Promoted content: World’s first liquid-cooled IE5 SynRM motor sets new benchmark for energy efficiency and high power output

Electric motors keep industries, processes, and applications in constant, productive motion. They also consume over 45 percent of global electricity, and the number of motors is projected to double by 2040. If the more than 300 million industrial electric motor-driven systems currently in operation were replaced by high-efficiency, optimized alternatives, it could reduce global electricity consumption by as much as 10 percent.

Many industrial settings contend with challenges such as excessive moisture, dirt, and dust. For example, marine propulsion systems and thrusters operate in rough conditions requiring high power density motors within restricted spaces. In industries like rubber and plastics and food and beverage production, processes are often sensitive to airflow and noise levels. To operate in these environments, motor technology must offer design flexibility while delivering a high power output and lower energy usage, which can significantly reduce the total cost of ownership.

ABB has addressed these challenges by developing the world’s first IE5 SynRM Liquid-cooled motors – ranging from 75 kW to 710 kW. The new design sets a new benchmark for high power output and reliability in a compact footprint by combining the benefits of established ultra-premium energy efficiency with highly effective liquid cooling.

Higher efficiency and a longer life

For many applications, liquid-cooled motors are the preferred choice due to their compact size and the elimination of cooling fans. However, the IE5 SynRM Liquid-cooled motors offer a significant efficiency advantage over current traditional liquid-cooled induction motors. The high efficiency of SynRM motors, also at partial loads, reduces electricity consumption and CO2 emissions, making them a powerful option for upgrading.

Reliability is improved by the highly effective cooling system, with the SynRM’s cool rotor and cooling ribs on the bearing assembly reducing the bearings’ operating temperature. This helps to extend the lifetime of these crucial components and reduces the chance of bearing failures – the cause of around 70 percent of unplanned motor outages. Regreasable bearings are fitted as standard, and a grease outlet ensures easy removal of old grease.

Built tough

SynRM Liquid-cooled motors, featuring tight seals that block moisture, dirt, and dust, and a smooth exterior to prevent dust build-up, are ideal for demanding applications like marine propulsion systems and thrusters. The motors’ compact design ensures they deliver maximum output in confined spaces.

The motors’ torque capabilities, which include a broad speed range for constant torque applications and full torque availability from zero speed, make them highly suitable for powering extruders.

At the same time, their higher power density allows OEMs fabricating rubber and plastics machinery to upgrade to IE5 efficiency using the same or smaller frame sizes. This advantage facilitates more compact or more powerful machines.  This would typically require at least some re-design, but probably less costly and faster than a complete re-design.

Zero impact on airflow

One of the key advantages of liquid-cooled motors is the absence of fans or ventilation systems for cooling purposes, leaving the ambient air undisturbed. This feature is particularly beneficial in sectors where airflow can affect processes like rubber and plastics production and food and beverage applications like chocolate conche machines.

Additionally, liquid-cooled SynRM motors contribute to a more pleasant working environment in industrial settings by minimizing noise, making them the ideal choice where quiet operation is critical.

Easy to install, operate, and maintain

IE5 SynRM Liquid-cooled motors are also considerably lighter than competing designs, making them easy to handle and install. For instance, a 250kW IE5 SynRM motor with a 315 frame weighs 870kg, nearly half the weight of a corresponding IE3 induction motor.

The mechanical connections are designed for compatibility and easy integration with existing systems. The terminal box can be rotated in four 90-degree rotations for added versatility. The motors utilize a basic cooling circuit that includes only a pump and a chiller, components that are easy to share with other equipment. 

Moreover, these motors act as a drop-in replacement for older, less efficient induction motors, facilitating easy upgrades to IE5 ultra-premium efficiency without a change in motor size.

Optimized total cost of ownership

Energy efficiency is vital in minimizing an electric motor’s total cost of ownership (TCO). This is because around 97 percent of the TCO is typically attributed to energy expenses during the motor’s lifetime, while the initial purchase price only accounts for about two percent.

IE5 motors boast 40 percent lower energy losses than commonly used IE3 motors. Consequently, the payback time for investing in an IE5 motor instead of an IE3 motor is often under a year. Greater efficiency also means better profitability. In a typical application, an IE5 SynRM motor could reduce energy usage by 34,675 kWh annually, potentially leading to savings of around €5,200 and a reduction of 13,558kg of CO2 emissions. Over a typical 15-year life, savings would add up to €78,000 and 203,370kg of CO2.

Sweet efficiency in chocolate production

Chocolate production involves highly energy-intensive processing. As a result, energy efficiency has emerged as a crucial aspect of design and production at the SACMI Packaging & Chocolate facility in Poland. Recognizing this, the company’s designers have chosen ABB’s IE5 Liquid-cooled SynRM motors, paired with drives, as the optimal solution for the lengthy conching stage of chocolate production.

SACMI has identified their conche machines as the most energy-intensive, where operating cycles are often at partial load or the motors, ranging from 110 to 160kW, don’t always run at full speed. The conching process comprises intense mixing, agitating, and aerating of heated liquid chocolate for five to eight hours.

Following the installation of the SynRM motor-drive solution, SACMI reported four percent annual energy savings on a mid-sized conche machine over 7,000 hours of operation. This translates into a reduction of 22 tons of CO2 emissions.

Redefining industry benchmarks

The liquid-cooled IE5 SynRM motor redefines industry benchmarks for energy efficiency and compact, high-power performance. Given its exceptional capabilities, now is the perfect time for industries with the most demanding applications to make the transition. For further information, visit https://global.abb/topic/synrm-drive-package/en/synrm-liquid-cooled