DRIVES, MOTORS & GEARS
A SOUND INVESTMENT
LAFERT
Future proof your motor drive solutions
By: Brian Bannister, Motor Specialist, Lafert
Electric Motors Ltd
“Future proofed” is a description
employed by some manufacturers when
describing their machines or systems
in order to breath confidence into their
customers regarding their longevity and
long-term suitability for purpose says Brian
Bannister of Lafert Electric Motors in the
UK.
The phrase is intended to convey the
machine/system is a sound investment.
Frequently claims are valid at the time,
however technology moves on and there
are new opportunities for manufacturers
and designers to incorporate components
that can genuinely impart “Future
proofing” qualities for years to come.
IE5, AC electric motors is such an
example. From January 2021, the next
phase of motor legislation enforces that as
a minimum. IE3 efficiency rated motors are
used for all applications between 0.75kW
and 1000kW with or without a drive.
Accordingly, machinery manufacturers
are already incorporating these motors
as advised. As a result, however, they are
missing the opportunity to build in “Future
proofing” characteristics in respect of both
energy efficiency and possible reduced
overall size and weight of machines whilst
also avoiding possible future machine/
system redesigns.
Today, there are motors available that
meet IE4 and IE5 energy efficiency
specifications and from certain
manufacturers it is a tried and tested,
well established technology. Some of
these motors employ permanent magnet
rare-earth technology that enables the
motor manufacturers to get more power
from smaller motor frame sizes. Weight
reductions can be as much as 50% over
standard similarly rated units yet offer
between 3 to 4 times greater power
output than existing similar frame size
motors.
In addition to the rare earth route, some
manufacturers can also offer motors
employing specially developed permanent
magnet ferrite material that achieve similar
energy, weight and frame size reductions.
This option also offers the additional
benefits of stable pricing and assured
supply by avoiding the potential vagaries
of rare earth magnet material availability.
Depending upon the performance
requirements of the application and
the demands of the customer, some
manufacturers can supply rotors where the
magnets may be surface mounted (SMPM)
or internally mounted (IPM) drive packaged solutions for Automated
Guided Vehicles (AGV)
Typically, IE4 and IE5 motors are offered
as standalone units or with a “piggyback”
electric drive as integrated packages.
Ideal applications for them are continuous
duty work, such as fans, pumps,
compressors and heavy-duty conveyors. The major benefits to the user are the
dramatic cost savings available and
comparable short payback times when
considering implementing IE4 and IE5
motors within their plant. According to the
European Commission website, a more
efficient motor can generate savings
ranging from a few euros to several tens
of thousands of euros over its lifetime,
depending on its power and use pattern.
These IE4 and IE5 developments have
been achieved by companies drawing
upon their experience in various different
motor technologies employing rare earth
magnets and established technologies,
such as servos, combined with their
ability to adapt/modify motors to create
customised solutions to meet the end
users’ requirements.
This last capability has in turn spawned
high-performance compact motor
variations for specific duties. These
include gearless motors for passenger
lifts, integrated motor drive units for large
circulating fan applications and complete
Electric motors currently account for
around 50% of the energy consumed
in Europe, the early adoption of the IE4
and IE5 higher efficiency, permanent
magnet motors could help accelerate the
reduction in the use of electricity and cut
the release of CO2 emissions, thereby
helping to combat climate change in-line
with our UK government environmental
policies.
A typical example might be where an
18.5kW 4-pole IE1 motor is replaced by
a similar power IE4 motor. If used for
5000 hours per year, with an energy cost
of €0.15 per kWh, the IE4 motor would
give an annual saving of €386 thereby
achieving a very short payback period.
Information above retrieved from an
online calculator which can be found here
http://www.lafert.com/eng/electric-motor-
synchronous-smpm-ie4ie5.php
For further information, please visit www.lafert.com
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PECM Issue 43