Motor Drives. August 2017

Transcription

1 Motor Drives August 2017

2 Table of contents Section Pages Introduction and methodology 3 Key findings 4 Respondent profile 5-12 Variable-speed drives, ac/dc Servo and/or stepper drives Medium-voltage drives Additional resources 37 2

3 Introduction and methodology Objective This study was conducted by Control Engineering to acquire information related to the buying and specifying habits of automation engineering professionals for motor drives (variable-speed drives, ac/dc; servo and/or stepper drives; and medium-voltage drives). Sample The sample was selected from qualified subscribers of Control Engineering products with valid addresses who are involved in the purchase or specification of motors and/or drives. Method Subscribers were sent an asking them to participate in this study. The included a URL linked to the questionnaire. Qualifying questions limited survey respondents to those who are involved in specifying, recommending, and/or buying motor drives. Data collected: June 12 through June 29, 2017 Number of respondents: 327 o Margin of error: +/- 5.4% at a 95% confidence level Incentive: Survey participants were offered the opportunity to enter a drawing for one Visa gift card valued at $

4 Key findings Respondents to the Control Engineering 2017 Motor Drives study unveiled six key findings related to buying and specifying variable-speed, servo and/or stepper, and medium-voltage drives: 1. Usage: Eighty-seven percent of respondents use or expect to use variable-speed drives within the next 12 months; 46% use/plan to use servo and/or stepper drives and 22% use/plan to use medium-voltage drives. 2. Evaluation: When evaluating any type of motor drive, automation professionals first at reliability, followed by price, communication interface choices, customer service and support offerings, and simplicity of setup/controls. 3. Applications: When specifying variable-speed drives, 90% of applications are new, 76% are retrofit, and 73% are replacement. The breakdown for servo and/or stepper drives is 88% new, 63% retrofit, and 71% replacement. For medium-voltage drives: 92% new, 66% retrofit, and 61% replacement. 4. Purchasing: Thirty-six percent of respondents prefer to buy motors and related variable-speed drives, ac/dc controllers separately; 24% prefer matched units. Regarding servo/stepper drives, only 13% prefer separate and 56% look for matched units. For medium-voltage drives and Above NEMA motors: 29% prefer separate and 34% favor matched units. 5. Expenditures: Over the past 12 months, respondents estimated an average of $148,000 having been spent on variable-speed drives, ac/dc. For the same time frame, respondents also estimated average values of $96,000 for servo/stepper drives and $509,000 for medium-voltage drives. 6. Important factors: The most critical qualities respondents look for when choosing a motor drive are frequent start/stop tolerance for variable-speed drives (78%), accurate positioning for servo/stepper drives (93%), accurate speed and torque control for medium-voltage drives (88%). 4

5 Respondent profile 5

6 Primary job function One-quarter of survey respondents are primarily responsible for system or product design and/or control or instrument engineering at their companies; 20% are mainly involved in system integration or consulting. General or corporate management 6% Other 5% Operations or maintenance 12% System or product design, control or instrument engineering 24% Other engineering 16% System integration or consulting 20% Q: What is your primary job function? (n=327) Process, production or manufacturing engineering 17% 6

7 Engineering experience The average respondent has been working in an engineering-related position for the past 24 years, with 51% having more than 25 years of engineering experience and 14% 10 years or less. 5 years or less 7% 6 to 10 years 7% 11 to 15 years 6% 26 years or more 51% 16 to 20 years 13% 21 to 25 years 16% Average 24 years Q: How many years have you been working in engineering? (n=327) 7

8 Primary business Ten percent of respondents work for a company that primarily provides system integration, consulting, business, or technical services. System integration, consulting, business or technical services 10% Primary metal mfg 3% Machinery mfg 8% Plastics and rubber mfg 2% Food, beverage, tobacco mfg Instrumentation, control systems, test, measurement or medical equipment mfg Utilities including electric, gas, water & waste and telecommunications Wood, paper mfg and related printing activities Automotive and other transportation equipment mfg 7% 7% 6% 6% 6% Aircraft, aerospace or defense mfg Hospitals, health care facilities Mining and mineral product mfg Pharmaceutical mfg Fabricated metal mfg 2% 2% 2% 2% 2% Chemical mfg 5% Distribution centers, warehousing 1% Government or military Oil, gas and petroleum, including refining Miscellaneous or other mfg Plant/facilities engineering or maintenance services Electrical equipment, appliance and component mfg 4% 4% 4% 4% 3% Computers, communications, consumer electronics and electronic product mfg Agriculture or construction Textiles, apparel and leather products mfg Information, data processing or software and services Other 1% 1% 1% 0% 10% Q: What is the primary business at your location? (n=327) 8

