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Novel high-efficiency motor ‘will shake up the industry’

09 November, 2023

The Brazilian motor-maker WEG has invented a hybrid motor technology that, it says, combines the best technical characteristics of permanent magnet (PM) and synchronous reluctance (SynRM) motors, and will provide higher efficiencies at all speeds than induction motors. WEG predicts that the W23 Sync+ technology, which will be available in IE5 and IE6 efficiencies, “will shake up the industry”.

As well as delivering high efficiencies at constant torque over a wide speed range without needing forced ventilation, the new motor also boasts a higher power factor than synchronous reluctance motors. This will result in lower TCOs (total cost of ownership), according to WEG .

“We’re looking to the future with the W23 Sync+,” says Marek Lukaszczyk, WEG’s European and Middle East marketing manager. “The IE5 and IE6 models far surpass the current European Ecodesign regulation, which are currently required to meet IE3 or IE4 standard. WEG offers the largest range of motors meeting IE5 and IE6 efficiency levels on the market.”

The W23 Sync+ will be available in IEC frame sizes 80–450 (Nema 140–7000) and in speed ranges from 750–6,000 rpm. Output ratings range from 0.75–1,250kW, and the motors are compatible with 220/380V, 230/400V, 240/415V and 400/690V power supplies.

The permanent magnet synchronous reluctance (PMSynRM) motors are suitable for applications such as compressors, pumps, fans, blowers and conveyors.

WEG calculates that replacing a 75kW IE3 four-pole induction motor with one of the new IE6 W23 Sync+ motors could save 126 tonnes of CO2 emissions during a lifetime of 25 years, based on 6,500 hours of operation a year.

In addition, while a conventional induction motor typically loses more than 20% of its efficiency across its varying speed and load ranges, the new design maintains its higher efficiency, losing less than 2% when the load and speed are reduced to 25%.

WEG says its new W23 Sync+ motors combine the best of permanent magnet and synchronous reluctance technologies

Another attraction of the W23 Sync+ is its compact size, with a similar power rating per frame ratio as induction motors. For example, IE5 versions are available in the same frame size as IE3 induction motors, making interchangeability with existing installations easy.

During 2022, WEG invested more than €122m in R&D. “WEG strives to increase efficiency, reduce costs, improve quality and reduce the raw materials used in products,” says Lukaszczyk. “The ferrite magnet used in the W23 Sync+ is constructed from a ceramic material and has a local supplier and producer. This avoids global supply chain issues and results in material price stability.”

The new technology is making its debut at the SPS exhibition in Germany.

WEG:  Twitter  LinkedIn

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