According to a recent white paper on energy efficiency savings, Schneider Electric identified oversized machine actuators (electrical motors, pneumatic actuators, etc.) This leads to machines that consume more energy than necessary, something that can easily be avoided through proper design.

This is particularly important considering industry and infrastructure consume more than 31% of the available energy in the world. Of this, electrical motors alone represent more than 60% of that energy consumption. Applications need to be carefully evaluated to consider how robust and reliable a machine must be, as well as what future evolutions of the machine might be needed. Small, simple motors are better ones than bigger ones.

Experience shows that from an energy-efficiency perspective, using motors that are precisely matched to an application rather than simply using motors with “more than enough” power optimizes energy consumption. This basic recommendation can lead to an average savings of 3 – 4%. At the same time, it can impact the reduction/sizing of the power control system.

Accurate sizing reduces machine and runtime cost

Using high-efficiency motors

Industrial electric motors are one of the prime targets of the new energy reducing regulations and standards. The transition to IE3 premium efficiency motors is underway raising challenges for businesses. High-efficiency motors have proven their effectiveness and typically have a payback period of only one to two years. The new standard IEC classification for high-efficiency motors specifies four categories. The additional benefit is that the longer machine life of high-efficiency motors contributes to sustainability with an expected benefit of a further 10% energy savings.

Variable speed drives offer big savings

For applications with variable loads, the use of speed drives can bring immediate benefits and up to 50% in energy savings (pumps, ventilation fans, and compressors are obvious applications). At the same time, any application that requires repetitive starting, the choice of speed drives over conventional contactors, limits starting current and therefore reduces losses and load peaks.

The instant benefits for end users, such as cost savings in their electrical bill, can be highlighted by a payback of less than one or two years. Some applications, such as hoisting and lifts, can benefit from regenerative devices like regenerative drives.

Download Schneider Electric offers to address tis by offering a freely downloadable Motion Sizer software engineering tool for CAM design and power unit dimensioning.