At its wire manufacturing operation in Jaraguá do Sul (SC) Brazil, WEG upgraded the primary wire-drawing machine, replacing a system based on direct current (DC) motors and AC/DC converters with an alternating current (AC) solution.
The new configuration consists of two high-efficiency W22 PRIME motors and two CFW900 variable frequency drives. As a result, the equipment achieved an approximately 19% reduction in energy consumption, along with improvements in reliability, maintenance, and operational availability.
Drive system upgrade
The technology previously in use presented challenges related to energy efficiency, specialized maintenance, and component availability.
With the new solution, the wire-drawing machine now operates with AC motors and variable frequency drives, reducing dependence on legacy technologies and making maintenance and support easier.
The project also included electrical system components, contributing to the modernization of the installation and its compliance with applicable safety requirements.
High efficiency and technology
W22 PRIME motors are available in the IE4 and IE5 efficiency classes, which exceed the minimum energy efficiency requirements established by Brazilian legislation. They combine high efficiency, robust construction with an IP55 degree of protection, and the WISE® insulation system, also designed for operation with variable frequency drives.
These features contribute to greater energy efficiency, reliability, and service life in industrial applications.
When paired with CFW900 drives, which offer precise speed and torque control, vector control modes, and the Advanced Energy Saving function, the system helps reduce losses and optimize energy performance. The CFW900 also offers extensive connectivity with major industrial communication networks, as well as advanced safety functions such as STO (Safe Torque Off) and SS1 (Safe Stop), providing greater integration, reliability, and operational safety.
Greater reliability and easier maintenance
In addition to energy savings, replacing the old DC motors helped reduce risks associated with technological obsolescence and the need for specialized maintenance.
The new architecture facilitates preventive and corrective maintenance, increases support availability, and reduces the risk of prolonged downtime, improving the reliability and availability of the wire-drawing machine.
Retrofitting for a more efficient industry
The project demonstrates how retrofitting industrial motor-drive systems can combine energy efficiency with technological advancement.
By combining W22 PRIME motors, CFW900 variable frequency drives, and expertise in industrial applications, WEG develops solutions that support equipment modernization and the pursuit of more efficient, productive, and sustainable processes.
Does your operation use outdated motors or drive systems?
WEG can assess the installed system and identify opportunities for technological upgrades, energy efficiency, and improved operational reliability.
Talk to a WEG specialist and discover opportunities to improve efficiency in your operation.