9 Facility size Sixty-four percent of respondents facilities employ fewer than 250 people and 24% employ more than 500; the average facility has 326 employees. 500 to 999 employees 9% Average 326 people 250 to 499 employees 12% 1,000 employees or more 15% 100 to 249 employees 19% Fewer than 100 employees 45% Q: How many people work at your location? (n=327) 9

10 Location within U.S. Twenty-six percent of respondents are based along the East Coast of the United States; the four central regions account for 35%; Mountain and Pacific areas are just 15%. 24% of respondents are outside the U.S., including engineers from Canada, India, and others. Pacific 11% Mountain 4% West North Central 7% West South Central 6% East South Central 2% East North Central 20% South Atlantic 11% New England 5% Middle Atlantic 10% *Data gathered using Control Engineering subscriber information; respondents were matched to their subscription profiles. 10

11 Motor drives used, expected to be used The majority of respondents currently or expect to buy, specify, or use variable speed drives, while 46% use servo and/or stepper drives and only 22% use medium-voltage drives. Variable-speed drives, ac/dc 87% Servo and/or stepper drives 46% Medium-voltage drives 22% Q: Do you buy, specify, or use motor drives (or expect to in the next 12 months) in any of the following categories? (n=327) 11

12 Motor drive criteria When evaluating motor drives, more than half of respondents look at drive reliability and upfront costs. Other important criteria include communication interface choices, customer service and support, and simple setup/controls. Drive reliability 70% Delivery speed 28% Price 62% Energy efficiency metrics, usage optimization 26% Communication interface choices Customer service and support Simple setup/controls Programmability in software Manufacturing reputation Maintenance Convenient operator interface Faster troubleshooting Downloadable parameters Warranty Running costs: Improved energy savings Ability to withstand harsh environments Longer motor life (asset management) 49% 49% 48% 46% 43% 43% 38% 33% 32% 32% 31% 30% 29% Improved product quality Increased process reliability Standardization of process Improved motion control of connected process Using IEEE standards Multiple motor control from one drive Regenerative braking Increased production capability Failure rating metrics Line drawings Line regeneration To gain more information about the manufacturing or plant process 26% 25% 24% 22% 17% 16% 16% 14% 14% 13% 11% 6% Location of technical support 28% Other 3% Q: What criteria do you look for when evaluating motor drives? (n=327) 12

13 Variable-speed drives, ac/dc Only survey respondents who use, expect to use, or indicated having buy/specify responsibility for variable-speed drives (ac/dc) were asked the questions reflected in this section of the report. 13

14 Applications and purchasing preference Nine in 10 respondents specify variable-speed drives for new applications, and 40% have no preference when purchasing motors and related variable-speed drives (ac/dc) controller products as matched or separate units. Applications Purchasing Matched vs. separately New 90% Retrofit 76% No preference 40% Separately 36% Matched units 24% Replacement 73% Q: For what types of applications do you specify variable speed drives, ac/dc? (n=284); Q: Do you prefer to purchase motors and related variable speed drives, ac/dc controller products as matched units or separately? (n=284) 14

15 Important evaluation factors Frequent start/stop tolerance and continuous operation at low speed are the two most important factors considered when respondents evaluate variable-speed drives. Highly important Important Frequent start/stop tolerance Continuous operation at low speed Low harmonics operation EMI/RFI protection (built-in filter) Installation space requirements Motion safety features available Torque limiting Tripless operation Dynamic braking Sensorless vector control Availability of application option cards Ultracompact sizes available (space limitation) Flux vector control Control different motor types from one drive (multidrive) 4-quadrant operation 38% 33% 33% 31% 22% 28% 24% 22% 40% 43% 37% 38% 47% 38% 39% 37% 78% 76% 70% 69% 69% 66% 63% 59% 20% 19% 14% 14% 14% 13% 36% 36% 40% 35% 32% 32% 56% 55% 54% 49% 46% 45% 15% 24% 39% Q: How important are the following factors to you when evaluating variable speed drives, ac/dc? (n=284) 15

