Tailored high-efficiency motors The art of efficient energy

Tailored high-efficiency motors
The art of efficient energy conversion
Unleashing the art of engineering
Artists have their palettes and paint, their toolbox to create. At
ABB, we share their ambition to innovate. We keep pushing the
frontline of motor technology development to come up with ever
more energy efficient concepts.
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Motors use almost one third of the world’s electrical energy.
That means they account for a substantial part of the total
human ecological footprint. We must lower our energy
consumption – and energy efficient motors are one of our
most important tools.
Regional minimum efficiency performance standards (MEPS)
push efficiency levels of standard motors higher and higher.
The share of speed controlled applications increases, which
opens the door to motor technologies that offer significant
advantages over traditional induction motor technology.
The electric motor industry is going through its biggest
change ever. The design culture towards higher energy
efficiency is becoming stronger and stronger – in motors as
well as in other kinds of machinery.
ABB is leading the way in energy efficient motor technologies.
We don’t settle for meeting today’s IE standards for energy
efficiency. We look at the next, and the one after, and beyond.
Our quest for developing more and more ingenious motor
concepts continues with undiminished force.
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One size doesn’t fit all
Many machine builders request higher motor efficiency than the
minimum level set by MEPS – in order to maximize the efficiency
of their machines. ABB meets their demands by offering a range
of IE4 motors and paving the way for IE5 and higher.
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Cost optimization of the entire machine
Demand for higher machine efficiency forces manufacturers
to consider ways to reduce the energy consumption of their
products. Many OEMs are realizing that a more expensive
high efficiency motor is the most cost efficient way to improve
overall machine efficiency. Cost efficiency remains the main
driver, but it no longer applies to individual components but to
the entire machine.
How do you assess the efficiency performance of your
ABB has invested substantially in efficiency measurement
systems for complete motor and drive packages. These
systems allow ABB to assess the efficiency performance of
the entire package, throughout the operating range. This
information, in turn, is necessary to optimize the efficiency
performance of the entire machine.
What is the best motor technology?
It would be convenient to argue that one technology meets
all technical and commercial needs. Unfortunately, that’s not
the case. The key is finding the most cost efficient solution
for each specific need, which requires a wide technology
portfolio. The right solution depends on the power range, the
speed range and whether the application is speed controlled
or not.
From “What do you have?” to “What do you need?”
Traditionally, products have been selected from motor
suppliers’ available product ranges. That is not necessarily
the case anymore. Let us know your needs and put your trust
in ABB to choose the right motor solution for you – selecting
from our wide technology portfolio.
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Your guide to higher motor efficiency
Different technologies are needed to provide the best high
efficiency motor solution throughout the power range of low
voltage motors. Your ABB motor will always be fit for purpose to
provide the most cost efficient and sustainable solution based
on your requirements.
Induction motor platform
The versatility of induction motor technology is unbeatable.
However, demand for higher and higher motor efficiency
means we are approaching the technical limit for induction
technology, particularly in smaller motors where rotor losses
play a significant role.
IE4 SynRM motors
This award-winning “basic” version was introduced in 2011.
It is now considered the working horse of the SynRM platform,
successfully proven in many applications. Magnet-free SynRM
offers outstanding simplicity, reliability and service-friendliness,
making it a good choice for a standard motor range.
Even if higher efficiency levels could be reached by
adding exotic elements, such as special rotor designs,
it is questionable whether induction motors will offer
a commercially competitive alternative to new motor
technologies. Especially in cases where motors can be
optimized to meet particular technical and commercial needs.
Flexible SynRM2 concept up to IE5 and beyond
The efficiency performance of SynRM motors can be further
boosted by adding permanent magnets into the rotor. Unlike
traditional permanent magnet (PM) motors, ABB’s SynRM 2
concept uses sustainable ferrite magnets. There are no rare
earth metals in ferrite magnets, making them more cost
effective and more securely available.
SynRM technology platform
The novelty of new synchronous motor technologies, such as
ABB’s SynRM, is that rotor losses are virtually eliminated. The
development of SynRM motors is focused on small motors,
where rotor losses have the most significant impact.
Eliminating one loss element compared to induction
technology means there is more freedom to find cost effective
ways to boost motor efficiency. As a result, it is today possible
to achieve efficiency levels that were unimaginable only a
few years ago. The core of the SynRM concept is its variety
of rotor technologies combined with classical, proven stator
technology and mechanical motor design.
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Magnetic forces in SynRM 2 are relatively low, which means
that there are no major service issues. This concept offers
efficiency performance up to IE5 or even higher. In addition,
electrical characteristics can be adjusted to find the most cost
efficient alternative for different needs.
IE4 DOLSynRM for fixed speed applications
As beneficial as speed control may be, there are still many
applications where it is not an alternative. DOLSynRM makes
SynRM technology available for fixed speed applications
as well. DOLSynRM is totally magnet free and offers all the
benefits of the SynRM platform.
These motors are optimized exclusively for fixed speed, i.e.
direct-on-line use. A frequency converter intended for variable
speed SynRM motors cannot be used for DOLSynRM motors.
Operation with scalar control may be possible but functionality
needs to be verified case by case.
ABB’s normal SynRM motor range is the ideal choice for
variable speed applications, and SynRM control software
provides excellent control performance even in demanding
In DOLSynRM there is a cage in the rotor, and during starting,
the motor works like an induction motor. After reaching full
speed, the motor synchronizes and continues operation as
a synchronous reluctance motor with eliminated rotor losses
and high efficiency.
The technology is most favorable in 4-pole execution, while
two or even six poles can be studied. It is suitable for most
pumps, fans, compressors and other applications where load
inertia is not particularly high and where high starting torque is
not required.
This means that DOLSynRM can cover the majority of motor
requirements – making it an ideal tool for finding a solution to
customer-specific needs.
Fixed speed applications
1 000kW
IE4 induction motors
Variable speed applications
1 000kW
IE4 induction motors
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modify the contents of this document without prior
notice. With regard to purchase orders, the agreed
particulars shall prevail. ABB does not accept any
responsibility whatsoever for potential errors or
possible lack of information in this document.
We reserve all rights in this document and in the
subject matter and illustrations contained therein.
Any reproduction, disclosure to third parties or
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9AKK106518 EN 03-2015
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