Promoted content: Measuring motor energy efficiency - From manufacturing to operation

In industry, there is often a perception that sustainability and profitability are in conflict. When it comes to industrial electric motors, however, energy efficiency allows both objectives to be achieved at the same time. But how do we define energy efficiency — not just in a moment of operation, but across a motor’s lifetime?

At a fundamental level, energy efficient motors use less energy to produce the same rotational force required for a certain application. Some motors are more efficient than others due to their design, a field in which ABB has built up its expertise for 140 years. When connected to variable to speed drives (VSDs), motors can be controlled to always run exactly at the speed required by the application and therefore minimise the amount of energy that is consumed, especially with a perfectly matched motor and drive from the same supplier. But there are also many cost- and energy-saving opportunities for businesses which currently use motors that are over-designed, or not optimised for the actual needs of an application.

For efficiency to mean something in any of these contexts, it needs to be quantified. As the saying goes: only what can be measured, can be improved. This is well worth the effort, because motor efficiency is one of the few things that can both reduce OpEx while simultaneously cutting carbon emissions.

The importance of standardisation

Adhering to regional standards is important for the purposes of communicating efficiency levels to local customers and regulators — but the world needs a common language of efficiency in order to cause widespread change.

This is precisely why the International Electrotechnical Commission (IEC) has outlined a classification system ranging from IE1 to IE5, distinguishing motors by their efficiency, from Standard to Ultra-Premium. IE4 currently represents the highest defined efficiency level for direct-on-line (DOL) motors, while IE5 has been defined for VSD-driven motors.

Based on these, in Europe Minimum Energy Performance Standards (MEPS) have been pioneered to ensure that motors adhere to a baseline of energy efficiency, and similar frameworks are being adopted worldwide, such as China’s China Energy Label. Meanwhile, standards set by the National Electrical Manufacturers Association (NEMA) have informed rules like the USA’s Electric Motors Integral Horsepower Motor Final Rule (IHP).

Testing our mettle

But even outside of classifications and targets, it’s ABB that’s leading the charge on motor energy efficiency. During the design and manufacturing phases, ABB's motors undergo strict testing procedures to ensure they meet efficiency benchmarks. This involves detailed assessment of parameters such as power consumption, thermal performance and material integrity. Our motors are tested under standardised conditions to simulate various operational scenarios.

ABB introduced SynRM IE5 "Ultra-Premium Efficiency" motors to provide higher energy savings and performance compared to previous efficiency classes. SynRM achieves such high-level efficiency thanks to its design: it has no permanent magnets or winding losses in the rotor, contributing to lower operational temperatures and easier maintenance requirements. And we’re continually pushing the boundaries toward even higher levels of efficiency — beyond even the official standards.

Going beyond IE5

The emerging IE6 Hyper-Efficiency class for SynRM, while not yet standardised, is anticipated to offer another 20% reduction in energy losses compared to IE5, marking a significant milestone in motor design and functionality which follows the logical progression each prior efficiency class.

IE6 will be a huge step forward that will dramatically cut the operational cost of motors on the market and boost sustainability in essentially every industry. Manufacturing motors to achieve this standard involves innovative design, precision engineering, and material enhancements that go beyond anything that has come before.

Efficiency for the long haul

That said, the journey of energy efficiency does not conclude at the manufacturing stage. The operational lifetime of a motor presents its own challenges and opportunities. Here, condition monitoring plays a crucial role in maintaining and enhancing motor efficiency. ABB uses advanced digital technologies to allow operators to assess motor conditions in real-time, enabling predictive maintenance and optimising performance.

We use ABB Ability Smart Sensors to keep an eye on metrics like vibration levels, bearing temperature, and power usage to determine a motor’s health and prevent unexpected failures and unplanned downtime. This ongoing monitoring also allows us to make sure that our motors are operating within their designed efficiency parameters throughout their lifespan, as well as reveal further operational saving opportunities based on usage patterns.

Efficiency in motors is ultimately a place where our goals as an industry — to boost profits and improve sustainability — intersect. It’s so important that it’s self-evident; but to push the standards of efficiency even further than they are today will take a concerted effort, backed up by rigorous standardisation, individual transparency, and thorough diagnostic practices. Naturally, ABB is spearheading this change.