ABSTRACT. The EU power generation system is well on its way to decarbonization, but that does not take away the need for further energy efficiency improvements. In the first place because power generation will still continue to emit GHG emissions in the years to come, but also to reduce the pressure on renewable generation capacity growth.

We have calculated the GHG emissions, land use and material use of 1 MWh of electricity per year in the EU in the period between 2025 and 2045. This 20-year period corresponds with the typical life-time of devices such as medium power electrical motors.

GHG EMISSIONS Based on a life cycle assessment recognised methodology and based on the electricity generation mix projections made by the European Commission in its Impact Assessment of the EU Green Deal, the consumption of 1 MWh of electricity per year between 2025 and 2045 will lead to an average of 146 kg of CO2eq emissions per year. This figure might be surprising, but stems from the reality that generation from coal fired power plants will still be part of the EU electricity mix until 2040, combined with the fact that there is a need for gas fired power plants to fill gaps between demand and variable renewable production, as modelled by the European Commission.

LAND USE Based on the above-mentioned methodologies and data sources, the consumption of 1 MWh of electricity per year leads on average to 3453 points of land use in the period between 2025 and 2045, which corresponds to 26.36 m2 of typical non-irrigated cropland. Note that the land use points only take the competition for land and certain aspects of biodiversity into account, and not the impact on the landscape and its perception by EU citizens. The construction of renewable generation plants is often triggering local protest, and the final share of renewable energy capacity needed for the energy transition will be the most difficult to realize – the low hanging fruit will have been picked and more difficult or controversial locations will have to be unlocked. Energy efficiency improvements reduce the need for this capacity.

MATERIAL USE Based on the U.S. Department of Energy (DOE) “Renewable Energy Materials Properties Database (REMPD)”, the consumption of 1 MWh of electricity per year in the period of 2025 and 2045 can be associated with an average of 490 kg of material use (all materials combined, for the case of onshore wind turbine). The extra material needed in a 110 kW induction motor to move from IE3 to IE4 efficiency level is about 93 kg, which allows to save 3.8 MWh/year, assuming 3500 hours full load equivalent per year. This results in a highly positive material balance, as 93 kg of additional material used in the motor lead 1850 kg of material savings in electricity generation infrastructure.

CONCLUSION The figures above demonstrate that efforts to harvest additional energy savings still make sense, today as well as in the years to come. The evolution of the electricity price over the next 20 to 40 years is difficult to predict, which can make it hard to assess energy efficiency pay-back times in a highly accurate manner. However, the environmental benefits of each MWh saved are irrefutable.

METHODOLOGIES AND DATA United Nations Economy Commission for Europe (UNECE) “Carbon Neutrality on the UNECE Region: Integrated Life-Cycle Assessment of Electricity Sources”. European Commission “2030 Climate Target Plan Impact Assessment”. U.S. Department of Energy (DOE) “Renewable Energy Materials Properties Database (REMPD)”.

ABSTRACT. The revision process of the EU Ecodesign regulation on motors is ongoing, leading to a proposal for revised regulation in 2025. Article 9 in the regulation stipulates which elements should be addressed, including, among others, the introduction of stricter Minimum Energy Performance Standards (MEPS), an extension of MEPS to permanent magnet (PM) motors, and the introduction of resource efficiency requirements in accordance with the objectives of the circular economy. This last topic should be seen in light of the ongoing reform of the existing Ecodesign Directive into the Ecodesign for Sustainable Products Regulation (ESPR), which will take a broader set of environmental impact categories into account.

How exactly the revised regulation will take shape is still unsure, but the upcoming restrictions are likely to confront motor manufacturers with unprecedented challenges. The potential introduction of stricter MEPS is not posing major design problems in itself, as some induction motors available on the market today already have efficiency levels above IE4. Combining increased efficiency levels with a reduction in material mass, however, is a totally different kind of challenge. The largest efficiency gains in induction motors up to now were achieved by increasing stator winding cross-sections, which leads to bigger sizes and weights. Alternative winding techniques could reduce both energy losses and the amount of material used to a certain point.

The precise nature of the upcoming challenges will largely depend on the way material efficiency will be formulated in the new regulation. Material use in the motor could be considered in a broader perspective. Increasing the energy efficiency of electric motor systems reduces the generation, transmission and distribution capacity required to supply the motor, bringing along an associated reduction in material use and improving the overall environmental balance. Furthermore, material masses are likely to be differentiated according to their criticality, as a result of which the use of copper, aluminium and steel would be less problematic than, for example, rare-earth permanent magnets. Finally, the recyclability of the motor could also be regulated. This is not only determined by the theoretical recyclability of the materials that are used, but also by their rest value and by the facility to dismantle the unit. Such criteria could fundamentally change the design strategies of motor manufacturing.

