Challenge: High starting current & irregularities
The bespoke shredder system initially faced substantial operational difficulties due to the selected motor technology and the demanding application conditions. The motor exhibited an exceptionallyhigh starting current, resulting in local voltage drops that adversely affected nearby electrical equipment. At the same time, both the motor and the shredder were exposed to irregular mechanical shocks and vibrations typical of high-capacity shredding operations. These dynamic loads increased the risk of accelerated wear and potential damage, particularly to the motor’s bearings.
Solution: Star-delta starter & fluid coupling
To mitigate the high inrush current and the resulting voltage fluctuations, MENZEL initially integrated a Softstarter. This allowed for a gentle motor startup, significantly lowering electrical stress on the local grid and surrounding equipment. In a subsequent step, a capacitor bank was installed to improve the power factor (cos phi), thereby enhancing energy efficiency and stabilizing the motor’s electrical operating conditions.
To address the severe mechanical stresses generated during shredding, MENZEL introduced a fluid coupling (turbocoupling) between the motor and the shredder. The coupling provided effective dynamic decoupling, damping shock loads and preventing their direct transmission to the motor shaft and bearing assemblies. Robustness was the guiding design principle for the entire system. Motor and shredder were mounted on separate foundations to minimize the transfer of structural vibrations, while the fluid coupling provided continuous damping during dynamic operation. Together, these measures resulted in a stable and reliable motor system that eliminated startup issues and sustained long-term operation under heavy-duty conditions.
Technical Data
Our Expertise: Your Advantage
This project demonstrates how MENZEL’s engineering expertise supports customers facing complex electrical and mechanical challenges. By delivering a motor solution that carefully balances electrical grid compatibility and mechanical robustness, we ensured that the shredder operates reliably within strict infrastructure and environmental constraints. The targeted integration of a fluid coupling and separate foundations for vibration isolation minimizes equipment wear and reduces the risk of unplanned downtime.
Do you face similar startup challenges or require a resilient, custom motor for a demanding shredding or recycling process? Speak directly with our engineering team to explore how we can deliver a solution precisely matched to your operational needs.
