Differences between a contactor-based controller and a frequency-inverter controller – impact on the wear of high-speed door drives
We have seen the long-term effects of using contactor-based controllers, and we know one thing for certain – this solution leads to inevitable and serious drive damage. Since the drive is the most expensive component of a high-speed door, its replacement can represent a significant cost.
That is why you will not find any systems based on contactor controllers in our offer.
We do not propose solutions that we know are bound to fail.
If we do something – we do it properly, or not at all.
Contactor-based controller – why is it a bad choice?
Contactor-based controllers operate by mechanically switching the voltage supplied to the door motor on and off, which means no smooth speed control and sudden torque impacts during every opening and closing cycle.
Consequences of using a contactor-based controller:
- Step-load on the drive – leads to accelerated wear of gearboxes and bearings.
- No soft start or soft stop – causes sudden jerks of the door.
- Reduced drive lifespan – no regeneration possible, replacement required.
- Higher operating costs – frequent failures, expensive repairs, increased energy consumption.
- No possibility to adjust operating speed – it is not possible, for example, to reduce the closing speed in order to increase safety.
How does a contactor-based controller operate?
The chart below shows the movement profile of a door controlled by a contactor-based system – without deceleration zones, resulting in sudden jerks and overloads of the drive:
Chart – No deceleration zones in a contactor-based controller
Frequency-inverter controller – the only right choice
Unlike contactor-based controllers, the frequency inverter controls the motor operation in an intelligent way. It regulates speed and provides soft start and soft stop, which significantly extends the service life of the drive and reduces energy consumption.
Advantages of an inverter-based controller:
- Soft start and soft stop – no sudden jerks, reduced mechanical wear.
- Smooth speed control – the ability to adapt operation to the requirements of the facility.
- Lower operating costs – fewer failures and reduced energy consumption.
- Drive in good condition for years – not just for the warranty period.
How does an inverter-based controller operate?
The chart below shows smooth acceleration and deceleration, which eliminates sudden jerks and significantly extends the service life of the drive:
Chart – Inverter-based controller with smooth speed regulation
Don’t save on the controller at the expense of the drive
The drive of a high-speed door is its heart – and it needs proper care!
When choosing a control system, it is important to think long-term rather than focusing solely on the lowest purchase price.
Some manufacturers offer low-cost doors with contactor-based controllers because customers are attracted by the low initial price.
The problem begins after just a few months of operation, when the first minor drive failures appear, and after a few years the drive is often fit only for replacement.
Summary – we do things right, or we don’t do them at all
Contactor-based controllers may appear to be a cheaper solution, but in reality they generate significant costs in the long term.
Our company does not use them in any of the doors we offer, because we are fully aware of the consequences of their operation.
If we do something, we do it properly – with full awareness and responsibility for our products.
If you want a door that will operate reliably for years, not just for a few months, choose an inverter-based controller – the only solution that guarantees drive durability. Additionally, both main components can be regenerated again at bramy.support.
We recommend Polish high-speed doors based on high-quality, professionally regenerated automation with a 24-month warranty – EkoMaster. You can find the door configurator at szybkarolka.pl
