• • • ENERGY EFFICIENCY • • • WEG’s W23 Sync+ motor ushers
in new era of efficiency From R&D to market: The story behind WEG’s hybrid permanent magnet and synchronous reluctance motor technology
n an era defined by evolving energy efficiency standards and a growing commitment to environmental responsibility, global motor manufacturer, WEG, has taken a giant leap forward with the launch of its W23 Sync+ motor line. The W23 Sync+, a hybrid innovation that combines permanent magnet (PM), ferrite or neodymium magnets and synchronous reluctance (SynRM) motor technologies, provides higher efficiency across all speeds when compared with conventional induction motors. Here Marek Lukaszczyk, European and Middle East marketing manager at WEG, introduces the benefits of the new PMSynRM technology.
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As a global manufacturer of motors and drives, WEG prides itself on staying ahead of international standards and regulations, and its new W23 Sync+ motor line is no exception. The quest for very high efficiency levels, now reaching IE6, was the driving force behind this innovation. That is why all W23 Sync+ motors meet or surpass the current European Eco-design regulation, which stipulates that new motors must meet the IE3 or IE4 standard. WEG’s flagship IE6 variety is known as the W23 Sync+ ULTRA, while the IE3 to IE5 models are known as the W23 Sync+ general line. As traditional induction motor technology approaches its efficiency limits, the need for
alternatives has become more apparent. To achieve higher efficiency levels, electric motors must have very high inrush current levels, and this demands new starters and protection systems when replacing an existing motor. While SynRM motors offer a potential solution to meet IE6, the motors also have shortcomings such as a low power factor that necessitates larger drives and increased costs.
Higher efficiency and lower losses
The PMSynRM technology developed by WEG has emerged as the optimal choice. The design ensures a flat efficiency behaviour, boasting a higher level of efficiency for the entire speed range compared with conventional induction motors, and a higher power factor than synchronous reluctance motors. This results in a lower total cost of ownership (TCO) for plant managers.
The PMSynRM technology varies in the separation of electrical losses in the electric motor by employing magnets. The magnets generate their own magnetic field without requiring induction of currents. Therefore, they reduce the motor’s total losses.
For example, while a conventional induction motor loses over 20 per cent efficiency across its varying speed and load ranges, the W23 Sync+ maintains its higher efficiency decreasing less than two per cent when the load and speed are reduced by 25 per cent. However, efficiency isn’t just a metric for energy consumption, it extends to the operational life of the motor. With efficiency levels reaching IE6 for the W23 Sync+ ULTRA variety and up to IE5 in the general W23 Sync+ line, both models generate less heat, which leads to a longer lifespan, fewer replacements and reduced maintenance requirements. This also eliminates the need for additional cooling. In addition, the W23 Sync+ motor line unlocks energy savings that directly impact on facilities’ CO2 reductions. In fact, the WEG team has calculated that replacing an IE3 induction 75 kilowatt (kW) 4 pole motor with an IE6 W23 Sync+ ULTRA may result in a reduction of 126 tons of CO2 during the latter motor’s expected lifetime of 25 years. This takes into account an operation time of 6,500 hours per year.
While reducing CO2 emissions is a primary focus, the W23 Sync+ also contributes to a broader reduction in greenhouse gas (GHG) emissions. Its energy efficiency aligns with
26 ELECTRICAL ENGINEERING • JULY/AUGUST 2024
electricalengineeringmagazine.co.uk
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