16 Estimated expenditures Respondents estimated an average expenditure of $148,000 for variable-speed drives over the past 12 months, with 45% reporting $50,000 or less and 12% spending more than $250,000. $500,001 to $1 million 4% $250,001 to $500,000 4% More than $1 million 4% Don't know 9% Less than $10,000 17% Average $148,000 $100,001 to $250,000 14% $50,001 to $100,000 20% $10,000 to $50,000 28% Q; Which of the following ranges best reflects your estimated expenditures for variable speed drives, ac/dc, over the past 12 months? (n=284) 16

17 Future expenditures Forty-seven percent of respondents don t expect their variable-speed drive expenditures to change in the next 12 months, but of the 41% who expect an increase, they foresee an average growth of 12%. Decrease 12% Remain the same 47% Increase 41% Increase by 1% to 9% 17% Increase by 10% to 19% 16% Average 12% increase Increase by 20% or more 8% Q: How do you expect the expenditures for variable speed drives, ac/dc products to change in the next 12 months? (n=284) 17

18 Ordering preference, universal drive usage Three-quarters of respondents prefer to order standard off-the-shelf variable-speed drives over customengineered units. Forty-four percent of respondents currently use a universal variable-speed drive that handles several types of motors. Customengineered 9% Custom-engineered vs. standard off-the-shelf Standard off-the-shelf 75% No preference 16% Have not used, and have no plan to use 14% Have not used, but would consider using 19% Using universal drives with several motor types Currently use 44% Used in the past, would not consider using again 2% Used in the past, would consider using again 21% Q: Do you prefer to order a custom engineered variable speed drive or a standard off-the-shelf drive? (n=284); Q: Do you use a universal variable speed drive that handles several types of motors? (n=284) 18

19 Drive size The majority of engineers are currently using 1- to 50-hp (0.75- to 37.5-kW) variable-speed drives; 41% are using or plan to use drives with over 200-hp (150-kW) capacity. Currently use Not using, plan to use in next 18 mos. Not using, no plan to use Under 1 hp (<0.75 kw) 50% 12% 38% 1 to 5 hp (0.75 to 3.75 kw) 71% 13% 16% 6 to 10 hp (3.75 to 7.5 kw) 65% 12% 23% 11 to 50 hp (15 to 37.5 kw) 62% 14% 24% 51 to 100 hp (37.5 to 75 kw) 45% 12% 43% 101 to 200 hp (75 to 150 kw) 37% 11% 52% Over 200 hp (>150 kw) 31% 10% 59% Q: Which sizes of adjustable-speed drives (ac/dc) do you currently use or plan on using in the next 18 months? (n=284) 19

20 Drive control types used Seventy-eight percent of respondents are using a V/Hz control (open-loop) for their variable-speed drives. One-fifth of respondents are planning to use encoderless, flux vector, or direct torque controls in the near future. Currently use Not using, plan to use in next 18 mos. Not using, no plan to use V/Hz control (open-loop) 78% 6% 16% PWM control 44% 16% 40% Encoderless ("sensorless") control 40% 22% 38% Flux vector control 36% 21% 43% Direct torque control (DTC) 31% 19% 50% SCR/thyristor control 24% 17% 59% Q: For variable speed drives, ac/dc, select the type of drive control being used: (n=284) 20

21 Servo and/or stepper drives Only survey respondents who use, expect to use, or indicated having buy/specify responsibility for servo and/or stepper drives were asked the questions reflected in this section of the report. 21

22 Applications and purchasing preference The majority of respondents specify servo/stepper drives for new applications, and 56% prefer to purchase servo/stepper drive controller products as matched units. Applications Purchasing Matched vs. separately New 88% Replacement 71% No preference 31% Retrofit 63% Separately 13% Matched units 56% Q: For what types of applications do you specify servo and/or stepper drives? (n=151); Q: Do you prefer to purchase servo and/or stepper drive controller products as matched units or separately? (n=151) 22

