Comprehensive Guide to Industrial Drives: Knowledge, Selection Tips, and Core Concepts

Drives exist because in many industrial settings a motor simply running at full speed or fixed speed is not ideal. Changing loads, variable speeds, torque demands, energy constraints and automation all mean that a more intelligent system is needed to optimise machine performance, reduce waste, protect equipment and maintain stability.

Importance

Industrial drives matter today for several reasons:

• Energy efficiency and sustainability: Many processes use large motors and drives. By matching motor output to what is needed (rather than always running at full speed), energy consumption and associated emissions can be reduced.

• Precision and productivity: In production lines, packaging, robotics, conveyor systems and more, the ability to vary speed and torque accurately increases output quality, reduces scrap and improves throughput.

• Flexibility and automation: Modern manufacturing demands flexibility. Drives allow one motor to handle multiple speeds or modes rather than needing different machines. They tie into control systems, sensors and automation frameworks.

• Reliability and maintenance: Drives can incorporate diagnostics, overload protection, controlled start-up, and smoother operation, reducing wear and downtime.

• Economic impact: While the end-user is not “buying” a drive per se in this article, organisations that operate industrial equipment benefit from lower energy bills, fewer breakdowns and improved process control.
  The stakeholders include manufacturing plant managers, engineers, maintenance teams, equipment OEMs and even policy makers concerned with industrial efficiency and emissions.

Recent Updates

In the past year, several changes and trends have shaped industrial drives:

• Digitalisation: A 2025 report (September) highlighted that the digitalisation of industrial drives is being driven by four key upgrades: simulation, customisation, reliability & uptime, and cybersecurity.

• Efficiency and miniaturisation: For 2025, “drive technology trends” include increasing efficiency, sustainability, miniaturisation and the use of AI-based control.

• Market growth: The global industrial drive system market is projected to grow from USD 14.8 billion in 2023 to USD 21.7 billion by 2032.

• Automation and smart manufacturing: Drives are more integrated into the Fourth Industrial Revolution (Industry 4.0) context, where connectivity, sensors and edge computing matter.

• Regional focus: In India, for example, industry is increasingly switching to high-efficiency motors and drives (IE3/IE4 class) as part of energy efficiency efforts.
  These trends mean that when selecting or upgrading drives today, one must consider not just basic performance, but connectivity, data analytics, sustainability and regulatory alignment.

Laws or Policies

The selection, use and performance of industrial drives are influenced by regulations, standards and government programmes. Here are key points, with relevance to India (but similar ideas apply globally):

• The Bureau of Energy Efficiency (BEE) under the Energy Conservation Act, 2001 promotes efficient use of energy, identifies “designated consumers” (large energy-using industries) and mandates energy audits and performance standards.

• The Indian standard IS 12615 provides minimum efficiency performance standards (MEPS) for induction motors, including when used with variable-frequency drives (VFDs).

• Standards and labelling programmes aim to push industries toward IE3/IE4 efficiency classes for motors, which also drives expectations for compatible drives.

• The Indian government’s broader energy-efficiency policies include the Perform, Achieve & Trade (PAT) scheme under the National Mission for Enhanced Energy Efficiency (NMEEE) which sets targets for energy-intensive industries.

• For drives specifically, while not all countries have drive-specific regulations, drives are indirectly affected because their associated motors and systems must comply with motor efficiency and energy performance regulations.
  When evaluating or specifying drives, one should check whether local regulations require minimum efficiency, connection to energy-management systems or reporting/verification of performance.

Tools and Resources

Here are helpful tools, resources and calculators one might employ when working with industrial drives:

• Motor / drive efficiency calculators: Many manufacturers supply online tools to estimate energy savings when replacing fixed-speed motors with variable-frequency drives (VFDs) or high-efficiency drives.

• Simulation and digital twin tools: As drives become more digital, simulation software (for motor/drive/system interaction) helps optimise design, predict failures and assess performance.

• Datasheets and selection guides from manufacturers: These help compare drive types (AC vs DC vs servo vs stepper vs soft-starter) and required specifications.

• Vendor technical webinars and white papers: Many industry publications (see e.g., types of industrial drives article) explain drive categories and applications.

• Standards & regulation databases: For example, national standards bodies list MEPS requirements; energy-efficiency agencies publish guidelines for equipment performance.

• Maintenance & monitoring dashboards: Modern drives often include diagnostics and remote monitoring features—using cloud or edge platforms for condition monitoring and predictive maintenance.

• Industry associations and journals: These provide updates on trends (such as digitalisation, AI integration) and case-studies of drive implementation.

FAQs

What is the difference between a drive and a motor?
A motor is the device that produces mechanical motion (i.e., torque and rotation) when supplied with electrical power. A drive is the control system that regulates that motor—its speed, torque, direction and sometimes acceleration/deceleration—to suit a particular process. In essence, the drive “drives” or controls the motor rather than simply powering it.

What are the common types of industrial drives?
Typical kinds include:

• AC drives (often variable-frequency drives, VFDs) controlling AC motors.

• DC drives for DC motors (less common now, but still used in legacy or niche applications).

• Servo drives for precision motion control (robotics, CNC machines) with feedback control loops.

• Stepper drives for discrete position/step control.

• Soft starters which are simpler than full drives but reduce motor start-up stress by ramping voltage/current.

How do I choose the “right” drive for an application?
Key selection factors include:

• Motor type and power rating (voltage, current, speed, torque).

• Load characteristics: constant speed vs variable speed; high inertia or light load.

• Control requirements: precision, speed changes, direction reversal.

• Environment: ambient conditions, space constraints, cooling requirement.

• Energy-efficiency targets: does the system need to reduce consumption?

• Integration: does the drive need to connect to PLC/HMI/SCADA or IoT systems?

• Future proofing: modularity, diagnostics, maintenance features and connectivity matters.

What are the major energy-efficiency benefits of using drives?
By controlling motor speed and matching it closely to demand (rather than running at full speed and throttling), drives reduce energy waste. For example, replacing fixed-speed with variable-speed drives in fan or pump applications often yields large savings. Also, high-efficiency motor-drive systems reduce losses, improve power factor and cut greenhouse-gas emissions.

Are older drive systems obsolete or can they be retrofitted?
Many older systems can be retrofitted with modern drives if the motor, load and controls allow it. However, one must check compatibility (e.g., motor insulation, cable length, harmonic effects) and ensure safety/control requirements are met. The upgrade path often includes improved diagnostics and connectivity. If technologies like edge monitoring or predictive maintenance are required, newer drives may better support them.

Conclusion

Industrial drives are a foundational element in modern manufacturing and automation, enabling motors to become smarter, more efficient and more tightly integrated into control systems. Understanding what drives are, why they matter, and how to select or upgrade them is increasingly important in a context of sustainability, digitalisation and regulatory pressure. As we move further into 2025 and beyond, drives will continue to evolve: becoming more connected, more energy-efficient and more modular. For anyone involved in industrial processes, maintenance, equipment selection or automation, keeping up with drive technology and its implications is an investment in more reliable, efficient and adaptable operations.