Schneider Electric - Effective design and management of motor applications is the first step to an energy-efficient and sustainable industry
Most processes in industrial plants depend on electric motors. Electric motors are thus critical assets for many industrial activities, but at the same time also major consumers of energy. In a factory, for example, electric motors can be responsible for up to 95% of total electricity consumption. The potential to save energy in a simple way is therefore enormous in industrial processes. Effective design and management of motor applications is the first step in harnessing this potential and reducing pollution from CO2 emissions.
Make use of energy-efficient electric motors
An electric motor converts electrical power into mechanical power. The degree to which this happens is called motor efficiency or also motor efficiency. The higher the efficiency standard, the less energy the motor consumes. These efficiency standards are known internationally as the IEC standards, with ratings ranging from IE1, IE2, IE3, IE4 to IE5. IE here stands for International Efficiency and indicates how energy-efficient an electric motor is. The higher the number, the higher the energy efficiency and thus the higher the savings.
Apply variable speed control
When a motor is energized, it ramps up to a fixed speed. In many industrial applications, the motor runs at full power when in reality less power may be required. Applying an AC drive makes it possible to control the speed of an electric motor and adjust the power delivered to match the energy requirements of the application. By reducing the speed, energy consumption can be optimized and less energy is wasted.
Choose the right motor control method
The key to obtaining maximum efficiency is not only varying the speed, but also choosing the right motor control method that ensures the best torque-speed performance of the motor. Altivar Process AC drives
from Schneider Electric include built-in features to operate the motor at the best efficiency point to reduce electricity consumption by at least 30%. These type of AC drives incorporate various motor control methods, such as energy-saving control and Adaptive Cascade Vector Control (ACVC), which ensures high dynamic response to load and optimizes energy performance.
Analyze and monitor energy consumption
Measuring energy consumption is essential to identify inefficient energy use. A simple speed controller follows the system's instructions to regulate when and how fast the motor should run. An intelligent controller goes well beyond basic controls, collecting and analyzing information that enables it to respond in real time to changing process conditions. Altivar Process AC drives offer several energy-saving features and integrated dashboards and timeline reports for energy monitoring that help users manage and optimize energy consumption over time.
Create detailed analyses to calculate energy savings potential 
To support partners and customers in designing an energy-efficient motor control system, Schneider Electric has developed a dedicated tool: EcoStruxure Motor Management Design web application. This easy-to-use tool integrates the design aspects of your application to support you in designing a complete and energy-efficient motor management architecture. With the help of the Energy Saving Calculator, detailed analyses can be performed on such things as the energy and costs that can be saved per year when using a variable speed drive, the ROI and payback time of the investment in a variable speed drive, and the reduction of CO emissions.