Unlock savings and application potential with motor control centres

August 5, 2024 Editor

Motor control centres offer a variety of operational benefits at every stage of the application lifecycle, from design and installation, through operation and maintenance, to ongoing evolution and scalability, as Cihan Bulut, EMEA Product Manager MCC, and Jonathan Smith, Business Manager, Intelligent Devices, UK & Ireland, both at Rockwell Automation, explain.

Modern industry is all about efficiency, human empowerment, sustainability, and agility, and the best way to achieve all four (and more) is by getting smarter. But smart-machine capabilities are not just the domain of top-level hardware. Indeed, smart motor control centres (MCC) can deliver multiple smart capabilities to an incredibly broad range of motor-driven applications, through centralised control, broader connectivity, deeper data collection and collation, and the delivery of actionable analytics-driven insights.

With motors being so widely deployed, it makes sense to not only control them more efficiently – for both performance and sustainability purposes – but also to use their application locations and functions as pulse points, to extract critical localised operational data, based on their performance and consumption figures. However, it’s not all about this straight-line performance. A facility without smart MCCs will likely face other challenges, too, relating to automation capabilities, maintenance, safety, space utilisation, scalability, energy use/sustainability, production efficiency, and wiring complexity. And, in the role of a centralised intelligence and performance hub, smart MCC technologies offer the best possible solution for multiple reasons.

So, how does deploying smart MCC technology address these business challenges? First, it is important to note that not all MCCs are the same – there is a sliding scale of operational features and benefits. The features below relate to Rockwell Automation’s FLEXLINE 3500 Motor Control Center, a low-voltage solution that integrates motor control, power distribution, and electrical switchgear into a centralised package that is designed for global markets, meeting IEC standards 61439-1 and 2.

Automation: As well as deploying contemporary automation hardware, users should look to extract useful operational data delivered by widely accepted factory fieldbus protocols, such as EtherNet/IP, and managed switches for isolation, security, and cyberthreats. Operators can take this operational data and use it within analytical software to better understand how the plant is operating.
Maintenance: Look for modular hot-swappable components that will streamline maintenance. Faulty parts should be easily replaceable without disrupting or shutting down the entire system. Maintenance-free busbar systems also help eliminate the need for some preventive maintenance procedures.
Safety: MCCs group electrically hazardous components into one enclosure, reducing the need for personnel to come into contact with randomly dispersed live wires during operation or maintenance. If there is a fault in any motor, you should be able to remove the faulty part without disrupting the entire system, including the safety protocols.
Space utilisation: Look for footprint optimisation. The centralised approach should result in smaller panel/switchboard sizes, which then use less factory/machine real estate. There are other ways to save space, not just now but in the future, too, thanks to clever scalability.
Scalability: Modular panel frameworks will not only save valuable floor space, as they can be tailored to match the available real estate more accurately, but they also offer easier and simpler scalability for future expansion. A case in point being the CUBIC modular system and busbar technology deployed in the FLEXLINE 3500 MCC.
Energy use/sustainability: Energy efficiency is a primary expectation, as intelligent devices and variable-frequency drives optimise energy consumption while reducing energy waste. An MCC groups, controls, and monitors these technologies, offering even greater savings.
Production efficiency & overall equipment effectiveness (OEE): Integrated MCC diagnostics and predictive maintenance features will help identify issues early, maximising productivity while minimising downtime and production losses.
Wiring: MCC wiring is far less complex and uses less copper, thanks to much tighter component integration.

Further smart MCC capabilities and advantages are unlocked when paired with the proper software. Rockwell Automation’s IntelliCENTER technology gives users a clear view of MCC operations, while also providing real-time monitoring, predictive maintenance, and remote-control capabilities, helping users to optimise operations, reduce downtime, and increase overall efficiency.

Finally, regarding investment, it’s important to consider that in manufacturing and processing operations, every production minute counts. And, depending on the industry, this downtime can cost as much as €100,000 per hour or more. Smart MCCs not only provide greater levels of availability, but they can also assist in predictive maintenance, so avoiding unexpected and costly downtime.