23 Important evaluation factors More than 90% of respondents agree that accurate positioning, speed, and torque control are the most important factors when evaluating servo/stepper drives. Highly important Important Accurate positioning 71% 22% 93% Accurate speed and torque control 64% 28% 92% Motor sizing and tuning software 33% 47% 80% Single cable communications 21% 48% 69% Resonance reduction/damping 24% 44% 68% Microstepping 17% 36% 53% On-the-fly step change 13% 40% 53% Availability of application option cards 17% 33% 50% Ultracompact sizes available (space limitation) 11% 39% 50% Q: How important are the following factors to you when evaluating servo and/or stepper drives? (n=151) 23

24 Estimated expenditures Respondents estimated $96,000 on average to have been spent on servo/stepper drives over the past 12 months, with 16% reporting more than $100,000 was allocated to these products. More than $500,000 4% $250,001 to $500,000 5% $100,001 to $250,000 7% Don't know 7% Less than $10,000 29% $50,001 to $100,000 17% Average $96,000 $10,000 to $50,000 31% Q: Which of the following ranges best reflects your estimated expenditures for servo and/or stepper drive products over the past 12 months? (n=151) 24

25 Future expenditures Half of respondents don t expect servo/stepper drive expenditures to change in the next 12 months, but 40% do expect an increase with the average percentage increase expected being 14%. Decrease 9% Remain the same 51% Increase 40% Increase by 1% to 9% 15% Increase by 10% to 19% 13% Increase by 20% or more 12% Average 14% increase Q: How do you expect the expenditures for servo and/or stepper drive products to change in the next 12 months? (n=151) 25

26 Ordering preference, number of axes Eight in 10 respondents prefer to order a custom-engineered servo/stepper drive as opposed to standard off-the-shelf products. Servo drives currently used by respondents have an average of 3 axes. No preference 10% Custom-engineered vs. standard off-the-shelf Standard off-the-shelf 81% Customengineered 9% 7 to 8 axes 2% 5 to 6 axes 5% 4 axes 6% Average number of axes 9 to 10 axes 3% 3 axes 24% Average 3 axes More than 10 axes 8% 1 axis 27% 2 axes 25% Q: Do you prefer to order a custom engineered servo and/or stepper drive or a standard off-the-shelf drive? (n=151); Q: What is the average number of axes for the servo drives (ac/dc) that you currently use? (n=151) 26

27 Using universal drives with several motor types Six in 10 respondents use or have previously used a universal servo/stepper drive that handles several types of motors; 25% have not used such a drive but would be open to considering for the future. Have not used, and have no plan to use 13% Used in the past, would not consider using again 2% Have not used, but would consider using 25% Currently use 34% Used in the past, would consider using again 26% Q: Do you use a universal servo and/or stepper drive that handles several types of motors? (n=151) 27

28 Drive size, amplifier output Three in 10 respondents buy or specify stepper drives up to 100 W. Forty-six percent of respondents currently use servo drives with an amplifier output of up 10 A. Stepper drive sizes Servo drive amplifier output up to 20 W 21 to 50 W 51 to 100 W 101 to 250 W 251 to 500 W 30% 36% 29% 23% 17% >100 A 3% 51 to 100 A 3% 26 to 50 A 12% Don't know 15% 11 to 25 A 21% 0 to 5 A 15% 6 to 10 A 31% >500 W 13% Q: For which sizes of stepper drives do you have buy/specify responsibilities? (n=151); Q: What is the amplifier output for the servo drives (ac/dc) that you currently use? (n=151) 28

29 Drive control types used Closed loop drive controls for servo/stepper drives are most popularly used by respondents. Nearly onequarter of respondents are not currently using brushless dc controls but do plan to in the near future. Currently use Not using, plan to use in next 18 mos. Not using, no plan to use Closed loop 80% 11% 9% AC (sinusoidal commutation) 50% 20% 30% PWM control 50% 14% 36% Open-loop (for steppers only) 48% 14% 38% Brush dc 40% 14% 46% Brushless dc (trapezoidal commutation) 37% 24% 39% Q: For servo and stepper drives, select the type of drive control being used: (n=151) 29

30 Medium-voltage drives Only survey respondents who use, expect to use, or indicated having buy/specify responsibility for medium-voltage drives were asked the questions reflected in this section of the report. 30

