The synchronous reluctance motor
Holy Grail for the Dutch industry?
Entrepreneurs, industries and authorities are involved in a collective quest to find ways to reduce the energy consumption in the production chain. In part by reducing carbon dioxide emissions and a lower consumption of fossil fuels to stop the climate change, but also to improve the nett results.
In particular in the recent past, where energy prices went through the roof as a result of social uncertainty and the war in Ukraine, it is evident that every kWh saved is relevant. Is the synchronous reluctance motor the solution for this challenge?
A quick and non-capital intensive way to save energy is to optimize electrical drive systems in the heart of the production process. Ranging from transport to the building industry, from food processing to the off shore industry and from container transport to the process industry: in virtually every sector in our economy, electric motors combined with reducers and frequency inverters provide the driving force behind the production process. In many cases significant energy savings are possible with these integral drive systems
Multiple advantages
In all the sectors and applications mentioned above, controllability, flexibility, efficiency and compactness are key factors. To cater for these needs, Italian market leader Bonfiglioli developed the synchronous reluctance motor (BSR). These motors are usually combined with worm gear reducers, which are known for their robustness and wide torque ranges. The BSR has a number of advantages compared to other motor types, such as high efficiency, high starting and braking forces, and the ability to operate with very broad voltage- and frequency ranges.
40% Less energy
The Bonfiglioli synchronous reluctance motors comply with the IE4 energy class, using a conventional stator in combination with a rotor without any windings or magnets. With this type of rotor construction the usual energy losses are not present, while the rotor itself is also much lighter than usual. This results in a much lower rotor inertia which expresses itself in an improved efficiency and better motor dynamics. In contrast with other IE4 motor designs BSR motors do not rely on rare earth metals for the improved performance. The working principle of the BSR motor is completely different from the traditional induction motor, which makes it possible to reduce motor losses by 40% compared to a traditional induction motor. In plain language it takes 40% less energy to yield the same output.
Active Cube-Inverters
To enable further energy savings, Bonfiglioli has optimized the BSR motors for use in combination with the Active Cube series. These Bonfiglioli Vectron frequency inverters is available in two versions. Doing so users in any type of industry or application select the best option for their specific use. The High Efficiency Package results in an higher efficiency class compared to an induction motor with the same nominal power and frame size. Effectively less energy is required to generate the same power with equal motor dimensions When the High Output Package is selected the same nominal power and efficiency class is proved but with a smaller frame size compared to a traditional induction motor. In other words a smaller drive system provides the same output.
IE5 is already within reach
The remarkable efficiency of the synchronous reluctance motor reduces the operational costs and contributes to making the production process more sustainable. At the moment IE4 is the highest efficiency class for IEC standardized electric motors, and compulsory in the EU as from the first of July 2023 for motors up to 200 kW. Motors that comply to the IE4 standard convert up to 96% of the absorbed electrical energy into mechanical energy. This is very energy efficient, and can lead to substantial energy savings in a wide range of industrial applications. In combination with the right inverter the future IE5 class is attainable.
Also for your application?
The bulk of the frequency inverter controlled drives seldom operate at full power. Especially for these applications the BSR motor inverter combination is a serious option for significant energy savings. In particular during partial load the efficiency advantages of the synchronous reluctance motor over the conventional induction motor are remarkable. In particular in centrifugal pump and ventilator applications, that are usually running on a continuous basis but seldom at full power, and certain type of compressors the advantages of the BSR motor/Inverter combination come to light.
Double savings
Lies the emphasis in your production process on energy saving? Then a synchronous reluctance motor is a serious tool in reaching your goals. In these cases the synchronous reluctance motor can be mated to a straight or bevel gearbox instead of a worm gear box. Both the motor and the gearbox provide a serious efficiency improvement compared to a conventional setup, and the overall efficiency of the drive can almost double. The result of this is that a smaller motor and a smaller gearbox can be selected for the same mechanical output. Doing so both the initial investment and the operational cost can be reduced.