4 Innovative Ways AC Drives Are Used in Industry (Beyond Speed Control)

AC drives aren’t just for adjusting motor speed. In today’s industrial world, they’re enabling energy recovery, precision control, and automation in ways that might surprise you. From elevators to solar panels, here are four interesting, real-world applications for AC drives—plus what makes them work so well.

1. Regenerative Energy Recovery: From Elevators to Cranes

When a motor is driven by its load—such as when a ski lift chair descends under gravity—it turns into a generator. With the right AC drive, such as the Allen-Bradley PowerFlex 755T, this energy can be captured and reused instead of being wasted as heat.

How Regenerative Drives Work

AC drives with regenerative features detect when the motor is generating power and shift into energy recovery mode. Instead of dissipating energy through a brake chopper and resistor, the drive routes it back into the power system or across a common DC bus to support other equipment.

• Ski Lifts & Gondolas: Regenerative drives help stabilize load imbalances and recover energy from descending chairs.
• Elevators: Energy used to ascend is partially recovered during descent.
• Cranes: Lowering heavy loads with regen drives saves power and reduces braking wear.

2. Precision Tension Control in Winding Systems

Winding film, foil, or fiber at high speeds requires precise tension to avoid slack, wrinkles, or tears. AC drives make that possible by automatically adjusting torque as the roll diameter changes.

Why Drives Excel in Tension Control

As a roll gets larger, more torque is needed to maintain surface tension. Shrinking rolls need less. Modern drives like the PowerFlex 755T with TotalFORCE technology provide real-time control of speed, position, and torque, eliminating the need for external tension controllers and reducing wiring complexity.

Applications: Flexible packaging lines, converting systems, printing presses, and textile winding operations.

3. Solar Panel Tracking Systems

To maximize energy output, solar panels must be positioned to face the sun as it moves across the sky. AC drives help automate this process by precisely positioning the panels on one or two axes.

Benefits of Using AC Drives for Solar Tracking

• Slow-Speed Precision: Vector control keeps motors stable at low RPMs without stalling.
• Smooth Motion: Prevents backlash or wear on gear-driven tracking arms.
• Torque Limiting: Helps avoid damage during storms or snow buildup.
• Remote Adjustability: Parameters can be tuned for seasonal changes or maintenance.

Drives like the PowerFlex 525 or PowerFlex 753 are well-suited for these tasks, as is the plug-and-play-friendly Kinetix 3, which Allen-Bradley specifically lists as solar-ready.

4. Retrofitting Legacy Machinery

Many shops still rely on heavy-duty machines, such as drill presses and lathes, that were built to last but not designed for precision or automation. Retrofitting these machines with AC drives gives them a new life.

What Drives Enable

• Digital speed control without pulleys or belts
• Precise motor coordination with CNC controllers
• Repeatable, semi-automated operations for high-volume tasks

With drives like the PowerFlex 753, it’s possible to transform an old drill press into a dedicated, semi-automated workstation—perfect for repeated part production, prototyping, or single-task operations.

Final Thoughts

From regenerative braking to retrofits, AC drives have evolved into powerful tools for energy efficiency and automation. Whether you're engineering a new solution or upgrading legacy systems, the right drive can change everything.

Need help choosing the best drive for your application? Contact us today—our in-house experts can guide you to the right model for your project, and we stock a wide variety of Allen-Bradley drives ready to ship.