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Research for Reducing the ie3 motors in india.

Research for Reducing the ie3 motors in india

Research for Reducing the ie3 motors in india.

New issue of IEC60034-30 "Efficiency classes of single-speed,three-phase,cage-induction ie3 motors in india prescribe the efficiency level of the electric motors.The new methods of determining losses and efficiency from tests,and particularly describing measure for reducing the losses of electric motors with the new methods for determining losses and efficiency from tests are described.

The purpose of this article is to design electromagnetic model for a three phase induction motor premium efficiency (IE3), rated power of 7.5 kW, 1000 rpm single layer windings, designed and produced as prototype by the company Electroprecizia Electrical Motors located in the county of Brasov, Romania.

A scroll spring for energy recovery for a washing machine was designed mainly including the spiral spring, ratchet clutch, new gear clutch and other components. The program is that we have stored the mechanical energy with a spiral spring when the washing machine is (anti) to brake and decelerate, and use it while the washing machine is anti-(positive) to start or accelerate.

To weaken the additional torque and noise caused by slot harmonics field, squirrel cage asynchronous motor with skewed rotor bars are widely used in small and medium cage induction motors. However, with skewed rotor, the distribution of the fundamental fields along the axial direction is non-uniformly, which may cause greater core saturation and higher iron losses. Furthermore, the inter-bar or the transverse currents are also produced by non-insulation between the rotor bars and lamination steels, which also lead to the excess loss significantly, especially for the small and ie3 motors in india. Therefore, it is necessary to eliminate the influence of the skewed rotors on the motor losses. In this aspect, a design method of non-skewed rotor bars for cage induction motors is presented, in which the asymmetrical straight rotor bars is adopted to weaken the slot harmonic field, at the same time, the excess loss caused by transverse currents can also be avoided. Therefore, it is helpful to design the small and medium size induction motors with premium efficiency IE3 level.

Research for Reducing the ie3 motors in india

In the UK electric motors are estimated to account for almost two-thirds of industrial electricity consumption. However, according to GAMBICA, if variable speed control was added to the motors of relevant applications which are not currently using it, savings of around 25,000GWh of energy could be achieved (roughly the output of 6,000 medium-sized wind turbines) with a corresponding reduction in CO2 emissions. This is the goal of the EU energy related products (ErP) directive. Research for Reducing the ie3 motors in india.Within this context, the commission regulation for motors 640/2009/EC prescribes minimum efficiency classes for three-phase low-voltage induction motors. The first stage of the regulation, which stipulates efficiency class IE2 as the minimum for new motors, took effect.

This study carried out a comparative analysis of indicators of electricity consumption and CO2 emissions for four-pole induction motors (IMs) of efficiency classes IE3 and IE4 with a rated power of 2.2–200 kW in a variable speed pump unit. In addition, innovative IE4 converter-fed synchronous reluctance motors (SynRMs) were evaluated. The comparison was derived from the manufacturer's specifications for the power drive systems (PDSs) at various rotational speeds and loads. The results showed that the emission indicators for IE3 class motors were significantly worse compared with IE4 class motors for low power ratings, which make up the vast majority of electric motors in service. This justifies expanding the mandatory power range for IE4 motors to at least 7.5–200 kW or even 0.75–200 kW, as it will dramatically contribute to the achievement of the new ambitious goals for reducing greenhouse gas emissions. In addition, the operational advantages of IE4 SynRMs over IE4 IMs were demonstrated, such as their simpler design and manufacturing technology at a price comparable.



Modern synchronous reluctance motors allow improving energy efficiency of many industrial applications. The new standards define five classes of energy efficiency for electric motors, from IE1 to IE5. This paper considers issues related to the mathematical modeling and testing of a magnet-free synchronous reluctance motor of the highest energy efficiency class IE5. The proposed mathematical model allows calculating the efficiency factor, power factor, torque ripple, winding losses in the stator and rotor magnetic cores, and other operating characteristics of the synchronous reluctance motor run in various operation modes. The motor was tested on a test bench, which involved direct torque measurements. Thermocouples were used and measurements made in steady-state thermal mode to find the winding temperature. The body of the prototype synchronous reluctance motor has the same dimensions and rotation axis height as the body of ie3 motors in india of the same power.

