Driving speed-controlled tech uptake

THE INTERNATIONAL Energy Agency (IEA)'s Energy Efficiency 2025 market report highlights that industrial electric motor systems account for about 60% of global industrial electricity demand and ~25% of all global electricity use. Replacing the worst-performing 10% of global motors with new IE3/IE4 motors could save as much energy annually as Denmark consumes: around 30 TWh. And the potential savings become even greater when higher-efficiency motors rated at IE5 and above are installed.

While there are significant efficiency gains to be reaped from upgrading a motor, still greater energy savings – in the region of 25% or more - are achievable when a high-efficiency motor is used in combination with a VSD. Yet, their uptake by industry has progressed at rather a modest pace since they were first introduced 50 years ago.

As part of our “Engineered to Outrun” philosophy, at ABB we collaborated with our customers to investigate how we could improve this situation. A clear message emerged. To boost the uptake of speed-controlled technology it has to be as easy to install and operate as possible, especially in cases where using a separate drive can be challenging.

Our answer is the LV Titanium Variable Speed Motor (VSM) platform that now provides a simple, straightforward method to achieve IE5 Ultra-Premium efficiency in a wide range of industrial applications. It promises to be a game-changer, especially as a replacement for existing direct-on-line (DOL) induction motors, where it offers an easy upgrade path to a VSD-driven motor with a fast return on investment (ROI).

Streamlined motor and drive concept

The VSM was engineered as a streamlined concept, with an advanced drive module designed for optimal performance with a permanent magnet (PM) motor. PM technology is ideal in this case as it delivers high power density and high efficiency over the entire speed range. It also ensures a competitive route to an optimized total cost of ownership (TCO).

The result is a sleek, compact design, housed in a robust cast-iron frame, with the axial drive mounted on the end of the motor. This saves space and makes the VSM platform ideal for applications like both vertical and horizontal pumps, compressors and fans.

Plug-and-play functionality means that the VSM significantly reduces the need for commissioning, as its motor and drive are commissioned and optimised to work together before leaving the factory. Furthermore, there is no requirement for the special cabling associated with separate drives, as the VSM is connected in the same way as a standalone DOL motor. This makes installation fast and easy, with no need for cabinets or electrical rooms.

LV Titanium motors are available to cover frame sizes from 71 to 160, and power ratings from 1.1 up to 30 kW, with rated speeds up to 4500 rpm. This enables VSM technology to cover industrial sectors such as data centers, water treatment, food and beverage, HVAC and general machinery.

During customer testing we noted one additional benefit of the VSM is its exceptionally quiet operation – just above ambient levels.

Rapid payback

The savings on energy costs and carbon intensity that customers can achieve by switching to a VSM is illustrated by comparison with a conventional, standalone fixed-speed IE3 DOL motor in a typical 15 kW centrifugal pumping application.

Over a 15-year lifetime, running 6000 hours a year at 80% power, the savings on the energy bill are well over Euro 121,000, with an anticipated ROI of just a few months. This is based on a typical energy cost for Europe of Euro 0.21/kWh. At the same time, there is a lifetime avoidance of 174,000 kg in CO2 emissions –  that is equivalent to the emissions produced when driving 40 typical gasoline powered passenger vehicles for a year - based on the average European carbon intensity factor of 0.3 kg CO2/kWh.

The savings quoted here are for just one motor. Yet typical industrial facilities will have tens or even hundreds of this size of motor, and a large plant such as a paper mill can have thousands. So the global potential to cut costs and reduce emissions is enormous.

The LV Titanium VSM offers a 2-in-1 solution that combines an IE5 Ultra-Premium efficiency PM motor and drive into one compact unit. With its groundbreaking energy efficiency, versatility, robustness, and compact design, the VSM sets a new benchmark in performance and simplicity. The platform is poised to transform industrial operations worldwide by offering a forward-thinking solution that not only meets current industry demands, but also anticipates those of the future.

Michele Maggi is R&D engineer product development at ABB

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