When selecting motors, it’s critical to choose the right motor for the right job – especially when that job will put a demanding strain on the motor. Numerous specialty motors exist for specific roles, such as crusher duty motors, explicitly designed for rock crushing.
Industries such as mining and aggregates need to crush huge amounts of rock reliably, day after day. Beyond the sheer force required to crush rock, the motors must also withstand massive amounts of vibration, nonstop dust in the air, and all the outdoor elements. That’s a job that few standard motors can handle, and even many severe duty motors would struggle to keep up.
So, several major global motor brands – including Baldor, WEG, and Leeson – make crusher duty motors specifically for this role. If your workflow calls for rock-crushing, these are the standard features and new technologies you should look for in your crusher duty motors.
Key Features and Benefits in Modern Crusher Duty Motors
Pure Power
One of the key elements of the crusher duty motor is the sheer power and torque it can generate, allowing them to chew through huge amounts of rock without fail. Crusher duty motors are available in a range of horsepower, depending on your needs, but typically with horsepower going up to 500HP or more for maximum performance.
This is also paired with high service factors, allowing the motor to exceed its normal limits for occasional high-volume work. Service factors of 1.15 or even 1.25 are common, giving you peace of mind that your motor will always be able to deliver the crushing power you need.
Ruggedization
Crusher duty motors are put through some of the worst situations a motor could face. They operate continuously at high speeds in a dust-filled outdoor environment. The motors need to be able to stand up to this situation, day after day, for years – which calls for seriously rugged construction.
Expect solid cast iron and high IP ratings – including IP55 or IP66. Even relatively minor components, such as the fan covers, will be extra durable and capable of resisting abuse. Other elements, such as the roller bearings, will typically be extra strong or oversized to keep them functioning even in harsh conditions.
Energy Saving Features
Energy costs make up the vast majority of operating costs over a motor’s lifespan, typically up to 90% of the costs. This means motor manufacturers are pushing hard to keep energy use as low as possible.
One way this is achieved is through the introduction of inverter-duty crusher motors. These can be powered through a variable frequency drive (VFD), allowing you to precisely adjust motor speed to match your desired input and output targets throughout a project. They also require far less energy to start up compared to standard single-speed drives.
The motors themselves are designed for high efficiency, including high-quality electrical steel wiring for highly efficient energy transfer while resisting the high heat these motors can generate.
Easy-To-Access User Controls
When the motor controller needs to be accessed directly, it should be easy for workers to get at – while still being as shielded and rugged as every other component of the crusher duty motor. Keypads and access panels are shielded while still being simple to access when necessary. If necessary, locking systems can also be deployed to protect the access area from tampering.
However, it may not be necessary to directly access your crusher duty motor at all…
Smart Industry 4.0 Features
One of the most exciting new additions to crusher duty motors is the increased inclusion of smart connectivity features, allowing these motors to become part of an “Industry 4.0” automated workflow.
These smart crusher duty motors have chips installed that monitor the condition of the motor, inside and out – including elements that could only otherwise be accessed by disassembling the motor. These are tied to wireless or cellular connectivity services, allowing the motor to report its condition at any time or provide live updates as it works.
These numbers are reported to a dashboard app, allowing you or your overseers to monitor the motor at all times. This is typically paired with automation features, such as planning shutdowns and maintenance in advance.
Given how difficult in-person monitoring and maintenance of crusher duty motors can be, these new smart features make it far easier, faster, and even safer to keep tabs on your motors at work.
Other Common Features
Various other features and improvements you’re likely to find on crusher duty motors include:
- Reduced footprints to keep space usage to a minimum
- Heavy-duty feet for resting the unit upright rather than difficult wall-mounting
- Protected circuit breakers with weatherproofing
- Smart power supplies which protect from over/under-current
- Options for one-phase or three-phase power
- Heavy duty seals to maintain the IP rating
- Modular subpanel designs for easy modification or replacement
Wolters Motors & Drives Has the Crusher Duty Motors You Need
Since 1968, Wolters Motors & Drives has been one of America’s leading sources for motors, starters, power transmissions, parts, and accessories. We’re known for our vast in-stock parts collection and the ability to rapidly ship once an order is placed. We also keep an in-house team of engineering experts who are always here to consult on tricky systems engineering problems or recommend the best overall motor for your needs.
This keeps Wolters’ customers coming back year after year, decade after decade. We can support all your motorized operations!
To learn more or consult with our experts, just contact us.
