New winding technique boosts induction motors' efficiency

April 26, 2016 // By Julien Happich
Florida-based company Revolution Motor Industries, LLC (RMI) has developed a new stator winding topology that delivers more power while reducing energy intake.

The new winding technique is said to improve a three-phase induction motor's efficiency by one IE class. The technology, tested at 1.5kw, 37kw and 225kw by Advanced Energy – one of America's premier electrical motor test labs – has delivered results that illustrate RMI’s efficiency improvements over a wide range of application loads. The auxiliary winding uses smaller capacitors to improve the power factor without impacting motor efficiency.

“This new method will allow someone to go from an IE1 to an IE2 level, in a very cost-effective way, merely through winding, and then from an IE2 to an IE3. We are currently rewinding a number of 3.7kw IE3 motors to achieve IE4 performance, which is where many companies in Europe are now moving in terms of AC induction motor efficiency,” explains Dan Jones, the acting chief engineer for RMI and an electric motor designer with over 50 years of experience at a number of organizations.

“You don't need magnets, all you need is a winding change to achieve higher motor efficiency performance that will be required by various regulatory agencies as our industry tries to become more energy-efficient.”

“This new winding technology could benefit any industry that uses AC induction motors. Heating, ventilating, air conditioning, water pumping for many waterworks that we have around the world. It could be used in fans that send both hot and cold energy down the ducts that we use for heating and cooling off buildings. The number of applications are numerous,” Jones says.

Dan Jones will discuss the topic further at the CWIEME exhibition for coil winding, insulation and electrical manufacturing in Berlin.

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