Motor energy-efficiency developments: recycling, efficiency classes

Although an effective date isn’t expected before 2011, mandatory minimum energy performance standards (MEPS) for electric motors are coming to Europe in 2009. Learn more about recycling, replacement, and motor classes.

02/06/2009


Although an effective date isn’t expected before 2011, mandatory minimum energy performance standards (MEPS) for electric motors are coming to Europe in 2009. This will promote energy-efficient (EE) motor systems that can save up to 30% of the 70% of industrial electricity used by motors, according to Prof. Aníbal T. de Almeida, Electric Engineering Dept., University of Coimbra, Portugal.
At the recent Motor Summit `08 in Zurich, Switzerland, Aníbal T. de Almeida, Electric Engineering Dept., University of Coimbra, Portugal, presented details of a study prompted by the European Union’s Ecodesign Energy-using Products (EuP) directive. This study has spurred mandatory minimum energy performance standards (MEPS) for electric motors, which are coming to Europe in 2009. Control Engineering covered the topic in its February 2008 issue. Here are additional details about the study and some related discussion.
While the range of electric motors affected was 0.75-200 kW (subsequently extended to 375 kW), three specific motor sizes were analyzed in the life-cycle cost (LCC) and environmental impact calculations. These were 1.1 kW, 11 kW, and 110 kW (1.5, 15, and 150 hp), representing small, medium, and large units. An average motor load factor of 60% and various operating time scenarios from 2,000 to 8,000 hours/year were used.
Recycling and replacement
The motors’ bill-of-materials (BoM) received extensive analysis for environmental effects. Included here were insulation materials, impregnation resins, paint, and packaging materials. Replacement of windings and bearings over the long life of motors was considered in the BoM analysis. As much as 95% of metal content in motors can be recycled, which was factored into the LCC analysis.
As for brushless permanent magnet (PM) motors , the statement that they’re readily available only in the lower power range of 0.75-7.5 kW is largely true. However, it should be noted that much larger size brushless PM motors are offered by some U.S. and Japanese manufacturers. (For example, see “

IPM motors for highest energy efficiency

,” October 2008 Control Engineering .)
It’s not a question of technology availability. Today’s higher initial cost for large brushless PM motors limits current sales volumes. Superior efficiency may drive up future demand, which would lower pricing.
Motor efficiency classes
In reference to the new, globally harmonized motor efficiency classes defined in standard, IEC 60034-30, there is a fourth motor class called IE4-super premium efficiency. This “future” motor class has been left open as far as a specific motor technology. One promising candidate might be the brushless PM magnet motor.
Scenario 2 for implementing mandatory MEPS for induction motors in the European Union (see main article) was proposed because it’s more difficult to manufacture high-efficiency motors in smaller frame sizes applicable to the 0.75-7.5 kW power range. This is especially the case for IEC frame sizes and 50 Hz design. The task is difficult but possible as new IEC motors in the market attest.
Also see related articles :

Motor Summit 2008 preview


Enhancing motor harmony


—Frank J. Bartos, P.E., Consulting Editor, Control Engineering
Machine Control eNewsletter
Register here





No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2013 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
The true cost of lubrication: Three keys to consider when evaluating oils; Plant Engineering Lubrication Guide; 11 ways to protect bearing assets; Is lubrication part of your KPIs?
Contract maintenance: 5 ways to keep things humming while keeping an eye on costs; Pneumatic systems; Energy monitoring; The sixth 'S' is safety
Transport your data: Supply chain information critical to operational excellence; High-voltage faults; Portable cooling; Safety automation isn't automatic
Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Plant Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.

Maintaining low data center PUE; Using eco mode in UPS systems; Commissioning electrical and power systems; Exploring dc power distribution alternatives
Synchronizing industrial Ethernet networks; Selecting protocol conversion gateways; Integrating HMIs with PLCs and PACs
Why manufacturers need to see energy in a different light: Current approaches to energy management yield quick savings, but leave plant managers searching for ways of improving on those early gains.

Annual Salary Survey

Participate in the 2013 Salary Survey

In a year when manufacturing continued to lead the economic rebound, it makes sense that plant manager bonuses rebounded. Plant Engineering’s annual Salary Survey shows both wages and bonuses rose in 2012 after a retreat the year before.

Average salary across all job titles for plant floor management rose 3.5% to $95,446, and bonus compensation jumped to $15,162, a 4.2% increase from the 2010 level and double the 2011 total, which showed a sharp drop in bonus.

2012 Salary Survey Analysis

2012 Salary Survey Results

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.