With the development of the industrial manufacturing industry, electric motors are widely used in people’s production and manufacturing. According to data analysis, the electric energy used by the motor operation can account for 80% of the entire industrial electricity consumption. Therefore, improving the efficiency of electric motors has become a motor manufacturer. The main research and development Target.

Today, Shenghua Motor will organize and analyze how motor manufacturers improve the efficiency of motors.

First of all, we must first know that 70%-95% of the electrical energy absorbed by the motor is converted into mechanical energy, which is often referred to as the efficiency value of the motor. It is an important technical indicator of the motor. Heat generation, mechanical loss, etc. are consumed, so this part of the electrical energy is wasted, and the ratio of converted into mechanical power and energy consumption is the efficiency of the motor.

For motor manufacturers, it is not easy to increase the motor efficiency by 1 percentage point, and the material will increase a lot, and when the motor efficiency reaches a certain value, it is limited by the manufacturing materials, no matter how much material is added. The efficiency of the motor is reduced, and the use of too much material will also lead to a decrease in the efficiency of the motor.

The high-efficiency and energy-saving motors on the market are basically three-phase asynchronous motor products with an efficiency greater than 90%, which are optimized and produced based on the Y series motors.

Manufacturers mainly improve the efficiency of electric motors through the following ways:

1. Increase the material: increase the outer diameter of the iron core, increase the length of the iron core, increase the size of the stator slot, and increase the weight of the copper wire to achieve the purpose of improving the efficiency. For example, the outer diameter of the YE2-80-4M motor is increased from the current Φ120 To Φ130, some abroad increase Φ145, and at the same time increase the length from 70 to 90. The amount of iron used for each motor increases by 3Kg. The copper wire increases by 0.9Kg.

2. Use silicon steel sheets with good performance. In the past, hot-rolled sheets with large iron loss were used, and now high-quality cold-rolled sheets with low losses are used, such as DW470. Even lower than the DW270.

3. Improve machining accuracy and reduce mechanical losses. Replace small fans to reduce fan losses. High-efficiency bearings are used.

4. Optimize the electrical performance parameters of the motor, and optimize the parameters by changing the slot shape.

5. Adopt cast copper rotor (complex process and high cost).

 Therefore, to make a real high-efficiency motor, the design, raw materials, and processing costs are much higher, so that electricity can be converted into mechanical energy to the greatest extent.

Energy-saving measures for high-efficiency motors

Motor energy saving is a systematic project involving the entire life cycle of the motor. From the design and manufacture of the motor to the selection, operation, adjustment, maintenance and scrapping of the motor, the effect of its energy saving measures must be considered from the entire life cycle of the motor. In this aspect, the main consideration is to improve the efficiency from the following aspects.

The design of energy-saving motor refers to the use of modern design methods such as optimization design technology, new material technology, control technology, integration technology, test and detection technology, etc., to reduce the power loss of the motor, improve the efficiency of the motor, and design an efficient motor.

When the motor converts electrical energy into mechanical energy, it also loses a part of the energy itself. Typical AC motor losses can generally be divided into three parts: fixed loss, variable loss and stray loss. Variable losses are load-dependent and include stator resistance losses (copper losses), rotor resistance losses, and brush resistance losses; fixed losses are load-independent and include core losses and mechanical losses. The iron loss is composed of hysteresis loss and eddy current loss, which is proportional to the square of the voltage, and the hysteresis loss is also inversely proportional to the frequency; other stray losses are mechanical losses and other losses, including friction losses of bearings and fans, rotors and other windage losses due to rotation.

Shandong Shenghua YE2 high-efficiency energy-saving motor

 Features of high-efficiency motors

      1. Save energy and reduce long-term operating costs. It is very suitable for textiles, fans, pumps, and compressors. The cost of motor purchase can be recovered by saving electricity for one year;

      2. Direct start or speed regulation with frequency converter can fully replace the asynchronous motor;

      3. The high-efficiency and energy-saving motor itself can save more than 15℅ of electric energy than ordinary motors;

       4. The power factor of the motor is close to 1, which improves the quality factor of the power grid without adding a power factor compensator;

      5. The motor current is small, which saves the transmission and distribution capacity and prolongs the overall operating life of the system;

      6. Power-saving budget: Take a 55-kilowatt motor as an example, a high-efficiency motor saves 15% of electricity than a general motor, and the electricity fee is calculated at 0.5 yuan per kilowatt-hour. The cost of replacing the motor can be recovered by saving electricity within one year of using the energy-saving motor.

Shandong Shenghua Motor Co., Ltd. is a motor manufacturer integrating R&D, design, production and sales of three-phase asynchronous motors. It has 19 years of experience in customization and production of plateau-specific motors, and has long-term cooperation with hundreds of machinery and equipment manufacturers. With mature production technology and reliable quality, it has provided customized solutions for various three-phase asynchronous motors for more than a thousand mechanical equipment manufacturing customers.

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Post time: Aug-09-2022