Energy-efficient drives Investment in the future

Related Vendors

WATT DRIVE Antriebstechnik GmbH

ABB AG

Mitsubishi Electric Europe B.V. Factory Automation

FAULHABER Drive Systems

Taiwan Machine Tool & Accessory Builders' Association (TMBA)

more less

Wuxi InfiMotion Technology Co., Ltd.

less

The minimum efficiencies for motors in new installations are becoming stricter, and at the same time, industrial companies need to achieve their sustainability goals and save on energy costs. Therefore, we present some new developments in drive technology that users can rely on in the future.

Politics demands ever more efficient engines and drive systems—worldwide. Therefore, the issue of energy efficiency is far from old news, as the EU regulations and directives are dense and confusing! The EU Regulation 2019/2021/341, which originates from the European Ecodesign Directive 2009/125/EC, still regulates the minimum efficiency levels for electric motors and frequency converters in new installations.

The European Ecodesign Regulation 2024/1781 (ESPR), adopted in 2024, considers the bigger picture, including supply chains and materials. This is where companies come into play that rely on synchronous reluctance motors (SynRM), which are manufactured without the use of rare earths. Additionally, the guidelines will continue to tighten, and the requirements for energy efficiency will rise. With SynRM, users are preparing themselves for the future.

Gallery

Future-proofing with IE6

ABB is the first manufacturer to offer the expected efficiency class IE6 in a magnet-free SynRM design. This is the latest development in SynRM technology, which ABB initially pioneered in 2011. The motors are aimed at customers who want to future-proof their equipment with the highest energy efficiency class available on the market.

"Motor-driven systems in industrial plants are large energy consumers, so efficiency improvements here can significantly contribute to emission reductions and the achievement of climate protection goals. Additionally, significant energy savings can be achieved with the use of our new magnet-free SynRM," says Stefan Flöck, Head of the IEC Low Voltage Motors Division at ABB Motion. "Since the IE6 SynRM has the same size as the corresponding IE3 asynchronous motor, existing motors can be replaced quickly and easily. This allows customers to upgrade to modern, highly efficient products to future-proof their operations in a world of fluctuating energy costs."

ABB offers a comprehensive magnet-free SynRM portfolio, with efficiency advancing from class IE4 to the IE5 variants introduced in 2019. IE6 is likely the next logical step, underscoring the performance and technical superiority of SynRM technology. Although IE6 has not yet been specified in an official industry standard, each new IE efficiency class has so far shown 20 percent less energy loss than the previous level. ABB has followed this approach with the IE6 SynRM.

The SynRMs are part of ABB's Eco-Solutions portfolio, offering customers and partners sustainable products. The portfolio provides more transparency regarding the circular economy value and the environmental impacts of individual products, which aims to enable informed and responsible decision-making. Portfolio products meet a range of performance indicators defined in the ABB circularity framework. Additionally, they come with an environmental product declaration (ISO 14025 Type III) verified by independent parties.

ABB can achieve the expected level of the future IE6 efficiency class not only with a SynRM but also with permanent magnet (PM) and PMaSynRM technology – a hybrid technology that combines the SynRM design with the performance of permanent magnet motors.

Optimize SynRM performance

A SynRM must be operated with a frequency converter. The combination with Mitsubishi Electric frequency converters already meets the requirements of efficiency classes IE1-5.

The frequency converters of the FR-F800 and FR-A800 series from Mitsubishi Electric optimize the performance of SynRMs, which operate on the same principle as permanent magnet synchronous motors. This results in higher efficiency, especially in the partial load range. This eliminates costly retrofitting in the coming years.

This drive technology particularly shows its potential for savings in fan and pump applications with variable speeds. Synchronous reluctance motors operate without permanent magnets and offer additional advantages: high efficiency due to low heat losses, cost-effective manufacturing, and low maintenance requirements. Moreover, they provide excellent speed control behavior, which is optimized by modern control techniques.

It doesn't always have to be a SynRM

However, energy-saving potentials are not limited to the operation of pumps and fans. Lenze demonstrates that there is still room for improvement in drive technology for conveyor systems—and all without SynRM. The automation specialist presented its new, compact motor-drive system at the SPS trade fair in Nuremberg, consisting of the m550 three-phase motor, the g500 gears, and the i500 and i650 frequency converters. This combination achieves efficiency classes IE5 and IE7. Test customers from the intralogistics sector have already shown that the new drive system can reduce motor losses by up to 62 percent, thereby lowering energy consumption and CO₂ emissions.

Another innovation in this area was presented by WEG at the SPS: With the W23 Sync+Ultra, the company aims to set new standards in energy efficiency for conventional designs. The hybrid technology combines the advantages of permanent magnet and synchronous reluctance motors, achieving exceptionally high energy efficiency according to the company. Its advanced design significantly reduces magnetic losses and increases efficiency well beyond conventional standards such as IE4 and IE5—across a wide operating range. This can lower operating costs while simultaneously helping companies achieve their sustainability goals. (mi)