Market changes could mean a timely re-think on the integration of motor and driven equipment. EU eco-design demands now extend to fans, pumps and compressors with the first tier of efficiency levels introduced on 1 January 2013 and the second tier scheduled for 1 January 2015. Europe’s motor manufacturers are ahead of them with the now mandatory IE2 efficiency level which came into effect during the summer of 2011. 

From 1 January 2015 this efficiency requirement for relevant equipment will be stepped up again when IE3 motors (or IE2 + VSD) will become mandatory for 7.5 – 375kW. This requirement will extend down to 0.75kW from 1 January 2017. 

These changes occupy the time of design engineers throughout Europe. However, by looking forward, this step-by-step progress can be avoided by designing-in now motors that are already compliant with the higher level IE4

The obvious benefit of doing this is the elimination of expensive re-working of designs to accommodate a later minimum requirement. While helping to achieve this goal, the new Lafert permanent magnet High Performance motors, for example, also offer engineers the opportunity to potentially shrink their designs, both in size and weight. This might facilitate installation and/or transportation benefits that are attractive to the end user.

These benefits are combined with the advantages of enhanced control. The new IE4 compliant motors are compatible with many standard drives, consequently performance can be optimised effectively to ensure better operation capabilities. The largest benefit for the foresighted designer will be to gain the competitive advantage of IE4 efficiency levels.

As a major European manufacturer, Lafert can offer a complete range of IE3 motors, but for motors between 0.75 and 30kW the group can offer an innovative alternative. Drawing upon its experience with permanent magnet servo motors and drives, Lafert is able to provide a smaller, lighter motor solution that will comply with the IE4 efficiency level. 

By integrating the standard components of the squirrel cage induction motor with the permanent magnet rotor of the servo motor, Lafert has developed its High Performance range. The major advantage with this solution is that the power/weight ratio is lower rather than higher, resulting in IEC frame size being reduced by two (see diagram example 5.5kW 3000 rpm).  The system requires a sensorless drive and many standard drives can be configured for it. Another key benefit is that the efficiency remains high over a wide speed range not just over the duty point.

Lafert has developed two configuration types: the ‘HPI’ which includes the drive as an integral unit with the motor, and the ‘HPS’ which is a more conventional stand-alone motor and drive. The HPS is particularly appealing to the OEM because they can benefit from the use of standard motor components plus the option of Lafert’s motor customisation capabilities.

Also, Lafert has developed different magnet types with different magnet technologies so can closely match any application requirements and balance this with cost efficiency. Lafert’s reply to increases in the cost of rare earth elements since 2011 is to release the second generation of HPS motors which do not use rare earth element magnets. The result is a range of motors offering a greater stability of production costs and prices, due to the use of more available magnets.

The introduction of IPM (Interior Permanent Magnet) technology, specifically for the HEVAC OEM market is another innovation. This method of fitting the magnets to the rotor by insertion rather than the conventional surface mounted permanent magnet (SMPM) opens up yet more avenues for production cost efficiencies.

The combination of these features give engineers a compact, efficient motor solution, suitable for applications involving pumps, fans, compressors and other continuous running machines where there is an ever-increasing emphasis on reducing size, weight and operating costs.