “group motor to single drive” installation approach, where a single large drive powers multiple motors. This architecture introduces significant risks to operational reliability. A failure of the main drive would result in a total loss of motor function, bringing production to a halt. Moreover, this configuration prevents precise control of individual motors, limiting opportunities for performance optimization and improvements to energy efficiency. Simply replacing the drive would not resolve the core issues or ensure long-term supportability. To deliver a return on investment (ROI), the modernization strategy needs to increase reliability and control while still fitting within the constrained physical footprint of the existing motor and gearbox layout.

SOLUTION

Addressing the company’s concerns for reliability and the obsolescence of the existing motors, an Engineered Solutions Manager with McNaughton-McKay selected a readily stocked motor model as a long-term and serviceable replacement. In collaboration with SEW (the motor manufacturer), McNaughton-McKay engineers identified couplings that could match the original motor’s unique design, enabling direct mounting to the existing gearboxes without modifications.

The next part of the solution included a shift from a group motor installation to a modern architecture using one variable frequency drive (VFD) per motor. This configuration would increase reliability and (with the selected energy-efficient permanent magnet motors) deliver energy savings that would pay back the full project cost in under three years. This transition also improves process control through tighter motor tolerances, resulting in better raw material handling and reduced waste. Additionally, the Automatic Device Configuration (ADC) feature allows the AB Logix controller to automatically detect new VFDs and download firmware and parameters to them. This further reduces downtime by eliminating manual configuration in the event of a VFD failure.

Overcoming the unique enclosure and cabling challenges, McNaughton-McKay engineers designed the system to minimize maintenance and decrease changeover time. In response to the customer’s request for manual disconnect capabilities for each drive, Meltric disconnect-rated plugs and connectors were integrated with the motor junction boxes. This setup enables error-proof connections and adheres to current lockout/tagout procedures. Each VFD was then outfitted with Harting quick-disconnect connectors to further streamline service and reduce downtime. The connectors simplify changeouts and minimize the need for specialized tools or technical intervention. Finally, McNaughton-McKay engineers designed and had a trusted panel fabrication partner build a custom control panel to house all the VFDs, associated control logic and protection devices—delivering a complete, maintainable, and future-ready solution.

BENEFITS

McNaughton-McKay integrated NEC-compliant, disconnect-rated plugs directly into the system design, eliminating the need to mount separate disconnects on the wall. This solution contributed considerable cost savings and streamlined installation. The direct-mounted plugs also enhance system safety, reducing arc flash risks and simplifying lockout/tagout procedures.

Additionally, the move to a dedicated VFD per motor architecture provided precision control and isolation at the individual motor level, improving safety, serviceability and reliability. Operational benefits include enhanced handling of raw materials, reduced energy consumption and minimized downtime. Together, these advantages result in a more efficient and resilient production process.

The customer was highly satisfied with the proposed solution, its implementation and the overall delivery. Installation, startup and system integration were completed on time and under budget. Encouraged by the success of this initial machine cabinet retrofit, the customer plans to invest in similar solutions for the machinery throughout their facility. The project is ongoing, with expectations of even greater long-term ROI as additional lines transition away from the outdated group motor installations. These results reflect the strength of McNaughton-McKay’s project execution and engineering support.

PRODUCTS AND SERVICES USED

• SEW 480 V AC permanent magnet motors
• HOFFMAN enclosures
• McNaughton-McKay Engineered Solutions custom control panel design
• Complete integration and startup assistance provided by McNaughton-McKay and Partner
• Meltric UL disconnect-rated plugs and connectors
• Allen-Bradley^® VFD PowerFlex^® 525, Stratix^® Ethernet Switches
• Harting HAN series for the VFD connectors