31 Applications and purchasing preference The majority of respondents specify medium-voltage drives for new applications, and 37% have no preference when purchasing matched or separate units of medium-voltage drives and Above NEMA motors. Applications Purchasing Matched vs. separately New 92% Retrofit 66% Separately 29% No preference 37% Replacement 61% Matched units 34% Q: For what types of applications do you specify medium-voltage drives? (n=71); Q: Do you prefer to purchase medium-voltage drives and Above NEMA motors as matched units or separately? (n=71) 31

32 Important evaluation factors Accurate speed and torque control (88%), low harmonics operation (81%), and installation space requirements (78%) are the three most important factors considered when respondents evaluate medium-voltage drives. Highly important Important Accurate speed and torque control Low harmonics operation Installation space requirements EMI/RFI protection (built-in filter) Latest power switching devices Transformerless MV drive available Dynamic braking Tripless operation Motion safety features available Flux vector control Sensorless vector control 4-quadrant operation Cell bypass 51% 37% 88% 56% 25% 81% 27% 51% 78% 42% 32% 74% 28% 30% 30% 39% 35% 28% 23% 23% 42% 39% 38% 28% 31% 35% 34% 32% 70% 69% 68% 67% 66% 63% 57% 55% 20% 31% 51% Q: How important are the following factors to you when evaluating medium-voltage drives? (n=71) 32

33 Estimated expenditures Thirty-seven percent of respondents budget medium-voltage drives during Q4, and 31% said their estimated expenditures for these products in the past 12 months were $250,000 or less, while 7% estimated spending more than $1 million. Evaluation/purchasing period Estimated expenditures January to March 20% April to June 21% July to September 22% October to December 37% More than $2.5 million 1% $1,000,001 to $2.5 million 6% Don't know 23% $500,001 to $1 million 19% Average $509,000 $250,000 or less 31% $250,001 to $500,000 20% Q: What time of year do you budget for medium-voltage drives? (n=71); Q: Which of the following ranges best reflects your estimated expenditures for medium-voltage drive products over the past 12 months? (n=71) 33

34 Future expenditures More than half of respondents don t expect medium-voltage drive expenditures to change in the next 12 months, but those who expect an increase predict an average growth of 15%. Remain the same 58% Decrease 13% Increase by 1% to 9% 8% Increase 29% Increase by 10% to 19% 11% Increase by 20% or more 10% Average 15% Q: How do you expect the expenditures for medium-voltage drives to change in the next 12 months? (n=71) 34

35 Drive size More than half of respondents currently use 200 to 499 hp medium-voltage drives, and 37% use 500 to 699 hp or 700 to 1,340 hp medium-voltage drives. Currently use Not using, plan to use in next 18 mos. Not using, no plan to use 200 to 499 hp 58% 11% 31% 500 to 699 hp 37% 18% 45% 700 to 1,340 hp 37% 14% 49% 1,341 to 13,400 hp 25% 17% 58% 13,401 to 67,000 hp 7% 14% 79% 67,001 to 134,100 hp 4% 11% 85% > 134,100 hp 4% 10% 86% Q: Which sizes of medium-voltage drives do you currently use or plan to use in the next 18 months? (n=71) 35

36 Current, future applications The top applications for which respondents are using or anticipate using medium-voltage drives in the near future are pumps (63%), compressors (45%), and forced or induced draft fans (34%). Pumps 63% Compressors Forced draft (FD) fans and induced draft (ID) fans Belts or conveyors Cooling fans Chiller HVAC unit 34% 31% 30% 28% 24% 45% Extruder Other 15% 14% Q: Select applications for medium-voltage drives for which you are currently using them or anticipate using them in the future. (n=71) 36

37 Additional resources Thank you for downloading the 2017 Motor Drives Report! Use the links below to access additional information on related news, products, and research. Technical articles, news, case studies, products Discrete manufacturing: motors, drives Discrete manufacturing: new products New Products for Engineers Programs and resources Global System Integrator Database Engineers Choice Awards Online Training Center Videos Webcasts Case studies eguides Newsletters Editorial research studies 2017 HMI Software & Hardware 2017 Career & Salary Survey 2016 Industrial Internet of Things & Industrie System Integration 2016 Cybersecurity More research: Contact information Amanda Pelliccione Director of Research Mark Hoske Content Manager Control Engineering 37