WEG has launched its W23 Sync+ motor line, a hybrid innovation that combines permanent magnet (PM), ferrite or neodymium magnets, and synchronous reluctance (SynRM) motor technologies. The W23 Sync+ motor line meets or surpasses the current European Ecodesign regulation, which mandates motors to meet the IE3 or IE4 standard. The PMSynRM technology developed by WEG ensures a flat efficiency behavior, offering higher efficiency levels and a higher power factor than conventional induction motors. This results in a lower total cost of ownership (TCO) for plant managers.
In an era defined by evolving energy efficiency standards and a growing commitment to environmental responsibility, global motor manufacturer WEG has taken a giant leap forward with the launch of its W23 Sync+ motor line. The W23 Sync+, a hybrid innovation that combines permanent magnet (PM), ferrite or neodymium magnets and synchronous reluctance (SynRM) motor technologies, provides higher efficiency across all speeds when compared with conventional induction motors. Here Marek Lukaszczyk, European and Middle East marketing manager at WEG, introduces the benefits of the new PMSynRM technology.
WEG prides itself on staying ahead of international standards and regulations, and its new W23 Sync+ motor line is no exception. The quest for very high efficiency levels, now reaching IE6, was the driving force behind this innovation. That is why all W23 Sync+ motors meet or surpass the current European Ecodesign regulation, which stipulates that new motors must meet the IE3 or IE4 standard. WEG’s flagship IE6 variety is known as the W23 Sync+ ULTRA, while the IE3 to IE5 models are known as the W23 Sync+ general line.
As traditional induction motor technology approaches its efficiency limits, the need for alternatives has become more apparent. To achieve higher efficiency levels, electric motors must have very high inrush current levels, and this demands new starters and protection systems when replacing an existing motor. While SynRM motors offer a potential solution to meet IE6, the motors also have shortcomings such as a low power factor that necessitates larger drives and increased costs.
Higher efficiency and lower losses
The PMSynRM technology developed by WEG has emerged as the optimal choice. The design ensures a flat efficiency behaviour, boasting a higher level of efficiency for the entire speed range compared with conventional induction motors, and a higher power factor than synchronous reluctance motors.
This results in a lower total cost of ownership (TCO) for plant managers. The PMSynRM technology varies in the separation of electrical losses in the electric motor by employing magnets. The magnets generate their own magnetic field without requiring induction of currents. Therefore, they reduce the motor’s total losses.
For example, while a conventional induction motor loses over 20 per cent efficiency across its varying speed and load ranges, the W23 Sync+ maintains its higher efficiency decreasing less than two per cent when the load and speed are reduced by 25 per cent.
However, efficiency isn’t just a metric for energy consumption, it extends to the operational life of the motor. With efficiency levels reaching IE6 for the W23 Sync+ ULTRA variety and up to IE5 in the general W23 Sync+ line, both models generate less heat, which leads to a longer lifespan, fewer replacements and reduced maintenance requirements. This also eliminates the need for additional cooling.
In addition, the W23 Sync+ motor line unlocks energy savings that directly impact on facilities’ CO2 reductions. In fact, the WEG team has calculated that replacing an IE3 induction 75 kilowatt (kW) 4 pole motor with an IE6 W23 Sync+ ULTRA may result in a reduction of 126 tons of CO2 during the latter motor’s expected lifetime of 25 years. This takes into account an operation time of 6,500 hours per year.
While reducing CO2 emissions is a primary focus, the W23 Sync+ also contributes to a broader reduction in greenhouse gas (GHG) emissions. Its energy efficiency aligns with sustainable practices, which reduces the demand for natural resources and minimises environmental impacts.
Bringing the W23 Sync+ to market
Creation of the W23 Sync+ began in 2021, aligning with the global challenges posed by climate change and the increasing demand for environmental responsibility. During the development phase for the W23 Sync+, WEG’s in-house research and development (R&D) team wanted to ensure its customers could benefit from the best technical characteristics of both PM and SynRM motor technologies, which included harnessing the potential of ferrite and neodymium magnets.
The task at hand was challenging: to reduce environmental impact, decrease CO2 emissions and improve overall sustainability by exceeding ultra-premium efficiency levels. WEG’s multidisciplinary team tackled these challenges through innovation, with a view to turning obstacles into opportunities during the product’s development. WEG’s successful development of the W23 Sync+ motor line was reinforced by its robust R&D capabilities — in fact, the company invested over €122 million in R&D in 2022.
WEG’s technical competence groups, spanning electromagnetic analysis, structural analysis, lamination analysis, electrical and magnetic materials, insulation materials, polymeric materials, vibration of rotating electric machines, fluid-thermal-acoustic analysis and bearing and lubrication, work collaboratively to ensure a comprehensive approach to product development. These units serve as a linchpin for WEG’s global business growth, fostering innovation and pushing the boundaries of motor technology.
Staying ahead of international standards and regulations is pivotal and WEG achieves this by actively participating in committees such as the International Electrotechnical Commission (IEC) and the National Electrical Manufacturers Association (NEMA). The W23 Sync+ motor line stands as a testament to this commitment, holding certifications from UL, CSA, and SGS Baseefa, ensuring compliance with stringent regulations — particularly in hazardous areas.
Suitable for a range of varying load applications
The W23 Sync+ and W23 Sync+ ULTRA are available in a range of frame sizes from IEC 80 to 450 (NEMA 140 to 7000). Able to operate over a wide speed range at constant torque, without the use of forced ventilation, this multi-platform solution is available in speed ranges from 750 up to 6000 revolutions per minute (rpm). The motor’s output rating ranges from 0.75 to 1250 kW, while it is compatible with a 220/380 volt (V), 230/400 V, 240/415 V or 400/690 V power supply.
The versatility of the W23 Sync+ extends to its applications, catering to a diverse range of industries — though it is preferred in applications with varying loads. Maintaining high efficiency, even at partial load, makes it ideal for applications with load variations. The PMSynRM line is suitable for applications including compressors, pumps, fans, blowers, conveyors and more.
Another key advantage of the W23 Sync+ is its compact nature with the same power per frame ratio as induction motors. For example, the IE5 variety is available in the same frame size as an IE3 motor, which makes interchangeability with existing installations smooth and hassle free.
Global availability and technical support
Manufactured in Brazil and China, the W23 Sync+ motor line is globally available, backed by WEG’s comprehensive technical support and services. This ensures that customers worldwide can seamlessly integrate this innovative motor into their operations. Furthermore, the ferrite magnet used in the W23 Sync+ is constructed from a ceramic material, and has a local supplier and producer. This avoids global supply chain issues and results in material price stability.
In the realm of electric motors, the W23 Sync+ stands as a beacon of innovation, addressing the challenges posed by efficiency limits and environmental responsibility. WEG’s commitment to pushing the boundaries of motor technology has resulted in a motor line that not only meets, but exceeds, global standards. As industries strive for efficiency, reliability and sustainability, the W23 Sync+ emerges as a transformative force, ushering in a new era of motor technology.