This paper presents various design options coping with possible future requirements and summarises the main implications in terms of energy performance, use of materials and circularity.

ABSTRACT. In the modern world of CO2 emissions concerns it’s important to ensure that any major repairs on electrical motors do not adversely affect the motor efficiency. Whilst replacing a motor may make economic sense and it may in some cases also have a better efficiency, this needs to be considered against the carbon impact of the manufacture of a new motor. The motor repair specifications IEC 60034-23 and IEC 60079-19 for ATEX machines are little known, but was created to specify the best practice for the overhaul and repair of electric motors to ensure efficiency is maintained. This specification is backed up by industry studies on the effect of a rewind on the motor losses across a variety of frame sizes. This paper will talk through the results of these studies, some of the technical techniques and controls needed to maintain efficiency. Electrical Apparatus service association (EASA) have developed an accreditation scheme to ensure energy efficiency and quality based on their specification AR100. Finally, this paper will discuss how to select and audit suitable potential repairers.

ABSTRACT. Facing the European environment Regulation tsunami with Ecodesign for Sustainable Product Regulation (ESPR), the United States Right to Repair (R2R) jurisprudence and laws, Original Equipment Manufacturers (OEMs) are struggling with some new challenges for the next decade. On one hand, countries are creating specific regulations to protect the environment and consumers. The French Repair Index is the first example followed by other countries such as Belgium and Argentina. The European Commission is also reinforcing its regulation through consumer protection by creating a suite of regulations on the Environment. The Energy Labeling and Ecodesign directive enlarges its perimeter for concerned product groups with additional criteria. On the other hand, the standardization activity is implementing product-specific rules for Life Cycle Assessment and the latest revisions are implementing rules to assess material efficiency aspects for dedicated products. This article aims to establish projections on industrial power electronics products, based on the study of regulation already available for Business-to-Consumers (B2C) products. Comparing the French Repair Index and the European energy and ecodesign labeling for smartphones regulation, this article analyses the trends and the criteria applicable to this first group of products. The way of choosing criteria and related levels provides too much variability and misleading in comparing products. The criteria chosen by Europe address durability, reparability, and robustness whereas the French index is only focusing on repairability. This competition between indexes in the same area can no longer continue from the point of view of the European Commission. The industry constraints are different from those of B2C domain. Our industrial customers are waiting for us on safety, reliability, and services. Power electronics, especially variable speed drives are part of a system and usually, the end-users or the industrial asset managers do not imagine repairing such a small part of machineries or processes. Consequently, this article proposes some preliminary questions to answer before communicating on the repairability of variable speed drives. Material efficiency assessment, according to EN 4555X series, aims to guide users on communication with customers. Applying this series gives rules to create product-specific assessments, this article will investigate specifically the repairability assessment. For Power Electronics, the customer's main priority is to maximize the uptime, way before the aspects of repairability, durability, or serviceability. Material efficiency criteria, taken apart from one to the other, may not be relevant to reducing resource depletion. In order to maximize the impact, the material efficiency topics should be hierarchized. In conclusion, this study proposes to use environmental value analysis to prioritize for each product group the most relevant material efficiency topic. Based on value management, this methodology compares the material efficiency topics one to another to achieve a ranking of the environmental functions by environmental benefit, customer interest, and economic viability. The value analysis may be introduced into a product-specific rules standard for material efficiency, justifying for a product group, like variable speed drive, the list of relevant material efficiency items.

ABSTRACT. It is commonly known that controlling motor speed is the most efficient way of capacity control in e.g. HVAC systems. However, making sure that the motor itself runs in the most efficient operating point can be challenging, as it would require extensive knowledge of the motor parameters, including non-linear or saturation effects, over a wide operating envelope. Furthermore, indirect factors such as ambient temperature or ageing effects could likewise complicate matters. In this paper, it is shown that the efficiency of a converter driven motor may be increased when deviating from the operating point dictated by nominal parameters. Both asynchronous and synchronous motors are considered. Considering the volume of inverter driven motor systems worldwide, it is shown that even small improvements can bring substantial energy savings in a larger context.

