Globalisation has altered the equations for the Indian manufacturers. Today, the need to be economically competitive is of utmost importance and Energy-Efficient Motors offer the manufacturers just that.

All our Energy - Efficient Motors are characterized by low values of no-load currents. These result in the superior values of power factor, through out the operating load range. Overall efficiencies at partial loads ( 50 %, 75 % ) are also better than most other brands. Energy Efficient Motors are designed to minimize losses both in the core and in the windings. Thus, there will be lesser generation of heat. This leads to a higher in-built thermal reserve.

 

Our following designs of eff-2 and eff-1 level motors are operational in the field :

RPM
POLE
kW RATING
3000
2
7.5, 3.7, 1.5, 0.75, 0.37
1500
4
45, 22, 18.5, 15, 11, 9.3, 7.5, 5.5, 3.7, 2.2, 1.5, 1.1, 0.75, 0.37
1000
6
18.5, 15, 2.2, 0.75
750
8
1.5, 1.1, 0.75

Efficiency levels of our following sizes are certified by ERDA (BIS and NABL approved Lab.)

Efficiency Values of 3 – Ø Squirrel Cage
Energy Efficient Induction Motor
Rating in kW
0.75
1.1
3.7
7.5
11.0
22.0
45.0 *
Syn. Speed
1500
1500
1500
1500
1500
1500
1500
Frame Size
80
90 S
112 M
132 M
160 M
180 L
225 M
Date of Testing
29.12.95
29.100.03
31.01.02
05.02.03
29.10.03
28.02.02
05.02.03
N.L. Current (A)
1.13
1.14
2.89
4.82
6.77
12.04
23.36
Eff. at 100 % Load
75.63
78.4
85.2
87.73
89.99
90.08
-
Power Factor at 100 % Load
0.803
0.846
0.874
0.837
0.844
0.862
-
Eff. at 75 % Load
-
-
86.33
88.16
90.0
90.14
-
Eff. at 50 % Load
-
-
-
-
-
88.40
89.26
Conforms to IEEMA-19
Eff-2
Eff-2
Eff-2
Eff-2
Eff-1
Eff-2
Eff-2
* Due to non-availability of loading facilities, 45kW (at ERDA), motor was tested at 50 % load i.e. 22 kW (partial loading). Efficiency obtained was 89.26 % and powerfactor – 0.83.

NOTE :

  1. Eff-2 level of IEEMA-19 surpases the efficiency values of IS : 12615, in all cases.
  2. For most of the above sizes, further design improvements have already been effected. Thus Eff-1 level can be offered, with the prior confirmation.

In the event of bulk supplies of any one size, type testing can be arranged at ERDA, if intimated at the enquiry stage.

 

Copper Rotor Energy-Efficient Motors :-

There are many international papers on Rotating Machines, advocating the advantages of copper rotors over the mass produced aluminium die-cast rotors. The advantage of higher conductivity of copper over aluminium is just one advantage. Secondly, the slip reduces, thereby resulting in the further savings in the rotor losses. The motor runs at higher speed.

We have supplied many designs with copper rotors. Such motors are being supplied to OEMs, on the regular basis as well as end users – infrequent buyers of different sizes. The following copper rotor designs have been built. The motors are operational in the field.

RPM
POLE
kW RATING
1500
4
45, 30, 18.5 3.7, 1.1
1000
6
18.5, 15

Special features are built into designs so that the required starting torque is available for all the above motors. e.g. 45 kW, 1500 RPM, copper rotor motor drives Centreless Grinding Machine, which has a high inertia load.

PAY BACK PERIORDS :

In many cases the power consumption data is already generated at motor users’ premises, using

A : Standard Motors
B : Changing over to our Energy-Efficient Motors.

Payback periods, accepted by clients, have ranged from six months to one – and – a half year.

Other Advantages of Enery-Efficient Motors :

  • EE motors can withstand wider voltage and frequency fluctuations and higher
    ambient temperatures, without breakdown.
  • EE motors can take occasional as well as continuous overloads, without damaging
    winding.
  • The life of insulation of EE motors is considerably higher than that in standard
    motors, even when the same grade of insulation materials are used.
  • In the event of field repairs, the EE motors would retain its rated capacity (kW ratings), even when repairs are carried out by less skilled workers and in inexact conditions. [Stampings subjected to higher temperatures while removing burnt winding, incorrect coil sizes, errors in wire gauges etc.]
  • When motors run at partial loads, the savings of EE motors are even more pronounced as compared to the standard motors.