Due to the different power standards around the world, to the motor and construction machinery export enterprises design and production management more difficult, raising the cost. If in accordance with international standards IE3, producing a series of ultra-efficient motors, power supply to meet world standards, while not changing the size and weight, without increasing the manufacturing cost, convenient motor export to the world, in particular by providing machinery and engineering supporting exports to the world great convenience. This article describes a frequency and voltage universal motor design method, as well as using this method to design ultra-high efficiency motor calculation data and prototype test data. Calculation data and type test data show that it is feasible that the same motor is basically invariable under the power standards of all countries in the world.

Research for Reducing the ie3 motors in india

State and utility energy efficiency programs have historically supported incrementally more efficient general purpose, induction motors as a measure to help achieve energy savings goals. Over time, federal minimum efficiency standards have been raised to the level of premium efficiency(R) ie3 motors in india specifications and the benefits from administering programs for slightly more efficient motors no longer outweigh the costs. Advanced technology motors, such as permanent magnet (PMAC) motors, may provide program administrators with the opportunity to continue to capture significant energy savings from motor programs.Bench and field tests of small horsepower permanent magnet motors, following CSA 838-13 or the input-output model from IEC 60034-2-1 and IEEE 112, indicate they are 2%-26% more efficient than the same size induction motor across the same operating load range. Typically, the lower the loading or speed of the motor the higher the percent energy savings. The tests demonstrate energy savings from PMAC motor technology.

Recently, energy saving by improving motor efficiency and adopting variable speed control systems have come to be accelerated. Fuji Electric has developed an inverter-integrated motor, which incorporates inverter functions into a motor. In addition to adopting a high efficient motor, variable speed operation with inverter control achieves signifi- cant energy saving effect. Moreover, it achieves downsizing by the incorporation. The energy-saving effect amounts to a reduction of 45% (1,923 kWh per year) from standard motors with IE1 class efficiency and 43% (1,742 kWh per year) compared to IE3 "Premium Efficiency Motors."

High efficiency standards are slowly being introduced with IE3 efficiency levels shortly becoming compulsory in many countries; IE4 efficiency levels being developed for future implementation. In this paper a review is carried out of the IE 60034-30 standard which covers standard line-start induction motors. Research for Reducing the ie3 motors in india.Some design techniques that can be used to increase efficiency in order to meet the IE4 standards are discussed. This standard is now being replaced by the IE60034-30-1 standard which extends to other line start motors and also IE 60034-30-2 is being introduced to cover variable speed drives in order to address developing technology. The conclusion is that IE4 standards are obtainable but careful design is needed to reach this.

In the last few years, new efficiency requirements for induction motors have been imposed. Therefore electrical machines manufacturers have had to redefine the design criteria in order to reduce losses aiming to achieve the efficiency values established by the IE2 and IE3 standard categories according to the IEC. Given that, in the near future, an increasing demand regarding efficiency (IE4 and IE5 categories) is expected, it would be appropriate to seek new alternatives to further reduce losses in induction motors. In this work, the possibility to use magnetic wedges in induction motors with semi-closed slots is studied. This strategy allows to reduce copper and core losses, therefore increasing then the motor efficiency. The study analyses low power motors and considers different permeabilities and geometries for the magnetic wedges. In addition, it focuses attention on the starting torque and currents. Finally, an experimental validation using a 3-kW 380-V 4-pole IE2-class induction motor is presented.

The global process of harmonizing standards of electric motors is most important to make progress in global trade with Premium Efficiency motors (IE3) and energy efficient motor drive systems in pumps, fans and compressors, and industrial handling & processing. The standards include energy efficiency testing, labels and efficiency classes as well as setting mandatory performance requirements. Progress is reported with the Ecodesign policy in Europe joining the world of countries with Minimum Energy Performance Standards (MEPS) from 2011 while other countries like USA, Canada and Mexico have upgraded their existing mandatory requirements by the end of 2010 to reach IE3. Europe has also started to introduce system performance standards for fans and pumps.

Research for Reducing the ie3 motors in india

Strong energy efficient policies are being adopted in many countries to achieve reductions of energy consumption in electric motors. Improvements in the design, processes and the introduction of new technologies has contributed with penetration of different efficiency classes, from IE1 to IE4, IE4 being the most efficient. A comparison between induction motors classes IE2, IE3 and IE4, in order to assess the performance of these technologies in the presence of fifth and seventh harmonics is presented. Results show that the IE4 Super Premium Motor, presents lower values of current and temperature, however, showing non-linear characteristics.