ABSTRACT. In the European Union, electric motors consume 46% of the electrical energy [1]. 70% of the motor energy is consumed by pump, fan and compressor applications. These applications often operate in partial load with reduced flow using mechanical flow controls like throttle valves, bypasses and dampers. These flow control systems lead to a high energy consumption in partial load. As an alternative, a variable speed drive (VSD) could be used where the mass flow is varied through the variation of the motor speed. Because these applications power demand grows approximately cubic with the mass flow, small reductions in the rotational speed result in high savings of consumed energy [2]. The energy savings per unit application are between 10% and 75%, depending on the specific application and load cycles.

In this paper, the energy saving potential of electric motors, that could be achieved by equipping the aforementioned applications with a VSD, is investigated and quantified. The focus is on pump, fan and compressor applications in the European Union. A calculation methodology is presented, that estimates the currently possible annual saving potential as well as the energy that has already been saved by using VSDs. Based on a literature review, the model uses the saving potential values of the different applications and combines them with the market conditions. The market conditions consider besides the size of the market also the share of applications that could potentially be driven with a VSD. With the determined real energy saving potential and the energy consumption, the total value of energy saving potential is calculated, which is estimated to 116 TWh per year for the European Union. As well, the analysis shows, that fans and pumps still offer great energy saving potentials, whereas the potential is limited for compressors as many compressor applications are already equipped with VSDs.

References [1] Waide P and Brunner C Energy-Efficiency Policy Opportunities for Electric Motor-Driven Systems Energy Efficiency Series [2] Almeida A T de, Fonseca P and Bertoldi P 2003 Energy-efficient motor systems in the industrial and in the services sectors in the European Union: characterisation, potentials, barriers and policies Energy 28 673–90

ABSTRACT. Topic: 1. Electric Motors

Rotating machinery is a substantial part of industrial production in many branches. Since decades the electrification of rotating machinery is a remarkable option for many applications. It became even more relevant due to the accelerating climate change and correlated adjustments in industrial production processes. The use of electric drive systems is a great chance to improve the carbon footprint and to cope with regulatory and administrative requirements as well as to comply with the growing mindset of industrial companies regarding sustainability, especially when renewable electric energy is available. The variability in rotating speed of the drive system gives the system operator the freedom to react efficiently either to the available electric energy to drive the plant or to adjust the output of the plant to the momentary needs.

The replacement of steam and gas turbines by variable frequency drives is an exemplary application that shows the significant possibility to reduce the carbon footprint. Following an utmost sustainable replacement and preventing unnecessary costs, structural components of the plant are often reused, for instance the foundation. Adapter or intermediate frames are commonly used to adapt the anchorage of standard motor frame sizes to existing foundation conditions.

Even if the drive system is well capable of being operated at variable speed regarded from a purely electrical point of view, the mechanical characteristics regarding the dynamic behavior of the system need to be analyzed and assessed to ensure reliable operation with low vibration levels. Structural as well as rotor dynamics assessments ensure the successful mechanical integration of the electric drive system.

The rotor dynamics assessment requires an advanced approach regarding the representation of the support structure. The usual representation of the rotor support in rotor dynamics models by linear flexibilities is not sufficient if the support, particularly the foundation or the adapter frame, shows dynamic behavior. A frequency dependent representation of the support needs to be established in the rotor dynamics model. Thereby the compliance with separation margins or vibration limits can be evaluated and adjustments of the system design can be developed and assessed.

Facing the high variance of customer plants and the application-specific needs, a customized solution needs to be handled during the design process. The efficiency of the engineering phase of a project can be significantly improved by an automatization of time-consuming simulation tasks. That includes a parametric finite element model generation of the whole motor, the subsequent modal analysis and response analysis as well as the final evaluation process. The automized simulation approach reduced processing time for design optimization loops. The paper describes how challenges regarding the mechanical integration of high-speed variable frequency drive systems can be handled numerically and how the dynamic behavior can be assessed.

ABSTRACT. The US has a well-established process for reviewing and implementing new energy efficiency requirements since the US Department of Energy (DOE) began regulating products in the early 1990s. Typically, following statutes covering this topic, the DOE will review the scope and test methods for energy regulations every seven years. Separately, the DOE is required to review the minimum efficiency performance standards (MEPS) for existing covered products every six years.

However, from 2016 to 2020, largely due to certain policy decisions by the administration in control during this period, this cadence was disrupted. Nearly all regulatory work was paused, creating a backlog of energy efficiency-related rulemakings.

In 2020, the administration reversed course, and has over the last several years, devoted extra resources to restore expected timelines, eliminate the past due rulemakings, and update regulations to mirror advances in technology.

