高效节能电机，它可以是二到百分之八，效率比标准电机，欠其优异的性能，功能，新的技术和设计制造的改进。
汽车被发现在各种工业应用，日常工具，如风扇，鼓风机，泵供电。根据美国能源部的资料，在美国所有电能消耗的一半以上是由电动机。全国电气制造商协会说，电动机系统占制造业用电量的70％，展示一个能量守恒和效率的^大机会。因此，在面对经济的不确定性和不断增长的可持续性举措，电机的效率和寿命的能源消耗应该是在决策过程中的一个重要因素时，一个新的购买与重绕的马达。
高效节能电机，它可以是二到百分之八，效率比标准电机，欠其优异的性能，功能，新的技术和设计制造的改进。更好的电气钢和更多的铜在卷绕帮助减少的电动机的能量损失，这就需要一个较小的散热风扇。钕磁铁，这是用于电动汽车用马达，使电机产生具有较高功率密度更高马力在一个较小的框架。制造电机，低电损耗钢和更薄的定子叠片可以减少电力损耗。延长的核心和使用更符合空气动力学的散热风扇，可以进一步减少能源浪费。高效节能电机，但更昂贵的初期，有较长的绝缘和轴承寿命，振动小，寿命可靠性增加。
“电机采购价是其生活成本的基础上有20年的寿命大约只有2％，马林诺夫斯基说：”约翰，高级产品经理，交流电机保德电机公司。 “当电机的采购价相比，连续运行电机的电力约11倍的购买价格。”展望性价比第一的思想，制造商可以节省数千美元，每年的能源成本。
技术门槛
NEMA电机和发电机组已经建立了优质的能源效率电机的程序达成共识的基础上定义的“溢价效率，提供规范，高效节能的产品。”美国能源部也不断令人鼓舞的电机制造商，以提高效率，但马林诺夫斯基说，“我们的技术门槛，有没有更多的。”
他补充说，在电机制造商正在寻找新的技术，为未来的工业电机，如制造，采用钕磁铁，这使得功率密度，高效率马达。 “虽然这些电机是非常有效的，投资回收期延长，因为对他们已经从中国永磁材料的成本增加，”他说。
一种能量高效的电机可以是高达96％的效率，但如果其它系统组件只在50％的效率工作，一个高效的电机的潜力会去看不见。谁想要在他们的流程，以^大限度地提高效率的制造商正在寻找一切可能的机会，而不仅仅是电机。 “我们必须超越简单的组件更换，”马林诺夫斯基说，建议制造商在整个电机系统，它可以由配电变压器，智能起动，或变频调速，电机，机械动力传动部件，如以及被驱动的负载。
被驱动的负载的效率，设置所需的马力来驱动的移动设备所必需的水平，和一个较旧的泵或压缩机可能不会像今日取得的效率随着新技术。切换到一个新的泵或压缩机可以减少电机的评级。一个旧的变速箱，用于将电机连接到负载，可能有50％至60％的效率评级，其中一个新的传动装置可具有95％至96％的效率。切换到一个新的螺旋伞齿轮，可以降低电机的尺寸和功耗要求了近一半。
“虽然更复杂的系统，这是真正的低悬的果实是今天，马林诺夫斯基说。”为了帮助客户评估电机及其相关系统的能源需求，美国保德电机节能评估小组来看看目前在使用的过程和看到，如果有机会，以节省能源，提高生产效率。
电机的真正的敌人
而能源消费是一个重要的关注与电机，马林诺夫斯基说：“敌人的电机是真热。它的热和摩擦。“他解释说，每10度Ç温度越高，电机得到，绝缘寿命将减少一半。轴承运行热，造成油脂持续的时间较短的时间和轴承故障的风险增加。马林诺夫斯基说，电机故障的原因之一是因为不正确轴承脂润滑，要么过多，过少，或不兼容的类型的油脂。
“因此，预防性维护是不错的，”他补充说。许多新的监测系统可今天，现在可以收看到地面水平的轴承温度，振动水平，电阻和电压。一旦限制到大，重要的工业电机，此级别的监视正在成为越来越多的更小，更整体的电机。无线连接选项也在陆续推出，进一步扩大了一次成本过高，切出的数千英尺的电线，将电机连接到中控室的监控选项。
汽车在总能源使用量的工业产品制造商，有一个显着的影响，随着越来越多的制造商希望在他们的流程，^大限度地提高效率更高效率的马达和系统将成为优先事项。一个良好的预防性维护计划，将有助于提高系统的可靠性。
马林诺夫斯基说：“当人们获得更舒适的如何做这些事情，他们得到采纳，那将是一件好事。”
原文：
Efficient Electrical Machines
Tue, 04/17/2012 - 1:48pm by Rachel Leisemann Immel, Associate Editor, IMPO
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Energy-efficient motors, which can be two to eight percent more efficient than standard motors, owe their premium performance capabilities to new technologies and design manufacturing improvements.
