SynRM motors with unprecedented efficiency

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ABB is the first manufacturer to reach IE6 hyper-efficiency in a magnet-free synchronous reluctance motor (SynRM).

_{Robert Chin ABB IEC LV Motors Västerås, Sweden, robert.chin@se.abb.com} 

Because they generally work away in the background, unseen in daily life, the sheer quantity of electric motors needed to run society and the energy they consume is often overlooked. In fact, electric motors consume one-third of all electricity consumed globally. Low-voltage industrial motors are leading energy consumers, especially in the chemical, air separation, oil and gas, and energy industries, as well as in the water and wastewater treatment, metal and mining, and pulp and paper segments. The global consumption of electric energy by electric motors is dominated by just four major motor applications: compressors (32 percent), mechanical movement (30 percent), pumps (19 percent), and fans (19 percent)¹.

In 2019, ABB raised the bar for energy efficiency with its IE5 synchronous reluctance (SynRM) motor →01. This motor delivers ultra-premium IE5 energy efficiency, which is currently the highest level defined by the International Electrotechnical Commission (IEC). SynRM motors are characterized by high energy efficiency, reliability and low maintenance needs.

ABB is the first manufacturer to reach IE6 hyper-efficiency in a magnet-free design. This advancement is a significant step towards addressing the energy consumption challenges in the various industrial sectors mentioned above, offering a promising future of enhanced energy efficiency.

The launch of the IE6 SynRM is the latest testament to the rapid progress of the well-proven SynRM technology, which ABB pioneered in 2011. This technology has advanced so swiftly that it has outpaced the evolution of official industry-wide standards or definitions. However, so far, each higher IE efficiency class has demonstrated 20 percent lower energy losses than the previous one and ABB has continued this approach with the IE6 SynRM, reaffirming its technological leadership in the industry.

What is a SynRM?

SynRMs work on a well-known and very elegant principle. But only since the recent rise of sophisticated variable-speed drive (VSD) control has it been possible to exploit these super-efficient electrical machines fully.

In a SynRM, the rotor is designed to produce the smallest possible magnetic reluctance (the resistance to the flow of a magnetic field) in one direction and the highest reluctance in the direction perpendicular. The VSD steers the stator field so it “rotates” around the motor. The rotor’s directionally unequal magnetic reluctance properties cause it to rotate with the field and at the same frequency →01a-b.

SynRM technology combines the performance of the permanent magnet motor with the simplicity and service-friendliness of the induction motor. SynRMs do not feature rare-earth-based components like permanent magnets. The rotor has neither magnets nor windings and suffers virtually no power losses. Maintenance is as straightforward as with induction motors because there are no magnetic forces in the rotor.

ABB pioneered SynRM technology in 2011 with an IE4 efficiency class. In 2019, ABB introduced the IE5 SynRM ultra-¬premium efficiency motor and recently extended the portfolio with an Increased safety version for hazardous industries as well as a liquid-cooled design for demanding applications in harsh environments, such as food and beverage, rubber and plastic production, and marine. Now, ABB has taken SynRM technology to the next level by offering hyper-efficient IE6 models.

Reduced energy costs and increased productivity

These motors will appeal to innovative customers who want to futureproof their fleet by adopting the highest level of energy efficiency commercially available. Early adopters of IE6 hyper-efficiency motors will reap the benefits of reduced energy costs and increased productivity while moving ahead of current sustainability targets.

Motor-driven systems in industrial facilities are major users of electricity and, therefore, maximizing their efficiency offers huge potential to cut emissions and help meet climate change targets. Using new magnet-free SynRM motors, reaching efficiency levels anticipated for future IE6 definitions will also take energy savings to the next level. Because the IE6 SynRM is the same size as the equivalent IE3 induction motor, it is an easy replacement for legacy motors. That makes it possible for customers to upgrade to modern, high-efficiency products to futureproof their operations in a world of fluctuating energy costs. This compatibility also simplifies spare part provision and maintenance.

ABB’s wide range of SynRM motors has set the benchmark for magnet-free design. Their efficiency has progressed from IE4 to the IE5 versions, which were launched in 2019. IE6 is the next logical step that demonstrates the capability and technical superiority of SynRM technology.

Performance and simplicity

SynRM combines the performance of permanent magnet (PM) motors with the simplicity and service-friendliness of induction motors to achieve the highest levels of energy efficiency that ensure a short payback time. The rotor has neither magnets nor windings and suffers virtually no power losses. The design also requires no rare earth metals and offers a high level of usability due to the wide availability of suitable VSDs to provide the required control capabilities.

IE6 SynRMs offer 20 percent lower energy losses than comparable IE5 motors, so CO₂ emissions are reduced. Constant, quadratic torque with high efficiency delivers fast, precise control. ABB IE6 SynRMs deliver full torque from zero speed and give excellent partial-load efficiency. Their low rotor inertia allows precision movement and speed control that is very accurate due to the synchronous nature of the motor. This quiet motor is ideal for driving pumps, fans, compressors, etc., in any industrial application →02.

SynRM technology also offers much lower winding and bearing temperatures than traditional motors. These lower operating temperatures have multiple benefits – including longer insulation life and longer bearing greasing intervals and lifetime. Lower bearing temperatures are important because bearing failures cause many unplanned motor outages.

The ABB EcoSolutions™ portfolio

ABB SynRM motors are part of the ABB EcoSolutions product portfolio that enables customers and partners to make more sustainable choices by providing enhanced transparency about each product’s circularity value and environmental impact. This comprehensive collection of information ensures informed and responsible decision-making. Products within the ABB EcoSolutions portfolio comply with a set of key performance indicators defined in ABB’s circularity framework and carry an external, third-party verified environmental product declaration – ISO 14025 Type III².

Motoring ahead

In motors, ABB makes a point of having the right solution for any industrial need to respond to market demands for higher output, better efficiency, longer service intervals and footprint reduction. ABB believes that IE6 SynRM technology – which exceeds by far the minimum efficiency performance standards put in place by all major industrialized regions – provides the basis for sustainable efficiency of low-voltage motors into the future →03.

Magnet-free SynRM motors are just one element of ABB’s comprehensive premium portfolio of high-performance motors that incorporates over 140 years of domain expertise to ensure maximum reliability combined with a commitment to sustainability. Recognizing that a single technology does not answer all customer needs, ABB aims to master all motor technologies. That is why, in addition to SynRM, ABB can also achieve the anticipated levels for future IE6 efficiency with PM and permanent magnet-assisted-SynRM (PMA-SynRM) technology – a hybrid technology that pairs the SynRM design with a PM “boost.” This extension offers the right solution based on a comprehensive range of hyper-efficient technology building blocks to meet every segment- and application-specific need. 

_{References
[1] Stoffel, B. 2015. Science Direct, “The role of pumps for energy consumption and energy saving.” Available: https://www.sciencedirect.com/topics/engineering/electric-energy-consumption. [Accessed June 9, 2024.]
[2] ISO, “ISO 14025:2006. Environmental labels and declarations – Type III environmental declarations – Principles and procedures.” Available https://www.iso.org/standard/38131.html. [Accessed June 9, 2024.]}

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