Motion Control & Drives

High efficiency electric motors for mining

April 2023 Motion Control & Drives

BMG’s highly experienced team of electric motor designers and engineers has worked closely with global electric motor specialists to develop high efficiency electric motors that set the benchmark locally for arduous duty, high efficiency motors. The flagship Synergy range of asynchronous cast iron motors complies with the efficiency requirements as stipulated in SANS 60034-30:2009 and has SABS certification, which translates into production efficiency advantages for the local market.

Standard Synergy 3-phase asynchronous cast-iron motors encompass the latest technology in electric motor design and are used in many industries, including mining and metallurgy, pumps and water treatment, petroleum, chemical, cement, sugar and paper milling. BMG supplies a full range of Synergy IE3 motors ex stock and can also supply IE4 and IE5 units from the factory to meet exact requirements on each mine.

“Almost two thirds of the power consumed by the mining sector is associated with electric motors, particularly those used for pumps, fans and conveyors. The majority of motors on the mines are not optimised for maximum efficiency,” says business unit manager, Graeme Neilson. “Apart from energy saving – a critical issue facing southern Africa – Synergy motors have important advantages over other electric motors. These benefits include longer service life, suitability for voltage variation applications, reduced temperature rise and minimal maintenance requirements. Synergy motors also have reduced noise and vibration levels, higher reliability, greater flexibility and lower cost of operation.”

Synergy IE3 motors incorporate high level specifications and features, including an IP66 rating for protection against the ingress of dust and water and an oversized terminal box with a removable gland plate for easy replacement of the cables. Class H insulation, with a Class B (80°C) temperature rise, means the insulation can safely withstand heat that is higher than the motor’s operating temperature at full load. Motors from frame size 80 to 132 have sealed bearings and all motors 160 frame and above have re-greaseable bearings. The standard lubrication nipples are manufactured from brass or stainless steel material and are suitable for all environments. These motors have a rated voltage of 400 V and 525 V and rated frequency of 50 Hz. The efficiency and power factor values of this range ensure cost efficiency, with a return on investment of between three and five years. An important performance feature is that Synergy motors are most efficient when running between 75% and 100% of full load.

An electronic soft starter − which controls parameters like current and voltage − ensures the starting sequence is efficiently controlled. Standard motors operate at fixed speed, regardless of the actual output required, while Synergy motors can operate efficiently, without cogging at low speed, in conjunction with a variable speed drive (VSD), reducing energy consumption by over 50%. VSDs are designed to manipulate power from a constant 3-phase 50/60 Hz supply, converting it to variable frequency. This enables the speed of the motor to be controlled to achieve maximum efficiency at the required load.

The Synergy IE3 motor has undergone surface treatment to ensure extended service life in harsh mining conditions. For maximum flexibility during installation, both integrated and removable feet are available. Solid motor feet provide a more resistant structure against vibration, while removable feet can be placed on different positions of the motor frame. The latest design allows the terminal box to be mounted top, right or left and the cable entry can be rotated 360°, without disassembling the complete motor. This minimises modification time and reduces stocks. An SPM bearing monitoring device is an option that can be installed for continuous monitoring of the bearing condition.

Synergy has also developed aluminium housing motors with cast iron end shields for frame sizes up to 180. Advantages of this design include a robust structure and reduced noise.

BMG’s electromechanical division is uniquely positioned to meet the exact gear drive and motor requirements of contractors, designers and the end-users in diverse industries. A team of technicians with extensive experience offers a technical advisory and support service and a substantial stockholding is held at BMG World for quick and efficient delivery throughout the entire southern African region.


Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

The world’s greatest model railway
Horne Technologies Editor's Choice Motion Control & Drives
Located in Hamburg’s traditional warehouse district, Speicherstadt features the largest model railway in the world, and is one of the most exciting tourist attractions in Germany.

Bearings deliver major savings at snack food plant
Motion Control & Drives
Production uptime is vital in process industries such as food and beverage. A case in point is a producer of snack foods that began experiencing frequent bearing failures on its process-critical cutter lines. To resolve the situation as quickly as possible, the plant turned to the expertise of NSK.

Spherical roller bearings setting the benchmark in food safety
SKF South Africa Motion Control & Drives
Any operation involved in food manufacturing and processing has to adhere to extremely strict regulations and for good reason. In a bid to address these needs, SKF developed and designed spherical roller bearings specifically for the food and beverage industry.

Reliable pumps for high-volume transfer and dispensing
Bearing Man Group t/a BMG Motion Control & Drives
BMG’s range of Ingersoll Rand ARO fluid management equipment comprises FDA-compliant air-operated diaphragm pumps that provide dependable solutions for the food and beverage sector, and also in pharmaceutical and cosmetic pump applications.

Robotic solution for adhesive tape application
Beckhoff Automation Motion Control & Drives
In industry, even elaborate processes, such as the application of adhesive tape to parts with varying geometries are automated. Innovative Automation has developed a platform with Beckhoff control technology and a remote feeding module, which increases productivity and enables flexible customisation for different requirements.

I-Mak brand for industrial solutions
Bearings International Motion Control & Drives
From planetary, worm and aerator units to flagship products like its inline helical, parallel shaft, helical bevel and monoblock IGU, I-MAK provides over one million product references, ensuring a solution for every specific industrial need.

Cable carrier systems for harsh conditions in the steel industry
Bearing Man Group t/a BMG Motion Control & Drives
BMG supplies and supports Tsubaki Kabelschlepp cable carriers, which have been developed to withstand operation in many industries, including highly corrosive environments.

Wedge belts for tough conditions
Bearing Man Group t/a BMG Motion Control & Drives
BMG’s extensive range of Fenner power transmission components encompasses high-performance Fenner Quattro Plus Twin Wrapped (QPTW) wedge belts, that transmit 30% more power than the standard Fenner drivebelts.

BMG’s machine tools on show at Machine Tools Africa
Bearing Man Group t/a BMG News
BMG will be participating at the Machine Tools Africa exhibition. Its stand will showcase the company’s comprehensive range of quality branded tools and equipment, which has been carefully selected by specialists, to meet the exact requirements of customers in diverse sectors.

Quality gearboxes for irrigation
SEW-Eurodrive Editor's Choice Motion Control & Drives
SEW-EURODRIVE is offering a complete gear solution for centre pivot irrigation systems as an original equipment manufacturer (OEM) closer to South Africa’s farming sector.