Global energy systems are undergoing a transition process towards renewable energy and energy efficiency practices. Induction motors play an important role in this energy transformation process since they are widely used as industrial loads, representing more than 53% of global energy consumption. With more countries adopting minimum energy performance standards through more efficient induction motors, comparisons between these new technologies in the presence of electrical disturbances must be systematically evaluated before adopting a substitution policy in the industry. Research for Reducing the ie3 motors in india.To this end, this work presents a comparative analysis of the impact of harmonic voltages on the performance and temperature rise of electric motors classes IE2, IE3 and IE4 in the same operational conditions in view of future substitutions. The results show that under ideal operating conditions the IE4 class permanent magnet motor has better performance in terms of consumption and temperature, however presenting non-linear characteristics.

More than 30 million electric motors are sold every year in the world, in the last 20 years the appearance of more efficient electric motors resulted in the replacement of more than 70% of the old motors installed. New technologies are being presented by manufacturers as substitutes for the squirrel cage induction motor (SCIM). Given this scenario, studies should be carried out to analyze the performance of these motors in the same operating conditions to know their main advantages and drawbacks. This study presents a comparison of the performance of electric motors classes IE2, IE3 and IE4 in the presence of voltage unbalance (VU) with under and over voltage. Results show that not only the unbalance percentage present impacts the motor performance, but also the magnitudes of the voltages present. The VU also results in an increase in the harmonics present in each motor, mainly in the permanent magnet hybrid motor, which presents non-linear characteristics.

Higher-efficiency motors (IEC class IE3/IE4) have entered the market as a result of worldwide regulations on energy efficiency. The electrical behavior of these motors is different with typically higher inrush and locked-rotor currents. In some cases issues may occur with other components of the installation. In this paper we investigate potential issues regarding direct-on-line starting. We give an overview of the work being done in standardisation technical committees to adjust switchgear and motor standards. Finally we provide guidelines to design an energy-efficient and robust motor system.

Research for Reducing the ie3 motors in india

Optimal design of premium efficiency (IE3) squirrel-cage induction motor by utilizing radial scaling, axial scaling and rewinding of an existing 4 kW 4-pole high efficiency (IE2) motor. The scaling factors are defined for all parameters of the equivalent circuit and consider the influence of saturation on main and leakage inductances in all operating points. The optimal scaling factors are determined using Differential evolution optimization algorithm with minimum volume of iron stack defined as a cost function.

An overview of the main motor features influencing the protection devices settings is presented, pointing out key differences between three-phase direct-on-line (DOL) motors of different efficiency classes. The results of experimental tests and simulations are presented and discussed in the scope of the motor protection against overload, short-circuit, current unbalance, and locked-rotor conditions, for 7.5-kW, four-pole, IE2- and IE3-class squirrel-cage induction motors (SCIMs) and for IE4-class line-start permanent-magnet motors (LSPMs), offering important data related to their electrical and thermal behaviors. Two commercial digital thermal-magnetic motor protection devices, whose thermal models were designed for IE1- and IE2-class motors, are evaluated in terms of operation effectiveness in the tested motors. This paper is important for industry due to the significant penetration of IE3-class induction motors, as well as to the recent introduction into the market of IE4-class induction motors and LSPMs.

As it is known, the induction motors with squirrel cage rotor are classified according to IEC 60034-30:2008 in three efficiency classes: a. Standard Efficiency IE1; b. High Efficiency IE2; c. Premium Efficiency IE3. According to the ecodesign requirements, since 01.01.2015 respectively 01.01.2017 motors shall not be less efficient than IE3 efficiency level. The motor manufacturers are obliged to comply with this requirement, developing the IE3 variant. This paper refers to the mode of execution of these motors, to the applied technical solutions and to the obtained results.

The injudicious and automatic replacement of standard motors with IE2 and IE3 motors can have potentially serious, unwanted and unintentional side effects. If one does not make allowances for these in the system design, a 1% improvement in energy efficiency on the motor alone may well result in an actual increase in the overall system energy consumption. The main message of this paper is that when one looks at optimising energy conservation and efficiency one should never look at only the specific efficiency of a single item of a system, (e.g. the electric motor as is usually the case) but always at the efficiency, and energy consumption, of the entire system. The electric machine/motor discussed in this paper refers to AC induction machines.

