Fixed-Speed Aggregate Applications
Soft starters offer an efficient, cost-effective solution …
Fixed-speed aggregate applications are common in the construction and infrastructure industries. These plants process large volumes of crushed stone, sand and gravel, relying heavily on fixed-speed motors for crushers, conveyor belts, vibrating screens and pumps. However, full voltage or direct on-line starting methods often cause mechanical stress, voltage drops and high inrush currents that lead to frequent breakdowns and operating inefficiencies.
Soft starters, by contrast, offer an efficient, cost-effective solution for controlling the acceleration of fixed speed equipment – reducing mechanical shock, enhancing reliability and lowering maintenance costs.
Challenges of Fixed Speed Motors
- High Inrush Currents – At startup, motors draw six to eight times their full load current. Excessive current draw during startup can increase energy costs.
- Mechanical Shock – Sudden torque stresses belts, couplings and bearings. Repeated stress on motors and mechanical equipment increases maintenance costs.
Key Benefits of Soft Starters in Fixed Speed Applications
- Enhanced Crusher Performance and Longevity – Sudden applications of full voltage and torque cause significant mechanical stress on a crusher’s drive system. Soft starters gradually increase torque, reducing mechanical stress to belts, shafts and couplings.
- Smooth Conveyor Belt Operation – Uncontrolled startups cause belt slippage, misalignment and excessive tension, leading to premature belt wear and roller damage. Soft starters provide gradual acceleration, preventing belt slippage and reducing disruptions to material flow.
- Reduced Stress on Vibrating Screens – Vibrating screens operate under constant mechanical stress. High starting torque can lead to crack formation in screen decks, motor misalignment and increased vibration levels. Soft starters smoothly ramp up speed, preventing sudden shocks to the screw frame, bearings and drive motor.
- Pump Protection and Water Hammer Reduction – Abrupt starts can cause water hammer … a damaging pressure surge that weakens pipelines and valves. Soft starters gradually increase pump speed during startup, reducing shock and providing a steady pressure buildup.
Whether applied to crushers, conveyors or pumps, soft starters help increase reliability, reduce energy consumption and extend equipment life in fixed-speed aggregate applications. Contact our team today to discuss the best motor control or drive solution for your application.
Join Us at the World of Asphalt Show and Conference
Benshaw will be on hand March 25-27, 2025 at the 2025 World of Asphalt Show and Conference (Booth #7032) in St. Louis, Missouri featuring our latest applied motor control products and technologies. World of Asphalt is the industry’s leading trade show in North America, featuring equipment more than 400 manufacturers.
About Benshaw
Benshaw is widely recognized as a leading provider of applied motor controls and technologies. We thrive on complex applications and work diligently to bring cost-effective, advanced motor control and protection solutions to our customers. With operations spanning the globe, Benshaw now offers the broadest family of globally supported, globally certified, low and medium voltage soft starters in the industry.