Motors are found in a variety of industrial applications, powering everyday tools such as fans, blowers, and pumps. According to the U.S. Department of Energy, over half of all electrical energy consumed in the United States is used by electric motors. And the National Electrical Manufacturers Association says electric motor systems account for 70 percent of manufacturing electricity consumption, presenting one of the largest opportunities for energy conservations, and efficiency. Therefore, in the face of economic uncertainty and growing sustainability initiatives, motor efficiency and lifetime energy consumption should be a major factor in the decision-making process when making a new purchase versus rewinding a motor.
Energy-efficient motors, which can be two to eight percent more efficient than standard motors, owe their premium performance capabilities to new technologies and design manufacturing improvements. Better electrical steel and more copper in the winding help reduce a motor’s energy loss, which requires a smaller fan to dissipate heat. Neodymium magnets, which are used in electric vehicle motors, allow motors to be produced with a higher power density—higher horsepower in a smaller frame. Manufacturing motors with lower-electrical-loss steel and thinner stator laminations can reduce electrical losses. Lengthening the core and using more aerodynamic cooling fans can further reduce energy waste. Energy-efficient motors, though more expensive initially, have longer insulation and bearing lives, less vibration, and increased lifetime reliability.
“The motors purchase price is only about two percent of its life cost based on a 20 year life,” says John Malinowski, senior product manager, AC Motors with Baldor Electric Company. “When compared to a motor’s purchase price, electricity to run the motor continuously is about 11 times the purchase price.” Looking beyond first cost thinking could save a manufacturer thousands of dollars a year in energy costs alone.
The Technological Threshold
The NEMA Motor and Generator Section has established a premium energy efficiency motors program to provide standardized, highly energy efficient products based on a consensus definition of “premium efficiency.” The U.S. Department of energy is also continually encouraging motor manufacturers to improve efficiency, but Malinowski says, “we’re at about the technological threshold—there is no more.”
He adds that motor manufacturers are now looking at new technologies for future industrial motors, such as manufacturing them with neodymium magnets, which allows for a more power dense, high efficiency motor. “Although these motors are very efficient, payback on them has been extended because of the cost increases from China on magnet materials,” he says.
An energy efficient motor can be up to 96 percent efficient, but an efficient motor’s potential will go unseen if other system components are only working at 50 percent efficiency. Manufacturers who want to maximize efficiency in their processes are looking at all possible opportunities—not just the motor. “One must look beyond simple component replacement,” Malinowski says, and advises that manufacturers look at the entire motor system, which may consist of the power distribution transformer, smart starter, or adjustable speed drive, electric motor, mechanical power transmission components, as well as the driven load.
The efficiency of the driven load sets the required horsepower level necessary to drive the device, and an older pump or compressor may not be as efficient as new technologies available today. Switching to a new pump or compressor can reduce the motor rating. An older gearbox, used to connect the motor to the load, may have an efficiency rating of 50 to 60 percent, where a new gear may have 95 to 96 percent efficiency. Switching to a newer helical or bevel gear can reduce the motor size and power requirements by nearly half.
“Although systems are more complicated to do, this is where the real low hanging fruit is today,” Malinowski says. To help customers assess the energy requirements of their motor and its related systems, Baldor Electric energy assessment teams are available to look at the processes currently in use and see if there are opportunities to save energy and increase productivity.
A Motor’s Real Enemy
While energy consumption is a major concern with motors, Malinowski says “the enemy of a motor is really heat. It’s heat and friction.” He explains that for every 10 degrees C hotter the motor gets, the insulation life is cut in half. The bearings run hotter, causing grease to last for a shorter period of time and the risk of bearing failure to increase. Malinowski says that the number one cause of motor failure is because of bearings being incorrectly greased, with either too much, too little, or an incompatible type of grease.
“So preventive maintenance is good,” he adds. A number of new monitoring systems are available today that can now watch bearing temperatures, vibrations levels, resistances, and voltage to ground levels. Once limited to large, critical industrial motors, this level of monitoring is becoming more and more available for smaller, less integral motors. Wireless connectivity options are also being introduced, further expanding once cost-prohibitive monitoring options by cutting out the thousands of feet of wire that would be necessary to connect a motor to the control room.
Motors have a significant impact on the total energy usage of an industrial manufacturer, and as more manufacturers look to maximize efficiency in their processes, higher efficiency motors and systems will become a priority. And a good preventive maintenance program will help to improve system reliability.
Malinowski says, “As people get more comfortable with how to do these things, and they get adopted, that’s going to be a good thing.”
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