Comparative analysis of energy consumption by 2.2 kW electric motors of various types and energy efficiency classes in the electric drive of a pump unit with throttle control in a water supply system. Line-start permanent-magnet synchronous motors of the IE4 energy efficiency class and induction motors of the IE4 and IE3 energy efficiency classes of various manufacturers were considered (IE4 and IE3 are labels of energy efficiency classes of electric motors according to IEC 60034-30-1 standard). Energy consumption at a hydraulic load changing under a typical duty cycle was calculated based on the nameplate data of the pump and electric motors. The developed method shows that selecting an electric motor based on the IE energy efficiency class under the IEC 60034-30-1 standard (i.e., based on efficiency at a rated load) may not provide the minimum energy consumption of a variable flow pump unit over a typical duty cycle.

Premium (IEC IE3 Class) efficiency Motors are now mandatory in North America. Super-Premium (IEC IE4 Class) and IE5 Ultra-Premium efficiency classes are defined in the second edition of Standard IEC 60034-30. For line-start fixed-speed applications, Super-Premium IE4-Class Line-Start Permanent-Magnet Motors and Squirrel-Cage Induction Motors are recent entrances in the industrial motor market. For variable-speed applications, IE4-Class Variable-Reluctance Synchronous Motors are also a recent entrance in the market. For the low power range, moving from IE4 to IE5 class, may require moving away from radial-flux induction motor technology, into to the permanent magnet and reluctance technology, either using Rare-Earth or Ferrite magnets. In this paper, efficiency analysis on the best available electric motors and emerging motor technologies, such as axial-flux permanent-magnet synchronous motors, is presented.

This article introduces the recent technological progress of manufacturing copper rotors through die-casting techniques, which provides a simple and practical means for large-scale economical production of efficient and ultra-efficient induction motors. It also illustrates examples of using cast copper rotors to manufacture high efficient single-phase motors as well as high efficient motors at IE3 and IE4 efficiency levels and analyzes the technical characteristics of cast copper rotor motors.

The design and simulation of 15 kW, 2 pole, 50 Hz, three phase induction motor to achieve IE4 efficiency level as defined by the International Electrotechnical Commission (IEC). For achieving higher efficiency, the motor is designed, optimized and simulated with copper die-cast rotor and low loss electrical steel. The simulation method is first validated by comparing with the test results of standard IE3 motor. The same simulated model was taken as reference to design the IE4 motor. This design solution having IE4 efficiency is achieved without changing the stator geometry and frame size.

Premium efficiency motors are now mandatory in North America, but new higher efficiency classes are being introduced. Motors of IE4 Super-Premium Efficiency Class are already available in the market, and a new IE5 Ultra-Premium Efficiency Class is being considered. Within the IE4 Super-Premium Class, Line-Start Permanent Magnet Motors (LSPM) are a recent entrance in the industrial motor market. Its steady-state performance is outstanding, but, as in all technologies, there are some associated issues, both for retrofitting or new applications. The LSPM efficiency can be measured according to input-output (or direct) method specified in the IEEE 112 or IEC 60034-2-1 standards, but, if the losses are to be segregated, for example to allow proper temperature correction, it is important to evaluate if the specified test methods can be applied to this sort of machine. Due to the significant promotion and penetration of variable-speed drives (VSDs) in industrial motor driven systems, the motor tolerance and operation limits to such devices are key aspects.

As it is known, the induction motors with squirrel cage rotor are classified according to IEC 60034-30:2008 in three efficiency classes: a. Standard Efficiency IE1; b. High Efficiency IE2; c. Premium Efficiency IE3. According to the ecodesign requirements, since 16 June 2011 motors shall not be less efficient than IE2 efficiency level. The motor manufacturers are obliged to comply with this requirement, developing the IE2 variant. This paper refers to the mode of execution of these motors, to the applied technical solutions and to the obtained results.