Electric motors are an area that has seen significant activity as the DOE works through these backlogs. Over the last two years, the DOE has issued five major rulemakings. In addition, to provide the industry additional time to meet the significantly expanded scope of covered product, the DOE issued an official delay-of-enforcement.

This paper will provide an overview of the various rules that have been modified, including revised scope, compliance requirements, and updated efficiency levels. The paper will also address the marking and testing requirements for products within the updated scopes but where no MEPS exist. Finally, the paper will provide the implementation/enforcement dates for all rules discussed to help attendees understand when they should expect to see products reflecting the new and amended requirements.

ABSTRACT. Improving China’s energy efficiency standards for electric motors has had significant impacts on reducing power consumption and carbon emissions and contributing to China’s ambitious goals of peaking carbon emissions by 2030 and carbon neutrality targets before 2060. This paper firstly reviews the status of the Chinese Minimum Energy Performance Standards (MEPS) for electric motors, including small and medium-sized three-phase asynchronous motors, small power motors, permanent magnet motors, and high-voltage motors. This study finds that the current Chinese motor MEPS has in general reached the world-leading levels. However, the stringency of energy efficiency requirements varies among the different types of motors. The small-size motors are still less stringent than the large-size ones and there is a big space for further improvement. It also finds that China's 2013 MEPS for permanent magnet motors falls significantly behind the advancements in permanent magnet motor technology and market developments. Taking into consideration the international best practices, this paper analyzes the opportunities and challenges for China to improve its MEPS for motors. Using CLASP’s energy-saving potential modeling tool, this paper analyzes the potential of energy-saving and carbon emission reductions based on two different MEPS scenarios. Lastly, based on the status review and outlook of technological advancement, this paper provides policy recommendations on 1) continuous improvement of motor MEPS; 2) developing energy efficiency standards for motor systems; and 3) mobilizing subnational governments to develop local policies and standards to promote highly efficient motors or motor systems in China.

ABSTRACT. We have developed a methodology that utilizes electricity metering during energy audits. Our approach keeps costs low by lending metering devices to companies, utilizing wireless technology, and automating data collection and report genera-tion. The generated report supports energy consultants in their analyses. In the 17 audits where we applied this methodology, we discovered that most energy effi-ciency measures were related to process installations. The savings potential achieved through metering increased the saved energy by nearly 70% for the total sample. For individual sites, the impact of monitoring varied significantly, rang-ing from 5% to 100% of the total savings. The additional costs associated with metering were recouped in less than one year for 14 of the sites. Our field study demonstrates that integrating metering into energy audits not only increases the number of energy-saving measures found but also enhances the precision of es-timated energy gains while being profitable in most cases. Furthermore, measur-ing electrical drives provides valuable insights into sizing quality and future opti-mization opportunities.

ABSTRACT. IEC and ISO are working together to improve the energy efficiency of electric motor-driven systems, which greatly reduces carbon emissions, thus contributing to UN Sustainable Development Goal 13: Climate Action. To achieve even greater energy efficiencies, whole rotating machines need to be considered in an integrated context. For example, energy efficiency standards for electric motors produced by the IEC need to work with respective mechanical standards for fans produced by ISO, as an integral rotating machine. This is the reason the IEC’s advisory committee for energy efficiency, ACEE, brought different stakeholders from IEC and ISO together in 2022 to form the Joint Advisory Group 22 (JAG 22) “Optimized Energy and Power Consumption of Electric Driven Machine Units”. JAG 22 has been founded by IEC TC2, IEC SC22G and ISO TC 117 and seeks to align system standards for electric motor systems and contribute to their energy efficiency. When in the preparatory phase forming JAG 22 electrical engineers from IEC started to get to know mechanical engineers from ISO in order to discuss improved electric driven machine systems, the traditional barriers between the two global standard makers started to fall. JAG 22 acts as a catalyst between the various technical committees that are responsible for their own specific components. JAG 22 aims to help to improve interfaces and accelerate the work of TCs when it comes to energy efficiency and lower energy use. It works to bridge any gaps between TCs that the TC liaison-function has historically not covered as such. Common interests were identified early on: the extension of the field of operation of a rotating machine beyond 100% torque and 100% speed, the use of common calculation and interpolation methods for efficiencies of entire motor systems including the variable speed drive (VSD), the necessity to learn about each other’s standards projects in progress before they are published, JAG 22 is currently providing input and critique for the update of the Motor Systems Tool (MST) by the Electric Motor Systems Annex (EMSA) as part of the IEA Technology Collaboration Programme 4E. MST is an independent calculator for complete motor systems that uses impartial models of standardized components to determine the efficiency at any given duty point on a complete motor system. In addition, many larger industrial systems are designed with separately sourced components, often from different manufacturers and very often oversized and not well matched. JAG 22 works on providing a checklist to assist engineers with selecting such components with the right sizes for optimum energy performance of the individual applications. JAG 22 also works on generating information for the general public about the two sets of test points that presently support the rating of motors and VSDs.

