Increasing the Efficiency to IE4 Class for 5.5 kW Induction Motor Used in Industrial Applications

Abstract

Energy efficiency means using less energy for the same need. Increasing the efficiency of electric motors can save energy and decrease operating costs. The use of a correct sized electric motor with higher efficiency for the same need will result in energy saving. AC induction motors are dominating the installed electric motor capacity because it offers simple construction, easy maintenance, robustness, and cost-effective solution. They are available in single or multiphase at different power ratings from fractional powers to MWs. In this study; a 5.5 kW, 4-pole, 50 Hz, 3-phase, squirrel cage induction motor with IE2 high-efficiency class is chosen as the reference motor. The motor is re-designed and analyzed to increase its efficiency to IE4 Super-Premium efficiency class. A commercial software based on the finite element method (FEM) is used for numerical modeling. Various techniques are applied to get higher efficiency values in terms of sizing, materials, and manufacturing. IE4 efficiency class is achieved and all designed models are compared to the reference motor in terms of the electrical performance parameters and the cost.