The aim of this paper is to analyze the noises and heating produced by a three phase induction motor, power of 11kW, 1000 rpm, simple layer windings produced by the company Electroprecizia Sacele located in Brasov county, Romania. It was chosen this engine knowing that from 2015 it will be adopted the standard IEC 60034-30 IE3 category which provides noise limits and also efficiency limits for these induction motors. For the simulation of magnetic noise, was used Flux 2D finite element program and thermal measurements were performed by means of a fixed thermal cameras.Research for Reducing the ie3 motors in india. Measurements of noises (in the audio spectrum) were performed in semi-anechoic chamber, of the enterprise, wich produced the induction motor. In order to analyze the functioning in variable speed regime it was considered the supply of motor through the inverter (variable frequency-variable speed) and directly from the network. In the simulation of magnetic noise has been taken into account also the transitional regime, which appears when the motor starts.

Single-phasing is one of the major causes of motor failure in the industry. The electric motor market is changing fast due to the minimum energy performance standards being adopted around the World. In a large number of cases, particularly when the original old motors are retrofitted with motors of higher efficiency classes, the respective overload protection devices are not properly tuned/configured or upgraded/replaced. In this paper, an overview of the motor protective devices and the main results of an experimental study on the behavior of five three-phase 7.5-kW, 400-V, 50-Hz, 4-pole motors, namely, four squirrel-cage induction motors including IE1, IE2/EPAct, IE3/NEMA Premium and IE4/Super Premium efficiency classes and one line-start permanent-magnet of IE4 class, under single-phasing supply at no-load, locked-rotor and part-load operation, are presented. On the basis of the obtained results, it can be concluded that, in general, modern commercial thermal overload relays or thermal-magnetic circuit-breakers are able to protect line-operated motors against single-phasing.

The EU Commission Regulation (EC) No. 640/2009, Ecodesign Requirements for Electric Motors has been in effect since June 2011. This regulation imposes mandatory minimum efficiencies for many types of three-phase, low-voltage electric induction motors. These new motor generations have much higher start-up currents, which require a higher switching capacity and current carrying capacity far above the current standard IEC 60947. This trend will be enforced by additional changes within the motor standard IEC 60034 and further ecodesign initiatives in future. The altered behaviour in start-up and operation of IE2, IE3 and IE4 motors is quantified. This leads to increased requirements in respect of make and break operations and also endurance. In order to ensure a proper functionality in practical use it is necessary to improve design concepts, dynamic behaviour and contact materials. This paper considers different measures, particularly a well-adapted making behaviour of low voltage switching devices.

Research for Reducing the ie3 motors in india

ABS has launched the EffeX range, which it claims is the world's first submersible sewage pumps to use premium-efficiency motors that reduce energy consumption and environmental impact. The new range has greater safety margins and blockage-resistance free-solids passage of at least 75 mm. The efficient IE3 motor included has been designed and tested in accordance with the IEC 60034-30 standard, and has optimised hydraulics, giving the best total efficiency available, ABS says. The range is suitable for wastewater treatment facilities and matches anticipated forthcoming legislation in many countries regarding higher motor efficiency for submersible pumping.

The plant engineers have employed high efficiency electric motors and variable speed drives to reduce energy consumption and running costs of operations. The IE3 electric motors are readily available for the significant majority of applications at up to 250kW. ABB has released its motor dimensioner and launched a technology that enable to switch from direct on line (DOL) fixed speed motors to variable speed, using its drives. Research for Reducing the ie3 motors in india.All the motor applications are not right for speed control. The innovative drives are at least 10% more efficient than their old counterparts and are provided with significantly improved additional control and synchronization functionality. The technology is based on inherently more efficient power plates and electronics that enable better flux optimization so that motors running with variable torque and load on centrifugal pumps or fans do not run at full torque when it is not required.

The EU Commission Regulation (EC) No. 640/2009, Ecodesign Requirements for Electric Motors has been in effect since June 2011. This regulation imposes mandatory minimum efficiencies for many types of three-phase, low-voltage electric induction motors. These new motor generations have much higher start-up currents, which require a higher switching capacity and current carrying capacity far above the current standard IEC 60947. This trend will be enforced by additional changes within the motor standard IEC 60034 and further ecodesign initiatives in future. The altered behaviour in start-up and operation of IE2, IE3 and IE4 motors is quantified. This leads to increased requirements in respect of make and break operations and also endurance. In order to ensure a proper functionality in practical use it is necessary to improve design concepts, dynamic behaviour and contact materials. This paper considers different measures, particularly a well-adapted making behaviour of low voltage switching devices.

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