Efficient integration of the drivetrain in any industry

Energy efficiency is a hot topic across every industry at the moment, but without fully understanding all the components within the drivetrain, only a fraction of the potential savings can be realised. Throughout the drivetrain the potential energy savings are distributed via the ZVEI model:

• 10 per cent via improved efficiency of the motor
• 30 per cent via electronic speed regulation
• 60 per cent via optimisation of the mechanical system

This highlights the fact that while the current focus on energy efficient motors is important, it is even more important that engineers do not lose sight of the other areas where improvements can be made.

Bauer supplies electro-mechanical application products which are committed to delivering the best outcome possible for any given application, by maximising the savings potential across each of the three fields listed above. This means long-term reliability, low maintenance costs and excellent energy efficiency. Bauer's approach to optimisation is to adapt and simplify every aspect of the drivetrain, ensuring that it integrates seamlessly with the machine.

Motors - 10 per cent of potential saving

Recent technological advances in motor design have allowed manufacturers to deliver radical improvements in energy efficiency. Coupled with the recent IE2 and IE3 regulation - and the future IE4 regulations - this means that most applications are already benefitting from improved electrical efficiency. In fact, a recent comparison test of a standard IE2 asynchronous motor and a Bauer IE4 super premium efficiency motor showed energy savings of over 40 per cent are possible.

Not only does Bauer already conform to IE2 and IE3 classification, it is also leading the way in new IE4 technology. All of the company's motor competencies - from design to manufacture - are maintained in-house, which gives it autonomy over the quality of the product that goes into its drivetrain packages. It offers a full complement of products for all the energy classes, which means that there is a wealth of choice for any application.

Speed Control - 30 per cent of potential saving

Using a speed control device to monitor the required output of the motor and regulate its energy use accordingly is known to be a quick and simple way of increasing the efficiency of a system. Depending on the requirements of the application there are many different control and monitoring concepts which may offer the best combination of cost and efficiency. Bauer has developed relationships with many manufacturers of speed control systems to work hand-in-hand with its products to maximise the efficiency of its systems.

Mechanical Optimisation - 60 per cent of potential saving

While motor efficiency and speed control currently enjoy the majority of media coverage, the fact is that mechanical optimisation accounts for the majority of potential savings in most existing drivetrains. In fact, the opportunities are so vast that Bauer has split it into two further sub-categories: Gear Technologies and Drivetrain Optimisation.

Bauer has been manufacturing Gear Technologies since 1927; throughout these nearly 90 years it has always strived to offer the most efficient and reliable products possible. To service this aim it has developed a standard, modular gear programme as well as a bespoke design and manufacturing service.

Modular models include the helical BG series, parallel shaft BF series, bevel BK series and worm drive BS series; each series includes low-torque products (

Each product is specified by application experts, with the help of Bauer's technical centre, to optimise for the specific application in terms of energy efficiency, smoothness, noise, impact resistance and other attributes. Where bespoke systems are required, Bauer is able to provide a short time to market thanks to continued investment in its rapid prototyping capabilities.

Drivetrain Optimisation is the last piece of the puzzle, but no less important than the considerations that have come before it. Once each aspect of the drivetrain has been specified, it must then be integrated into the machine with as much efficiency as possible. This requires an in-depth understanding of the drivetrain as well as the specific demands of a given industry, which is why Bauer has a team of application experts who specialise in different industries.

Simple installation options, such as gearing that takes over the bearing functions, thus reducing the number of components, can offer improvements in efficiency that are equivalent to the step-up between an IE1 and an IE4 motor in the same drivetrain. As part of Altra Industrial Motion, Bauer is also able to work closely with the Altra Coupling division, which includes brands such as Bibby, Huco and Ameridrives, to specify coupling systems which integrate the drivetrain with minimal energy loss.

Thanks to its completely modular design, Bauer's standard product range offers thousands of potential drivetrain packages while, for more specialist applications, the Bauer Specialist Serial Demand service can build a completely bespoke design which is integrated into the machine from the ground up. Its engineers work to maximise the potential energy savings at every stage of specification and installation to deliver the desired system to each individual application.

To learn more about electro-mechanical application systems from Bauer, please visit www.bauergears.com.