ABSTRACT. Abstract. There is a global effort to optimize energy use and reduce the con-sumption of fossil fuels, aiming to decrease greenhouse gas emissions as a strategy for mitigating climate change. One way to improve this situation is by addressing the demand side, such as regulating trade and producing ener-gy-consuming equipment. Among the devices that consume the most electric-ity are electric motors, which use about half the electricity available in indus-trialized countries. Some countries have already included single-phase electric motors in their Minimum Energy Performance Standards (MEPS). Single-phase motors are commonly used in applications where, three-phase motors are limited and the power demand is typically lower, such as in residential, ru-ral, commercial, and service settings. Despite the significant market presence of this type of motor in Brazil, with approximately 55 million units consumed in 2019, Brazil has not yet implemented MEPS for single-phase motors. Con-sidering this context, this study aims to evaluate the possibility of including MEPS for single-phase motors in Brazil in three stages. Firstly, i) a literature review of MEPS for single-phase motors worldwide was conducted. Subse-quently, ii) an evaluation of 25 single phase motors from 11 different manu-facturers that are sold in Brazilian market was done to check how was the ef-ficiency level of these motors. iii) a proposal for the adoption of MEPS for sin-gle-phase electric motors in Brazil is presented. Additionally, lastly iv) an es-timate of energy savings from the implementation of MEPS for single-phase motors in three scenarios over a 30-year horizon is presented.

ABSTRACT. The initiators of Energy Efficiency Networks in industrial companies in the 1990s did not imagine how effective and adaptive this concept would turn out to be. This "group-based" Energy Management System EMS delivers far better and faster results than individually performed EMS and transformation activities. The moderated regular exchange of experiences among the energy managers, the potential acknowledgement among them, and personal competition induces much faster implementation of energy efficient solutions. On average, network participation doubles the efficiency improvement of a company compared to individual efforts. In addition, renewable energies are significantly more applied by companies participating in these networks. The paper reports on the accelerated diffusion of high efficient electrical motor applications and on new ideas generated and implemented by network companies to reduce electricity demand of electrical applications in fields of ventilators, transport chains, and substitution of thermal separation processes by membrane technologies (a new electrical motor market). Energy efficiency and climate protection networks are increasingly considered in European countries as an efficient policy instrument, but also in China, and other emerging countries such as Mexico, Brazil, Algeria, Tunesia, and Nigeria.

ABSTRACT. It is agreed that Energy Efficiency and Energy Saving are the most important enablers for reducing the overall energy consumption of motor driven applications. Industries have worked now for decades to optimize the design of motors, power electronics and the overall extended products and systems in that way. But Resource efficiency also includes the Material Efficiency aspects and today many regulations are prepared for supporting Circular Economy by suggesting such requirements for this equipment put on the market.

This Paper follows and updates information and principles provided in our paper two years ago for Eemods’22 (European Ecodesign Material Efficiency standardization supporting Circular Economy aspects of Power drive systems for sustainability) and four years ago for Eemods’19 (European Ecodesign Material Efficiency standardization overview for Circular Economy aspects in Motor & Power drive systems). It will include the recent regulatory proposals circulated under the European Green deal as well the most recent international and European standardization works in progress that should be applicable for Power Electronic parts of the Power Drive Systems.

When considering the complete lifecycle of a motor driven system, it is established that energy consumption is the most important impacting criterion to consider during the use phase of equipment. Especially, the avoided emission resulting from the optimal use of a drive system in extended products will be described as it is much more beneficial than the Energy Efficiency benefit obtained by design on component. But for other lifecycle phases from cradle to grave, the other aspects of the resource efficiency, meaning the material efficiency part is also to be considered carefully in the context of the second principle for circular economy from the Ellen MacArthur foundation saying, “Circulate products and materials at their highest value”.

The value here is to be considered from benefit for stakeholders and in particular from the customer view. This paper will describe the material efficiency impacts on the Environmentally Conscious Design from published standards on Value (EN 12973) and Lifecycle management (ISO/IEC/IEEE 24748-1) as well the impacts for stakeholders’ activities and for companies’ organization.

