Large-Scale Downsizing of Induction Motors Requiring Stator Rewinding as a Low-Cost Strategy to Save Energy and Extend Motors Lifetime

نویسندگان

  • Fernando J. T. E. Ferreira
  • Aníbal T. de Almeida
چکیده

Most three-phase, squirrel-cage, induction motors (IMs) are oversized. In the European Union (EU), the average load factor of IMs is slightly lower than 60%. In fact, in some industrial sectors, a large quantity of motors operates with a load permanently significantly under that value (e.g., 25-30%). Therefore, since the load factor is an average of the motor load over its operating cycle, it can be said that a large quantity of motors operates with a load permanently under that value. If the motor load is properly estimated, as well as the power quality at the terminals, it is possible to properly rewinding the stator in order to match the peak efficiency with the dominant load level by means of a downsizing of the motor (magnetizing flux level reduction). Moreover, since the motor maintains the original material quantity, the magnetic and copper losses will be much reduced, improving the motor efficiency, as well as its power factor. The efficiency gain can even be better if the cooling fan is properly replaced by a smaller one. The efficiency gains after downsizing can, in the worst situation, compensate by far the typical 1% efficiency drop during poor-quality motor repair/rewinding. Additionally, the motor lifetime can be extended, which is environmentally advantageous. In this paper, a short review on optimized stator winding redesign as a function of the motor actual load and the associated savings potential in the EU are presented.

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تاریخ انتشار 2009