Control System Integration for Auto Shredding / Recycling
Increase Shredder Throughput and Reliability Without Unplanned Downtime
Auto shredding operations push drive systems to their limits: instability, torque fluctuations, and aging equipment can quickly disrupt production. Quad Plus delivers coordinated drive control solutions for auto shredders that stabilize torque, manage extreme loads, and improve system responsiveness under high-impact operating conditions.
With deep industry knowledge and advanced system diagnostics, our engineering team works to optimize every component of your operation, from drives and motors to HMIs, PLCs, and process instrumentation.
We support auto shredding operations through:
- DC and AC drive upgrades for shredder systems
- 3D modeling and drive system design
- Utility coordination and high-voltage power system design
- System-level analysis, including harmonic and flicker studies
Results: Higher throughput. Stable torque. Improved reliability.
Auto Shredder Drive System Solutions
No matter what stage of auto shredding you are in, we can help. Our service team has the expertise to build, power, and maintain every system from the most straightforward setup to the most complex.
Power Company Relationships
Auto Shredding DC Drives
DC Drives have faster load response, lower initial cost, can run at any speed, and have full torque at low RPM. Enjoy lower energy and maintenance costs with dramatic increase to productivity. Plus, DC drives can be located where you need them without expensive line upgrades or power condition equipment.
We offer the most cost-efficient approach to upgradeing to fully-digital, closed-loop controls including onsite installation and re-commissioning of your system to keep downtime to a minimum.
Wound Rotor Induction Motor Installation (AC Drives)
A wound rotor induction motor (WRIM) is a type of induction motor where the rotor windings are connected through slip rings to external resistances. Adjusting the resistance allows control of the speed/torque characteristic of the motor. Wound rotor induction motors can be started with low inrush current by inserting high resistance into the rotor circuit; as the motor accelerates, the resistance can be decreased.
Compared to a squirrel-cage rotor, the rotor of the slip ring motor has more winding turns. The induced voltage is then higher and the current lower than for a squirrel-cage rotor. During start-up, a typical rotor has three poles connected to the slip ring. Each pole is wired in series with a variable power resistor. When the motor reaches full speed, the rotor poles are switched to short circuit. During start-up, the resistors reduce the field strength at the stator. As a result, the inrush current is reduced. Another important advantage over squirrel-cage motors is higher starting torque.
A wound rotor induction motor can be used in several forms of adjustable-speed drive. Certain types of variable-speed drives recover slip-frequency power from the rotor circuit and feed it back to the supply, allowing wide speed range with high energy efficiency. Doubly fed electric machines use the slip rings to supply external power to the rotor circuit, allowing wide-range speed control. Today, speed control by use of slip ring motor is mostly superseded by induction motors with variable-frequency drives.
Shredder System Analysis
Unexplained shaft failures and premature bearing failures mean frustrating downtime and costly repairs. If your vendors are pointing to one cause, but the problems are recurring, it’s time for a change. Quad Plus performs vibration, mechanical drive train, and system analysis to find the right solution and put an end to persistent failures and downtime.
Celebrating Our 100th Shredder
Did you know there are nearly 340 shredders with complex drive systems in North America–with 275 in the U.S. alone? Quad Plus has engineered, installed, or serviced well over 100 of those systems, making us the leading engineering and solutions provider in the country. Plus, we’ve just completed our 100th shredder installation, a uniquely engineered 4,000 horsepower DC system for Lakeside Auto Recyclers, further showcasing our expertise in delivering innovative and energy-efficient drive solutions! Learn more about this milestone.
Shredder Load Capacity Case Study
The Quad Plus team was contacted by a local recycling center looking to install a 2500 HP shredder load. The local utility performed a load analysis and advised the customer that there was not enough power in the local distribution circuit to provide power to the proposed shredder. Their solution included a dedicated circuit and modifications to the substation, a solution that would work based on the power data given to the utility by the customer. However, the estimate from the utility was in the millions of dollars—a price tag the owner could not afford.
Services Available
Quad Plus offers a wide variety of services to assist you no matter where you are in the system integration lifecycle. For new builds, we offer design and project management services, for existing plants, we can make your operation run smoother and more efficient. For plants with obsolete control systems, we can assist with retrofits and upgrades. No matter your business need, we have you covered!
Let’s Get Connected
Quad Plus has been leading the system integration industry for 30 years. Our complete solutions will have you up and running faster and with fewer hassles from the power company. Once you’re operational, we’ll make sure it stays that way with easy access to parts, friendly staff, and control repair expertise you need.
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