The method to achieve circular design of products will be described when applied to power electronics through requirements from European and international standards in process (draft EN 45560 and IEC 63428). Conclusions from analysis of these standards considered in a use-case for a Motor power electronic soft starter will be given. And finally, the paper will report with perspective of the most recent European standardization work for the Material Efficiency aspects of Power Electronics prepared by the European CENELEC TC 22X Committee, in the WG 9 team (Material Efficiency for Circular Economy) preparing the European homegrown standard for the near future: “Ecodesign for power electronics including approach for environmental product declarations and specifications for the material efficiency assessment”. That future standard should be the one to be harmonized under the ESPR (European Ecodesign for sustainable products regulation) and its delegated act applicable to electric motors and variable speed drives.

ABSTRACT. Enhancing electric motor efficiency plays a pivotal role in addressing climate change in industrial applications. Prior studies pre-dominantly emphasized efficiency during the operational lifecycle, neglecting the environmental ramifications of their production and maintenance. By July 2023, European regulations mandated that motors with a capacity ranging from 75 to 200 kW adhere to IE4 efficiency standards, while motors under 75 kW, specifically those utilizing Squirrel Cage Induction Motors (SCIMs), comply with IE3 standards. The pinnacle of efficiency, IE5, is obtained through Synchronous Reluctance Motors (SynRM) and Permanent Magnet Synchronous Motors (PMSM). This research delves into these motor technologies' environmental life cycle impacts, contrasting the environmental footprint of SCIMs at IE3 against that of SynRM and PMSM at IE5. Utilizing the EuP Eco-Report tool as part of the Methodology for the Ecodesign of Energy-related Products (MEErP), this analysis focuses on the life cycle impacts of 11 kW motors featuring a 4-pole design. Findings indicate that while IE5 SynRMs exhibit superior operational efficiency, their production phase incurs greater environmental impacts due to the materials required. PMSMs, although highly efficient, present substantial environmental challenges, particularly in their production, attributed to the mining of rare earth elements.

ABSTRACT. Since the beginning of the world industrialization, Electric motors are the most convenient and easy to use device to convert electric power into mechanical movement. Their usage is extremely developed, then the focus is to cut the consumption of these components to achieve major energy savings. Since a couple of decades mandatory efficiency classes for electric motors have been increased significantly and motors losses reduced by almost 40% driving significantly up the use of raw materials (Steel & Copper), not in line with the new Green Deal expectation to cut the carbon footprint of such products (copper is mostly not produced in Europe and Electromagnetic steel is more and more imported outside EC). To deliver the results one 11kW electric motors has seen its active material content from IE2 increased by 37% for IE3 and 55% for IE4. Future’ trends in energy efficiency classes is to go higher than IE3 and move to IE4 (already in place for power >75kW) and level IE5 is now defined in standard. This will push the use of more material which is not in line with the new Material Efficiency standards and booming carbon footprint of electric motors. Today engineers are facing a key challenge: how to meet efficiency classes with respect to the new material efficiency rules and some scarcity effects. There are solutions already with the use of variable speed, but market quite often prefers DOL products that do not match with PM, Synchro reluctant, EC or many other ones motor technologies. However the very promising values of efficiency and material content will emphasize need to deploy them. Electric motors will have to evolve as well as the end users to accept new technologies less demanding in material and more efficient. Technologies are existing today to comply with both energy savings requirements and raw materials contents. Facing global demand, the shift will require time but is the main proposal by the industry to meet the Green Deal expectations. It shall start tomorrow. As supported for many years by CEMEP, the use of variable speed is offering more energy savings than higher escalation of classes to IE4 or 5 or …. .

ABSTRACT. Rotating electrical machines can be found in many sectors of industrial production. For decades, rotating electrical machines have been a central component of numerous applications. Climate change is now accelerating the use of these machines in areas where they were not previously found. Variable-speed drives in particular are becoming increasingly important. By using electric drive systems, the carbon footprint can be sustainably improved and regulatory and administrative requirements can be met.

The innovative electric drive concept presented here takes account of speed variability, digital penetration of the machine right down to winding level and the resource-saving use of materials. This is achieved through the complete integration of power converter and machine. In this drive system, the power converter, rotating electric machine and the software for operating the hardware components can no longer be viewed separately from each other. The machine and power converter are to be seen as an integral functional unit. The software controls, regulates and analyzes the integrated drive system, whereby the spatial and temporal shape of the air gap field can be freely defined and configured by the software.

