Gain Control with Electric Actuator and Variable Frequency Drive

Blac Inc. Partners with Wesco on Cost-Effective and Space-Saving Precision Control

Challenge

Blac Inc. is a U.S.-based company specializing in the design and manufacture of valves and actuator systems that are critical in controlling the flow of fluids and gases in industrial environments. The company focuses on providing high-performance solutions with precision control, especially for applications involving high temperatures and rigorous operational demands such as refining, petrochemical, power generation and pipelines. Like most companies, Blac Inc. was impacted by supply chain and workforce challenges because of the COVID-19 pandemic. To help its business and the industry overall, the company started to think differently, exploring new routes to market and advanced technologies to “do more with less.” Already a trusted advisor to Blac Inc., Wesco was eager to assist the company with investigating, testing and implementing new ideas for cost-effective precision control in industrial environments.

Solution

Wesco scheduled a business alignment workshop with Blac Inc. to discuss the project requirements and steps to a solution. Blac Inc. quickly identified two priorities to address in the new precision control solution:  1. a design with little to no maintenance and 2. a lower cost and smaller footprint for high force and torque applications. The Wesco team worked closely with Blac Inc., providing technical expertise and testing various solutions and capabilities, including new advancements in variable frequency drives (VFD). Over the course of approximately 12 months, the innovative Viper™ VFD was designed – an electric actuator compatible with VFDs.

VFD technologies, like Rockwell’s 755TS, can control the Viper™ VFD like a motion system, but with slightly less precision. Although the speed of response is slower in VFD-based systems, the accuracy of final position control remains high. Modern VFDs now have onboard PLC-like capabilities; a single device can manage complex systems that previously required multiple components. Now that VFDs can control motor direction and speed and manage load inertia and velocity, VFD-based electro-hydraulic actuators have emerged as a viable alternative to servo systems. The Viper™ VFD works for the vast majority of applications, as it is capable of 0.1% resolution and linearity.

Result

As a self-contained precision control alternative, the Viper™ VFD delivers reliability and efficiency in situations demanding precise control and quick actuation speeds. Because it is a self-contained system, there are no bearings to be greased, and it does not require a preventative maintenance plan. There are no large components that need to be specified, purchased and installed for operation, substantially reducing procurement and installation efforts and saving valuable floor space. The cost benefits are significant for both OEMs and customers, which has helped to open new markets for Blac Inc.