Braking Energy Recovery (AFE) ROI Calculator
Recover energy normally lost as heat in braking resistors using Active Front End (AFE) technology... This page demonstrates the returned energy, reduction in cooling load, maintenance effect, and how many months the investment pays for itself.
The logic of AFE investment goes beyond the energy bill
Energy released during braking is fed back into the grid. It's highly effective in high-inertia or frequent-braking lines.
As heat from resistors is eliminated, the panel/room cooling load drops. This is the unseen secondary gain in most feasibilities.
A properly designed AFE draws controlled current and behaves more cleanly in terms of power quality compared to classical rectifiers.
As large braking resistors and their thermal loads decrease, internal panel risks and maintenance complexity drop.
Machine and Braking Profile
Recovery Model
Investment and Additional Gains
Gain Breakdown
BreakdownEnergy and Heat Impact
Energy5-Year Cumulative Cash Flow
CashflowEngineering Perspective
AFE is not just an energy device: In classical resistor setups, regenerative energy creates heat loss and requires extra infrastructure for heat evacuation. AFE turns this energy back into useful electricity, increasing overall plant efficiency.
For the right investment decision: Braking power, duty cycle, grid structure, harmonic targets, panel temperature, existing resistor load, and simultaneous consumers must be evaluated together. This page provides a quick financial outlook; the final engineering selection must be clarified by ONX Control on site.
Frequently Asked Questions
In which applications does AFE make the most sense?
Cranes, unwinders, winders, elevator-like regenerative axes, test stands, and high-inertia lines with frequent braking are the strongest candidates.
Why does this calculator use a 'recoverable energy ratio'?
Because not all braking energy can be practically recovered with the same quality and continuity. This coefficient conservatively represents the electrical and mechanical scenarios on site.
Why is HVAC saving calculated separately?
Because the energy burned in the resistor turns into heat, and in most facilities, this heat must be actively removed. With AFE, this indirect energy load can also drop.
Does this result replace a final quotation?
No. This page is for quick pre-feasibility. Drive topology, harmonics, filters, grid short-circuit power, and panel architecture must be reviewed separately in the final project.
AFE Financial Analysis
Executive summary
ONX Verdict
This calculator is a pre-feasibility tool. Grid analysis, harmonics, filtering, and site conditions must be verified in the final engineering study.