Hi,I am Circle. Welcome to follow our public account 【AI Motor Frontier】, sharing insights on motors, remanufacturing, and system energy savings. On the journey of progress, I walk with you.
1. The “Three Major Treasures”
As a major consumer of electricity in the industrial sector, motors often account for over 60% of a company’s total electricity consumption. Want to reduce costs and increase efficiency? Start with the motor itself and the drive system! Here are three core types of energy-saving equipment and their “unique skills”.
1. High-Efficiency Motors: Saving Electricity from the Source
China’s GB 18613 – 2020 and IEC 60034 – 30 energy efficiency level correspondence list:
|
GB 18613 – 2020 Energy Efficiency Level |
Corresponding IEC 60034 – 30 Energy Efficiency Level |
Applicable Motor Types |
|
1st |
IE5 |
Three-Phase Asynchronous Motor |
|
2nd |
IE4 |
Three-Phase Asynchronous Motor |
|
3rd |
IE3 |
Three-Phase Asynchronous Motor |
（1）Permanent Magnet Synchronous Motor (PMSM)
Technical Highlights:
The rotor uses neodymium-iron-boron permanent magnets for excitation, eliminating the need for excitation current, with efficiency reaching 96%~97%, far exceeding that of ordinary motors.
High power density, with a size approximately 30% smaller than that of asynchronous motors of the same power.
Applicable Scenarios:
High-precision equipment: long-term load, heavy load.
Constant speed loads: water pumps, fans (efficiency is better when used with variable frequency drives).
（2）IE5 Ultra-Efficient Motor
Technical Highlights:
Meets the highest international energy efficiency standards (IE5), saving 10%~15% compared to IE3 motors.
Optimized electromagnetic design and heat dissipation structure, with temperature rise 15% lower than that of ordinary motors.
Applicable Scenarios:
Continuous operation equipment: conveyor belts, compressors.
High-load conditions: mining machinery, metallurgical rolling mills.
Cost Comparison:
Initial investment is high by 20%~30%, but costs can be recovered through energy savings within 2 years.
2. Intelligent Speed Control Devices: Dynamically Matching Load Demand
（1）Variable Frequency Drives
Technical Highlights:
By changing the supply frequency to the motor windings, the motor speed can be adjusted, with energy-saving effects becoming more significant at lower load rates (e.g., 40% energy savings at 50% load).
Built-in PID control algorithm can accurately match the square torque characteristics of fans and pumps.
Fluid loads: Power ∝ Speed to the 3rd power.
Selection Points:
Select general-purpose variable frequency drives for light-load equipment.
Select high overload capacity models for heavy-load equipment.
（2）Permanent Magnet Synchronous Motor+Variable Frequency Drive Combination
Technical Highlights:
Variable frequency drives directly drive permanent magnet motors, eliminating excitation losses+ reducing energy losses in the transmission chain.
Supports four-quadrant operation (can generate electricity during braking, recovering energy).
Black Technology Applications:
Electric vehicle drive systems, high-end CNC machine spindle motors, industrial drives, especially fluid load drives.
3. Energy Recovery Devices: Turning Waste into Treasure
（1）Braking Resistors+Energy Recovery Units
Technical Highlights:
Traditional braking resistors waste kinetic energy by converting it into heat.
Energy recovery units can invert electrical energy back to the grid during deceleration (recovery efficiency≥95%).
Currently, most motor testing system equipment is energy recovery type.
（2）Supercapacitor Energy Storage Systems
Technical Highlights:
Instantly absorbs regenerative energy from motors and releases it during peak periods.
Cycling life exceeds 1 million times (compared to batteries’ 500~1000 times).
Special Scenarios:
For example, regenerative braking energy recovery in subway trains.
2. Energy Saving in Drive Systems: A “Combination Punch”
Having high-efficiency motors is not enough? The entire transmission chain needs optimization:
（1）Magnetic Couplers (Torque Transfer without Mechanical Connection)
Technical Principle:
Torque is transmitted through a magnetic field, replacing traditional mechanical couplings.
Automatically slips to protect the motor during overload (extending lifespan by 3 times).
Energy Saving Data:
After the renovation of a fan in a cement plant, the system’s electricity saving rate improved by 8%, saving 150,000 kWh annually.
（2）Permanent Magnet Eddy Current Flexible Drive Devices
Black Technology Highlights:
Contactless transmission eliminates mechanical friction losses.
Can remotely adjust speed (±1% accuracy), adapting to variable working conditions.
3. Selection Pitfalls: Don’t Let “Energy-Saving Equipment” Become “Energy-Consuming Traps”
1.Don’t blindly pursue high parameters:
A company equipped a water pump with an IE5 motor+ variable frequency drive, but due to a load rate of only 30%, the variable frequency drive operated inefficiently for a long time, failing to utilize the energy-saving performance of the high-efficiency motor! The correct approach: conduct load testing first, then match the equipment.
2. System optimization is more important than single-point modifications:
A certain steel plant’s fan equipment only replaced the motor without optimizing the piping, resulting in unchanged air resistance and the fan still running at high load. The golden rule: motor energy-saving renovations must be accompanied by transmission system and load characteristic analysis.
4. Practical Case: From “Electric Tiger” to “Electric Saving Expert”
Project Background: A drying furnace fan in an automotive paint shop.
Original System:
Y series motor+ running at power frequency, consuming 2 million kWh annually.
Renovation Plan:
1. Replace with IE5 permanent magnet motor.
2. Add a variable frequency drive+PID intelligent control.
3. Optimize duct design to reduce resistance.
Renovation Results:
Annual electricity savings of 800,000 kWh (equivalent to saving 400,000 yuan in electricity costs).
Noise reduced from 85dB to 70dB (improving the working environment).
5. Future Trends: The “Next Stop” of Energy-Saving Technology
1.Digital Empowerment:
Motors+ sensors+ cloud platforms for real-time monitoring of energy efficiency and automatic optimization.
2.3.Hydrogen Energy Motors:
Fuel cell-driven motors (zero carbon emissions).
!Energy saving is not a choice, but a must!!
Exploring the genealogy of remanufactured low-efficiency motors: the astonishing value of resource recycling.