APPLICATIONS :

(A)
Centreless Grinding Machine Case study-I ( 11 kW )
Case study-II ( 18.5 kW )
(B)
Projects Case study-III ( 18.5 kW )
(C)
Circular Looms Motor Case study-IV ( Looms Motor )
(D)
  Case study-V ( 1.1 kW )

 

 

  CASE STUDY - I  

Running Costs of 11 kW – 1500 RPM Motors :

For Centreless Grinders, the duty is assumed as :

10 Seconds : cutting operation
6 Seconds : idle runnig of wheel.

Whenever the wheel runs idle, the energy is required (output from motor) to maintain the speed of the wheel and other friction and windage losses. These would be with-in 10 % of the rated capacity of the motor. Thus, the is very near to no-load running condition of motor. When the wheel takes cut, the loading is assumed to be 5.5 kW, approx. (50 % of rated output of motor), as per the data from Grinding Machine Mfgr.

Consideration : 8000 working hours of the machine per year and electricity rate of Rs. 5.00 per unit.

COMPARISION CHART
Sr.
No.
Make
Typical Well Known Brand MNC Make
Polyphase Motors
E.E. Motor
Remarks
Claims from Commercial Tech. Literature
Test Results at ERDA
1.
No
Load
Current
[A]
10.4
(Measured Value)
6.77
2.
Power
[W]
754
492
3.
Saving of Power
[W]
-
262
4.
Saving of Energy
[KWH]
-
786
5.
Saving
[Rs.]
-
3930/-
6.
ON
50 %
Load
Current
[A]
13.3
(Back Calculation)
11.5
7.
Power
[W]
6379
6193
8.
Saving of Power
[W]
-
186
9.
Saving of Energy
[KWH]
-
930
10.
Saving
[Rs.]
-
4650/-
11. Total Savings (5 + 10)
[Rs.]
-
3930 + 4650 = 8580/-

 

 

  CASE STUDY - II  

Running Costs of 18.5 kW – 1500 RPM Motors

For Centreless Grinders, the duty is assumed as :

10 Seconds : cutting operation
6 Seconds : idle runnig of wheel.


Consideration : 8000 working hours of the machine and Electricity rate Rs. 5.00 per unit.

COMPARISION CHART
Sr.
No.
Make
Typical Organised Make
Polyphase Motors
E.E. Motor
Remarks
Tech. Literature
Test Results at ERDA
1.
No
Load
Current
[A]
20
(Measured Value)
11
2.
Saving of Power
[W]
-
407
3.
Saving of Energy
[KWH]
-
1221
4.
Saving
[Rs.]
-
6105/-
5.
ON
50 %
Load
Current
[A]
26
(Back Calculation)
19
6.
Saving of Power
[W]
-
900
7.
Saving of Energy
[KWH]
-
4500
8.
Saving
[Rs.]
-
22500/-
9. Total Savings (4 + 8)
[Rs.]
-
6105 + 22500 = 28605/-

Payback period for premium on the price - 40 days.

 

  CASE STUDY - III  

Rating : 18.5 kW / 1000 RPM

Make
MNC make
India Energy Efficient
Polyphase Morors
E.E. Motor
Remarks
Actual Results on Load at Customer’s end
No-Load A
Current
@ 13.0
9.6
Load A
Current
27.46
21.07

 

  CASE STUDY - IV  

POLYPHASE MOTORS CIRCULAR LOOM MOTORS

Make
X
Y
Polyphase Morors
(Special)
Current Consumed in Amp
4.33
5.6
3.52
Power Consumed in Watts
2179
2818
1941
Average Running
22
22
22
Units Consumed per Day
48
62
42.7

 

Polyphase v/s X
Polyphase v/s Y
Yearly Savings in Rs.
9520
35080
Pay Back Period in Months
11
4

Considering cost of “Polyphase” make motor = Rs. 8,500/-

Cost of Unit = Rs. 5/-

 

  CASE STUDY - V  

 

Sr.
No.
Make
Typical Organised
Make
Polyphase Morors
E.E. Motor
Remarks
Actual Results on Load at Customer’s end
1.
No-Load - Current A
1.83
1.14
2.
Load - Current A
2.21
1.53
3.
Power - W
1239
879
4.
Saving - W
-
360
5.
Saving - Rs.
-
14,400

CONSIDERATION :

8000 working hours of the machine per year and electricity rate of Rs. 5.00 per unit.

* The pay-back period is within six months.


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