Energy efficiency
The key lies in the overall system
The real key to greater energy efficiency lies in the overall system: the interaction of all individual measures - from more efficient motors with variable-speed control, to digital system components and tools, to the use of electrically buffered energy in the motor network - can achieve savings of up to 60% in the system network. It is precisely the consistent analysis of system data in a networked overall system that opens up opportunities to raise energy efficiency to a new level.
Technological developments promise further efficiency gains in all systems that comply with the new efficiency standards. While only marginal improvements can be expected from the future and more costly IE5 standard alone, the switch to variable-speed IE4 applications and thus "super premium efficiency" offers extremely efficient leverage for the overall optimization of existing systems for the foreseeable future. This is especially true with regard to digital system components: The development of the capabilities of analysis tools and self-learning industrial edge applications is far from complete, but has only just begun. With the data that modern motors and inverters already collect today, it will be possible in the future to realize even more significant increases in efficiency simply by further developing the corresponding software.
What are the success factors for the efficient powertrain?
Motors:
Even simple electric motors achieve high efficiencies of more than 90% due to their design. A modern 200 kW AC asynchronous motor to the IE3 standard achieves an efficiency of around 96%. New motors such as the Simotics low-voltage motors that meet the IE4 "Super Premium Efficiency" standard reduce energy losses by a further 15% and achieve the highest system efficiencies even in part-load operation.
Frequency converter:
It is often more efficient to use more and smaller motors that are precisely optimized for their specific tasks than to use a larger motor to permanently maintain excess power. In order to ensure greater flexibility at the same time, converters are used that adjust the motor to suit each requirement so that the drive is operated in an energy-optimized manner even in partial load operation.
The system approach:
In the industrial environment in particular, solution approaches are needed that take into account the system with its interactions and synergy effects and align it optimally at all times. The basis for this is provided by intelligent sensors and analysis tools that monitor, harmonize and improve all processes - from control and automation to energy management and maintenance with predictive maintenance to digital planning and implementation processes with a digital twin - as part of a higher-level system approach.
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