In this episode of the ABB Solutions Podcast, host Mike Murphy is joined by Robert Boyce, ABB U.S. Division Manager for IEC Low Voltage Motors, to discuss how motors are designed to perform in aggressive applications like crushers in the aggregate industry.

From heavy shock loads to extreme environmental conditions, crushers push motors to their limits. Robert shares how ABB designs motors to handle high starting torque, mechanical stress, vibration and contamination, all while maintaining reliability and efficiency.

Tune in to hear insights on:

• Aggregate Applications: How conveyors, shaker screens and crushers impact motor performance
• Starting Torque Demands: Why constant torque applications require higher locked rotor torque and overload capability
• Overbuilt Design: How larger shafts, reinforced materials and oversized bearings handle shock loads
• Vibration and Mechanical Stress: Why conduit box placement and internal components matter in aggressive environments
• Environmental Protection: How IP66 designs help protect against dust and moisture
• Electrical Reliability: Why terminal blocks provide stronger connections than flying leads in high vibration settings
• Efficiency Standards: How these motors meet and exceed IE3 and IE4 efficiency requirements
• Built for Survivability: Why durability and uptime are critical in crusher applications

References

If you would like to attend a training, head over to our U.S. Drives & PAC Automation Solutions Training page.

Interested in learning more about ABB Drives? Join our Tech Tuesday webinars where our experts tackle topics from improving efficiency and reliability to solving maintenance issues.

Podcast 1: Misconceptions Between NEMA and IEC Efficiencies – clearing up common misunderstandings around efficiency standards and how NEMA and IEC compare in real-world applications: https://www.buzzsprout.com/1770390/episodes/11049334

Podcast 2: IEC and what it means in the US – a closer look at IEC standards and what they mean for U.S. operations, compliance, and motor selection: https://www.buzzsprout.com/1770390/episodes/10839306

In this episode of the ABB Solutions Podcast, host Mike Murphy wraps up the motor starting methods series with a deep dive into variable frequency drives (VFDs). Joined by an ABB Drives expert, the conversation explores how VFDs provide advanced motor control by adjusting frequency, voltage, and torque to match application demands.

Building on previous discussions around full voltage starters and soft starters, this episode highlights how VFDs go beyond startup—offering continuous control, improved efficiency, and significant energy savings in many applications.

Tune in to hear insights on:
• What Is a VFD: How variable frequency drives convert incoming power into controlled output to manage motor speed and performance

• Speed & Torque Control: How VFDs allow precise control of speed, torque, and power across a wide operating range

• Energy Savings Potential: How reducing speed can dramatically lower energy consumption, especially in pump and fan applications

• How VFDs Work: A high-level look at how drives convert AC to DC and back to a controlled AC signal for the motor

• VFD vs. Other Starting Methods: How VFDs compare to soft starters and full voltage methods in functionality and cost

• Advanced Control Features: Capabilities like direct torque control (DTC), programmable settings, and system monitoring

• Real-World Applications: Where VFDs provide the most value, including conveyors, pumps, fans, and high-efficiency systems

References

If you would like to attend a training, head over to our U.S. Drives & PAC Automation Solutions Training page.

Interested in learning more about ABB Drives? Join our Tech Tuesday webinars where our experts tackle topics from improving efficiency and reliability to solving maintenance issues.

Podcast 1: Introduction to Motor Starting Methods – foundational overview of motor types and starting methods: https://www.buzzsprout.com/1770390/episodes/18739876-introduction-to-motor-starting-methods.mp3?download=true

Podcast 2 — Motor Starting Methods: Soft Starters – understanding voltage control and reduced inrush current: https://www.buzzsprout.com/1770390/episodes/18871039

Podcast 3 — Training with ABB Project Management – defining scope, scheduling, and resources for project success: https://www.buzzsprout.com/1770390/episodes/15697913

Podcast 4: Setting and Achieving Goals – creating clarity, ownership, and direction in personal and professional growth: https://www.buzzsprout.com/1770390/episodes/17963852

Podcast 5: Focus & Productivity – building habits and structure to stay consistent and avoid burnout: https://www.buzzsprout.com/1770390/episodes/18125609

Podcast 6: Teambuilding – strengthening alignment, roles, and collaboration for high-performing teams: https://www.buzzsprout.com/1770390/episodes/17267078

In this episode of the ABB Solutions Podcast, host Mike Murphy continues the motor starting methods series with a closer look at soft starters. Joined by Brion Flaningam, ABB Drives Technical Instructor, the conversation explores how soft starters regulate voltage, reduce inrush current, and provide a smoother alternative to traditional motor starting methods.

Building on the fundamentals from the previous episode, this discussion highlights when soft starters are the right choice and how they compare to both full voltage starters and variable frequency drives.

Tune in to hear insights on:

• What Is a Soft Starter: How soft starters use SCRs (thyristors) to gradually ramp voltage up and down during motor startup
• Voltage vs. Speed Control: Why soft starters control voltage—not speed—and what that means for your application
• Inrush Current Reduction: How soft starters minimize the high current spikes seen in direct online starting
• Soft Starter vs. VFD: Key differences in cost, functionality, and when each solution makes sense
• Bypass Contactors Explained: How bypass systems reduce wear and improve efficiency once the motor reaches full speed
• Application Use Cases: Where soft starters work best, including conveyors, escalators, and simple applications where only startup control is needed
• Advantages & Limitations: Lower cost and reduced mechanical stress vs. limited control over speed

References

If you would like to attend a training, head over to our U.S. Drives & PAC Automation Solutions Training page.

Interested in learning more about ABB Drives? Join our Tech Tuesday webinars where our experts tackle topics from improving efficiency and reliability to solving maintenance issues.

Podcast 1 — Introduction to Motor Starting Methods – foundational overview of motor types and starting methods: https://www.buzzsprout.com/1770390/episodes/18739876-introduction-to-motor-starting-methods.mp3?download=true

Podcast 2 — Business Strategy – strategic planning fundamentals to support long-term success: https://www.buzzsprout.com/1770390/episodes/17631204

Podcast 3: Training with ABB Project Management – defining scope, scheduling, and resources for project success: https://www.buzzsprout.com/1770390/episodes/15697913

Podcast 4 — Setting and Achieving Goals – creating clarity, ownership, and direction in personal and professional growth: https://www.buzzsprout.com/1770390/episodes/17963852

Podcast 5 — Focus & Productivity – building habits and structure to stay consistent and avoid burnout: https://www.buzzsprout.com/1770390/episodes/18125609

Podcast 6 —Teambuilding – strengthening alignment, roles, and collaboration for high-performing teams: https://www.buzzsprout.com/1770390/episodes/17267078