Drives & Controls May 2022

www.drivesncontrols.com May 2022 43 MOTORS n Mini upgrades its paint shop motors to IE5 and saves £40,000 a year B MW-owned Mini has upgraded ageing IE1/IE2 motors in the paint shop at its Oxford plant to IE5-efficiency synchronous reluctance (SynRM) motor- and-drive packages, thus boosting the plant’s efficiency, cutting costs and lowering the car- maker’s carbon footprint. An energy assessment carried out by Bristol- based APDS before the project began estimated that it would reduce the site’s energy costs by £40,000 annually as well as cutting carbon dioxide emissions significantly. Payback for the upgrade was estimated to be less than three years. “The incumbent motors were nearing the end of their lives,”recalls APDS managing director, Alan Jones.“This provided the perfect opportunity to build on the plant’s existing SynRM base and deliver the significant savings the company desired.” A large number of motors that power supply and exhaust fans for paint-spraying booths in the plant’s paint shop have been replaced. The new ABB IE5 SynRM motors, with ratings ranging from 55-132kW, have been paired with ABB general- purpose drives. As well as saving energy, the motor-and-drive packages are reducing ambient noise levels and running temperatures, cutting heat losses and reducing the need for maintenance. The new drives have been integrated with a new PLC system at the plant, improving communications across the site. The paint shop operates with a positive air pressure, so more air is introduced into the area than is removed. This ensures airborne dust does not settle on the painted surfaces and delivers a blemish-free finish. The PLC monitors the air pressure and triggers the drives to increase power to the fans if, for example, a door is opened. The drives also have an underload function that indicates if the load drops on the belt-driven fan systems used to ventilate the spray booth. It alerts maintenance staff and reduces the risk of costly downtime. BMW has joined other players in the automotive industry in pledging to cut emissions associated with manufacturing its vehicles by 80% within a decade, bringing it in line with the Paris Agreement. Switching to the IE5 synchronous reluctance motors will play a key role in ensuring that the Oxford plant contributes to the company’s sustainability objectives. n By upgrading end-of-life motors in its Oxford paint shop to IE5 synchronous reluctance machines, BMW’s Mini operation has cut its energy costs by £40,000 a year, and shrunk the plant’s carbon footprint. Have you tried our brand new webstore? 0800 034 5850 www.thorite.co.uk Food Grade Air Filtration Ranges Pneumatic Control Equipment Process Control & Pumping Compressors & Ancillary Equipment Electro Mechanical Drives & Bearings Hygienic, Stainless Steel Fittings & Tubing 10% OFF* DCMAG10 YOUR FIRST ONLINE ORDER USE OFFER CODE *T&Cs apply Anywhere . Anytime . Shop Online FREE P&P* The IE5 synchronous reluctance motors installed at Mini’s paint shop are helping to maintain positive air pressure efficiently in the spray booths. Image: Mini