The integrated drive system is suitable for a wide range of applications. The compactness of the drive, the adjustment of the machine performance via software and the comprehensive digitalization of the drive system are particularly noteworthy. An easily scalable modular system can be defined for the drive, which minimizes the use of materials and maximizes efficiency. This enables a wide range of drive tasks for a wide range of applications, reduced material usage and climate-friendly operation thanks to software optimization.

ABSTRACT. The teaching environment for modern drive systems suffers from the increasing complexity of modeling and using the various components. In order to realize efficient and reliable systems, thorough knowledge of the individual properties and optimal system integration are required.

In order to be able to deal specifically with the central aspects, the surrounding components such as the operating system, encoder recognition or real-time problems should be limited to a minimum importance in order to obtain a clear insight into the actual core elements such as the motor model or the control architecture.

In order to create an efficient and targeted educational environment, an intelligent mini test bench was realized with the combination of different motor types (DC, BLDC, PSM, SynRel and IM). Three-phase inverters with full access to switching patterns and current measurement topologies are used.

The implementation of the modulation strategy, the identification of the drive states and the control architecture takes place in a fast prototype environment on a real-time control platform. This enables either testing with prepared demonstrations or quick implementation of individual solutions.

As a result, the participants realize complete drive systems in which all control components are transparent and can be examined in depth. As a result, they gain comprehensive knowledge of modern drive technologies and are able to design and optimize drive concepts that meet the actual requirements in terms of application, system integration and energy efficiency.

ABSTRACT. The IEC 60034-2-3 and 61800-9-2 test methods both specify interpolation techniques which estimate losses for components of a Power Drive System at arbitrary load points given a known grid of performance values. These techniques are a foundation for potential calculated efficiency or other analytic PDS efficiency determination methods for US regulatory development and compliance. Our Motors Coalition Working Group seeks to develop a best case validation dataset, which enables high precision comparison between lab measured and calculated performance, especially at the forthcoming NEMA PI 2024 operating points. This project specifies several departures from default IEC test guidelines to reduce within product and between product variability, maximizing the utility of this dataset for evaluating these interpolation models. Additional specification is provided for: equipment sizing, initial setup, runtime programming setup, measurement guidance, and motor thermal constraints.

ABSTRACT. Compressed air plays a major role in industry throughout the world, but there currently exists no internationally accepted standard which provides a systematic procedure for the determination of the energy efficiency of air compressor systems. International Standard ISO 1217 (Displacement compressors – Acceptance tests) covers a very wide range of compressors, but is, of necessity, too general to be used as a means by which the energy performance of specific types of plant such as packaged compressors may be determined, with the expectation that comparable efficiency figures be obtained by laboratories throughout the world. It lacks, for example, specific requirements for a suitable measurement system layout, acceptable test conditions including ambient air temperature and barometric pressure limits, recommended ‘run-in’ and temperature stability requirements and guidance as to suitable instrumentation, including, most importantly, the measurement of air flow. This paper describes a ‘round robin’ procedure in which two packaged air compressor unitss have been passed between laboratories in Germany, Denmark and Australia where measurements of compressor performance were made, and the results compared. It has been found that by far the most critical of the required measurements are those of air flow, and recommendations are made as to the most appropriate types of flow-meter. The problem of calibration of flow measuring equipment is also addressed, and suggestions made as to means by which calibration may be performed in situ, using the compressor test rig itself, enabling verification of flow meter performance to be obtained under the same conditions as the air-compressor measurements themselves. The primary aim of this project has been to distill the results and experiences of the three laboratories and to compile these into a Guide to the use of ISO 1217, including a spreadsheet calculator to provide a final isentropic efficiency figure, so that by following its instructions, performance figures obtained by any competent laboratory may be expected closely to agree

