Maximizing Energy Efficiency with Magnet-Assisted Synchronous Reluctance Motors: A Revolutionary Solution by Hiatran Electric

As China's manufacturing industry continues to evolve, the demand for motors has skyrocketed. In 2023, the total installed capacity of motors in China reached 3.25 billion kilowatts, accounting for 60% of the country’s total electricity consumption and 25% of its carbon emissions. However, high-efficiency motors still make up less than 10% of the total motor population.

Recognizing the market potential for high-efficiency motors, Hiatran Electric developed and produced the magnet-assisted synchronous reluctance motor (SynRM)—an advanced version of the traditional synchronous reluctance motor. This new motor not only meets the IEC energy efficiency level IE5, but when combined with variable frequency drives (VFD), it can achieve up to IE6, reducing energy losses by 20% compared to similar IE5 motors.

 

What is a Magnet-Assisted Synchronous Reluctance Motor?

The synchronous reluctance motor (SynRM) operates on an elegant principle that has been understood for some time. However, its true energy efficiency can only be fully realized when paired with a suitable variable-speed drive (VSD).

In a SynRM, the rotor is designed to offer minimal magnetic reluctance (resistance to the magnetic field) in one direction, while providing maximum reluctance in a perpendicular direction. The VSD controls the stator field, causing it to "rotate" around the motor. This unequal magnetic reluctance in the rotor causes it to follow the rotating field, synchronizing at the same frequency.

SynRM technology combines the performance benefits of permanent magnet motors with the simplicity and service-friendliness of induction motors. Unlike permanent magnet motors, SynRMs do not use rare-earth magnets, making them more affordable and easier to maintain, as there are no magnets or windings in the rotor, which results in virtually no power losses.

The magnetically assisted synchronous reluctance motor further improves on SynRM by incorporating ferrite magnets, enhancing the motor's efficiency. Compared to the rare-earth permanent magnets commonly used in traditional motors (such as NdFeB), ferrite materials are significantly cheaper, more temperature-resistant, and more stable in high-temperature environments. This makes ferrite-assisted motors an excellent choice for applications where high temperatures are a concern.

 

IE5 SynRM vs. YE2 Asynchronous Motors: A Real-World Comparison

Hiatran Electric’s testing reveals that the SynRM IE5 motor outperforms the traditional YE2 asynchronous motor in both full load and partial load conditions, with the advantages of the SynRM becoming especially evident under lower load situations.

The graph below illustrates typical efficiency performance of an IE5 SynRM versus a YE2 motor in pump duty, showing that the SynRM IE5 motor maintains a wider high-efficiency range and achieves superior performance under varying load conditions.

 

Superior Temperature Resistance and Compatibility

The ferrite permanent magnets used in SynRM motors provide better temperature resistance than rare-earth magnets, which are prone to demagnetization at high temperatures. This makes magnet-assisted synchronous reluctance motors ideal for high-temperature environments.

 

The HCM5 external rotor motor features a housing compatible with standard three-phase induction motors, requiring no mechanical modification when upgrading. This ensures that traditional induction motors can be easily replaced, simplifying maintenance and spare parts supply.

 

IEC TS 60034-30-2: Defining the Future of Motor Efficiency

The IEC 60034-30-1 standard for motor efficiency has been replaced by IEC 60034-30-2:2016, which introduces new efficiency classes for variable-speed AC motors. This standard now includes IE5 SynRMs, enabling a direct comparison of traditional induction motors and advanced variable-speed motors designed specifically for VSD systems.

IE5 motors are more efficient than IE4 motors, with losses reduced by 20%, regardless of the motor type or standard. This offers substantial energy savings and improved environmental performance.

 

Energy Savings and Quick Payback

While the initial cost of an IE5 SynRM motor may be slightly higher than that of a YE2 motor, the energy savings far outweigh this difference. According to Hiatran Electric’s calculations, the energy savings from using an IE5 motor over its lifecycle are significant, with the cost difference paid back within approximately 12 months of operation. Over the motor's 10-15 year service life, the energy savings will continue to generate cost benefits, making the IE5 motor an excellent investment.

 

Conclusion: A Step Towards a Greener Future

The development of the magnet-assisted synchronous reluctance motor by Hiatran Electric marks a significant milestone in motor technology, offering a highly efficient, cost-effective, and environmentally friendly solution for industries worldwide. With its superior performance, temperature resistance, and energy-saving capabilities, the IE5 SynRM is poised to play a key role in reducing energy consumption and carbon emissions across a range of applications.

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