{"id":3412,"date":"2024-12-02T14:25:04","date_gmt":"2024-12-02T13:25:04","guid":{"rendered":"https:\/\/www.benbuchele.de\/?p=3412"},"modified":"2025-05-23T12:25:10","modified_gmt":"2025-05-23T10:25:10","slug":"dryining-systems-coninuous-operation-for-8000-hours-per-year","status":"publish","type":"post","link":"https:\/\/www.benbuchele.de\/en\/2024\/12\/02\/dryining-systems-coninuous-operation-for-8000-hours-per-year\/","title":{"rendered":"Drying systems \u2013 Continuous operation for 8,000 hours per year"},"content":{"rendered":"<p><em>Conventional off-the-shelf motors are unsuitable in many situations. For convection drying systems for building boards, nonwovens, and filter sheets, we supply powerful special motors that can run continuously for 8,000 hours a year in harsh environmental conditions. Further requirements include energy efficiency class IE3, a special shaft, insulation class H, a relubrication device, and specific cable connections.<\/em><\/p>\n<p>Products that are manufactured wet, such as plasterboard and construction boards, ceiling and fa\u00e7ade elements, nonwovens, insulation boards, and filtration layers, are thermally treated in our customer\u2019s convection drying systems. Air circulation fans are used for drying around 8,000 hours a year, 24\/7. The electric motors that drive each individual fan must be extremely robust, powerful, and durable in order to meet the exacting requirements.<\/p>\n<p>However, not all drying systems are the same. There are smaller laboratory dryers, which are equipped with just two fans and corresponding motors, and huge dryer systems 110 meters long, which apply hot air to products on up to 12 floors with 200 fans. These systems dry 3,000 to 4,000 square meters of construction boards or continuous elements, such as filter material, every hour. The products travel through the entire system on all floors on conveyor belts. The laboratory dryer evaporates 20 kilograms of water per hour, while the large-scale system evaporates up to 20 tons of water per hour. Moist air is extracted continuously and fed out of the drying chamber.<\/p>\n<h2><strong>The challenge of existing systems<\/strong><\/h2>\n<p>We primarily supply replacement motors for the customer\u2019s existing systems. This presents yet another challenge, as it does not require creating a new concept for scratch, but rather taking all local conditions into account. Requirements range from optimal energy consumption for generating hot air \u2013 with energy efficiency class IE3 \u2013 to special shafts, insulation class H, a relubrication device, and customized cable connections. The limited available space must also be taken into account. We mimic the tight installation space on our own premises in order to gain insights into temperatures and ventilation.<\/p>\n<p>Two motor sizes \u2013 90 and 132 \u2013 and four motor models were ultimately provided. Customers have also required motors that can be switched from four to two poles, which operate at two different speeds (1,500 and 3,000 revolutions), and have a power range up to 7.5 kW, depending on the desired dryer performance.<\/p>\n<h2><b>Special drive shaft<\/b><\/h2>\n<p>While drive shaft ends correspond to a standard size of 24 x 50 mm, increased diameter and triple-length shaft ends are required here, onto which the fan wheel is screwed. In addition, some installation situations require conical drive shaft ends; cylindrical shaft ends are standard.<\/p>\n<h2><strong>Adapted mains voltage<\/strong><\/h2>\n<p>As drying systems are supplied and motors replaced worldwide, the respective mains voltages of the countries must also be taken into account and motors from BEN Buchele adapted accordingly. Even in Germany, where 400 volts is standard in the industrial sector, a motor design for 500 volts was required for an old drying system. Other BEN replacement motors that were delivered to Japan were designed for 200 volts at a frequency of 50 hertz, as is standard there.<\/p>\n<h2><strong>Relubrication device for a long service life<\/strong><\/h2>\n<p>To ensure that replacement motors last a long time, it is important to add a relubrication device for the bearings, as this significantly increases the service life of motors. At insulation class H, the motors are designed for excess temperatures of up to 180 degrees Celsius. Although the ambient temperatures in the drying systems are generally only between 40 and 60 degrees Celsius, process temperatures in the ovens are significantly higher. The high insulation class also takes account of the narrow spaces in which the motors often need to be installed.<\/p>\n<h2><strong>Electrical connection<\/strong><\/h2>\n<p>Motor connections are also adapted to the respective drying system. As the usual terminal boxes cannot be installed due to space constraints, a 2-meter cable leads directly out of the motor and is connected to the control cabinet via a terminal box on the outside of the door behind which the motor is installed. Alternatively, the two cables for the motor connection and temperature sensor can run directly from the motor via a Harting connector.<\/p>\n<h2><strong>Designing for specific situations<\/strong><\/h2>\n<p>The ambient conditions for replacement motors are always different, so we always take the specific requirements into account in the design. In a drying plant, for instance, a sturdy steel tube was required for running grease through the relubrication device, instead of plastic hoses. In this case, our design engineers completely adapted the motor accordingly.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>The ever-greater demands on the energy efficiency of IE4 electric motors \u2013 currently the highest energy efficiency class in accordance with DIN-EN 60034-30-1 \u2013 are pushing asynchronous machines to the limits of what they can physically do.<\/p>\n","protected":false},"author":1,"featured_media":3414,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[4],"tags":[],"class_list":["post-3412","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.2 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Drying systems \u2013 Continuous operation for 8,000 hours per year - BEN Buchele<\/title>\n<meta name=\"description\" content=\"For convection drying systems for building boards and filter sheets, we supply special motors that can run continuously 8,000 hours a year!\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.benbuchele.de\/en\/2024\/12\/02\/dryining-systems-coninuous-operation-for-8000-hours-per-year\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Drying systems \u2013 Continuous operation for 8,000 hours per year - 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