ABSTRACT. Topic: 7. Refrigeration Systems

Refrigerated cabinets for supermarkets in Europe have an energy label which states, among other things, the efficiency class (A - G) and an annual consumption value for each cabinet. However, this information is not suitable for comparing a plug-in cabinet with a central refrigerated cabinet. This is due to the test standard, which on the one hand distinguishes between plug-in and non-plug-in cabinets in the assessment and on the other hand tests the refrigerated cabinets under fixed ambient conditions and therefore does not take seasonal differences into account. Furthermore, only the cabinet is examined for the energy label. However, this does not consider the influence of the heat or cold input on the indoor climate in the supermarket. The aim of the study is to provide a neutral comparison of plug-in and central refrigerated cabinet systems, considering the entire supermarket operation. For this purpose, three different supermarket variants were investigated: One supermarket with only conventional plug-in refrigerated cabinets, which all have an effective heat input. A second supermarket with hybrid plug-in refrigerated cabinets. These can either release the waste heat into the outside air via a waterloop system or transfer it to the store area as required. The third supermarket has a central refrigeration supply for the cabinets with a CO2 refrigeration machine, which can release usable heat via the deheater. For all variants, supermarket operation was simulated for one year for three different Swiss locations (Zurich, Lugano, Davos) in order to consider different ambient temperature profiles. The simulation was developed using Python. The results show that supermarkets equipped only with conventional plug-in cabinets have the highest electricity demand. One of the reasons for this is that this variant requires a high level of air conditioning. Hybrid plug-in refrigeration systems are significantly more efficient than conventional plug-in refrigeration systems, as the heat is released into the outside air and only enters the supermarket when required. The most efficient refrigeration system for a supermarket is via a central refrigeration supply, as the refrigeration is usually more efficient than with plug-in cabinets and because the heat from the refrigeration can also be used (with a CO2 booster refrigeration machine). Furthermore, it can be determined that cabinets in which the efficiency of refrigeration depends on the outside temperature (e.g. centrally refrigerated and water-cooled cabinets) have a greater deviation in annual consumption from the energy label than conventional plug-in cabinets.

ABSTRACT. Electric motor driven systems are currently responsible for some 53% of global electricity consumption, and approximately 70% of the industrial electricity use. Electric motor systems offer a broad field for the application of digitalisation technologies that can be used to record and reduce energy consumption. In an online conducted survey in 2020, more than 60 experts estimated the energy-saving potential of using digitalisation technologies at around 20%. Within this project, specific cases with savings between 10 and 15% could be identified. Task "New industrial developments and digitalisation" of the Electric Motor Systems Annex plans to draw up technical and policy recommendations on the use of digital technologies for increased energy efficiency in electric motor systems. For that, industrial use cases are described, interviews with suppliers and users are conducted and policy instruments are analysed. The first part of the paper summarises the results of a series of interviews conducted in Sweden and Austria on experiences with the implementation of digitalisation projects in this area. The specific goals of the companies when introducing digitalisation are explained. Furthermore, the three types of barriers (organisational, technical and economic) that are currently hindering the further spread of such solutions are described in more detail. Finally, the proposed measures at policy and company level are summarised. Next part of the paper contains the analysis of several use cases in this area that have been collected in this project in recent years. These use cases include measures, with which energy savings were achieved in various electric motor systems through the use of digital technologies. These include fan-, pumping- and compressed air systems that were optimized by additional sensors, by intelligent control or by advanced data analytics, but also energy and condition monitoring for machine tools and production lines. Among other things, the paper analyses the drivers for implementation and advantages and disadvantages of using digital technologies, including non-energy benefits. The last part of the paper describes and categorizes current policies in selected countries (Austria, Sweden) that are available to promote digitalisation in electric motor systems. Categories include research and implementation programmes in the area of energy efficiency, digitalisation and market entry. Furthermore, specific programmes and promoted cases in this area are described in more detail. Finally, based on that analysis, selected recommendations for supporting digitalisation in this area are derived.

ABSTRACT. Digital technologies open up novel possibilities for the continuous monitoring of parameters relevant to the energy consumption and maintenance of electric motor systems. While they can contribute to saving energy, digital technologies also consume energy. Within the framework of the International Energy Agency Technology Collaboration Programme 4E Electric Motor Systems Annex (EMSA www.iea-4e.org/emsa/) the energy consumption attributable to the digitalisation of industrial motor systems was analysed.

Since the availability of data considering the impact of digital energy consumption in motor systems is currently poor, this study aimed to make a first step through the analysis of concrete cases. The following five cases are included: (1) adaptive air pressure management system in a compressor system with intelligent control and real-time monitoring (2) water pump system equipped with electrical sensors allowing the optimisation and control of the pumps (3) results from a project where approximately 1’000 motors were equipped with electrical sensors (4) air ventilation system equipped with a sensor that can detect clogged air filters (5) smart sensors attached to motors.

The analysis shows that the advantages (both qualitative and quantitative) of using a digital solution outweigh the disadvantages, including an increased energy consumption. The energy consumption of applying digital solutions is negligible, in the range of a few percentages compared to the total energy consumption of an installation. The energy savings potential depends largely on how optimised systems already were and what type of hardware upgrades were made. Looking at the potential of the digital solutions without hardware upgrades, in our cases we found that these are below 10%.