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Energy Saving on Industrial Drive Technologies - Past, Present, and Future

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DOI: 10.1088/1757-899X/906/1/012005

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Energy Saving on Industrial Drive Technologies - Past, Present, and

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VCADPCA 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 906 (2020) 012005 doi:10.1088/1757-899X/906/1/012005

Energy Saving on Industrial Drive Technologies - Past, Present,

and Future Perspective
M. Baranidharan1, R. Rajesh Kanna1, R. Raja Singh2
1
School of Electrical Engineering, Vellore Institute of Technology, Vellore, India.
2
Advanced Drives Laboratory, Department of Energy and Power Electronics,
Vellore Institute of Technology, Vellore, India.
Correspondence: [email protected]

Abstract. Power is a crucial factor in sustainable economic development and growth, the world
is facing the obstacles to pass towards a cleaner and more accessible route for utilization, a recent
review of new developments in the energy-efficient sectors, concentrating on selected
innovations instead. Efficiency of energy for various application, enhancing the productivity,
performance and precision. At the same time, using the energy efficiently on any industrial
applications reduces the operation cost, therefore adopting suitable energy efficiently to the
system in a conventional profit. Also, there is no limit for innovation of new energy saving
technologies. These technology is defined by in terms of their energy efficiency, economy and
performance in the environment. This paper provides an overview of energy savings on industrial
drive technologies, sustainable economy and the environment, are going to be running out of
technologies in the future.

1. Introduction
Energy is the primary source of power to our lives. Power has an influence on the economic and social
development of the nation in modern society. Due to instant availability, controllability, flexibility and
cleanliness, electric power plays a prominent role in [1-2]. Over the last few decades, electrical energy
has led to human well-being, growth and technological advances. Adequate generation of energy and
proper use of electrical energy improves industrial investment in a country that results in gross domestic
product (GDP) production [3-6]. The motor drives of modern global industry are the backbone that is
well covered, but also play a major role in industries which often improve the world with our
environment more sustainable. Electrical energy produced at any time must be used by the consumer
within a small period of time. In figure 1 the sector wise energy consumption is mentioned, the Electric
power transmits through grid, and current distribution is centered on line impedance [7-10].

Others, 0.80%

Agricultural, 1%
Sectors

Transport, 2%
Residential, 13%

Commercial, 20%
Industry , 64%

0% 20% 40% 60% 80% 100%

Energy Usage (%)

Figure 1. Sector wise energy consumption

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VCADPCA 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 906 (2020) 012005 doi:10.1088/1757-899X/906/1/012005

In general, drives are commonly used for various application especially, fan, pump, compressor [11-
12]. Similarly, the drives are adapted to perform any one of the function, speed control, process control
in AC drives, high velocity drives, continuous frequency drives, VSD, frequency converters, power
converters and inverters, By varying the frequencies and voltage of the power supply to an electric motor
[13], drives can control the speed, enabling process control to be enhanced, reducing energy utilization
and producing energy reliably or controlling the function of industrial applications based on electric
motors [14-15].

1.1. Electric Drives for Industrial Application

Electrical drives are widely used in manufacturing industries and process industry to regulate the speed
and to enhance the efficiency of the system. Such specifications are used to assess the demands for
horsepower and torque. Owing to low starting torque requirements reduced voltage starters can be used
[20].

Table 1. Industrial Drives Application

Industry Application of Drives Motor Type Year &

Citation
Petrochemical Energy savings and process control Three phase induction 2002 [5]
industry optimization. motor
Pharmaceutical Minor alterations in the Design stage Brushless DC, AC squirrel 2003 [13]
industry and improve the energy efficiency cage, wound rotor, stepper
and servo motors.
Textile industry Controllers in energy saving. Induction motor 2007 [1][17]
Steel industry Reduced maintenance costs and saved AC Synchronous motor 2008[2][18][19]
a considerable amount of electricity.
Petrochemical Reduced Total Cost of Ownership and Three phase induction 2008 [4][21]
industry improve energy efficiency. motor
Cement plants Compare the operational Squirrel cage induction 2009 [9]
characteristics of the induction, motor
synchronous and DC motors.
Mineral products Converting DC systems to AC systems AC synchronous motor 2014 [8]
industry
Garments Reduce emissions for different energy- Brushless DC/ induction 2016 [14][26]
industry saving schemes. motors
Iron and steel Improvement of performance and more AC Synchronous motor 2017 [3]
industry energy-efficient
Oil, Fans are using air exchange, drying / Induction motors 2018 [6][22]
petrochemical, cleaning purposes.
pulp industry
Paper industry Reduce the energy input and Induction motors 2019 [7][23]
improving energy efficiency
Mining industry Improving its sustainable and efficient Induction motor 2019 [12][25]
industrial operating.

1.2. Industrial Revolution

Industrial Revolution, in modern history, the trend of moving with an agriculture and economy driven
by manufacturing industry and machinery. That process started in the 18th century in Britain and
expanded to other regions of the world from everywhere.

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IOP Conf. Series: Materials Science and Engineering 906 (2020) 012005 doi:10.1088/1757-899X/906/1/012005

Mechanisation,
Mechanical power Generation
1.0
1800
Eg: Steam Engine Industry
Electrification, Industrialisation 2.0
Eg: Henry Ford 1900
Industry
Digitalisation, Electronic Automation 3.0 1960
Eg:NC’s,PLC,Comp Industry
Industry 4.0, Cyber physical system 4.0
Today
Eg: IOT,Smart Automation Industry
Figure 2. Stages of industrial revolutions

The main features of a four industrial revolutions are the first industrial revolution are transformed our
economic and lives from the agricultural field and manufacturing economics to a production and
machinery-dominated economy. The initial manufacturing revolution introduced in 1760 when the
steam machine was invented. The second manufacturing revolution began in 1900 when the inner
burning engine was invented. In 1960 the third industrial revolution began to be characterized by the
use of microchip technology and IT for automating manufacture. The Fourth Industrial Revolution
describes a future in the people turn from virtual worlds to offline reality using connected technologies
to make life possible and controlled and also it includes computer-generated product design and 3D
printing which can build up successive layers of materials to produce solid objects are shown in figure
2 [16].
Over the past few decades, public awareness of environmental concerns has led to a strong focus on
topics such as resource-efficient, and energy-efficient development in both research and industrial
applications. Numerous studies were performed, evaluating the energy usage of manufacturing
environments from different perspectives. Among other things, the results showed substantial energy
consumption during periods of non-value adding, i.e. during times when production equipment is
stopped or idled, for almost every considerable way of classifying machinery and in almost all major
manufacturing industries.
A method was designed to provide a standardized collection of possible energy-saving states for the
production equipment, clustering these states according to the commonly applicable equipment
behaviour. Improving energy efficiency and increasing demand for energy are commonly seen as the
most promising, fastest, cheapest and safest means to mitigate climate change. Most incentives tend to
be cost-effective at current levels of energy, and can provide additional benefits such as increased fuel
poverty reduction and increased economic productivity. As a result, the International Energy Agency
(IEA) and other organizations are placing their priority on reducing energy demand, the European
Commission has set long-term targets to reduce energy demand, and countries around the world are
implementing a range of policies to achieve those reductions.

1.3 Energy Conservation on Industrial Drives

Energy saving means by reducing energy demand by means of a smaller amount of an energy used.
Although energy saving reductions vitality properties, it can contribute to improved quality of the
climate, national security, individual financial protection and advanced savings. Energy saving is a
significant element of vitality policy on a broader scale [24]. Vitality competence is also greatest

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VCADPCA 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 906 (2020) 012005 doi:10.1088/1757-899X/906/1/012005

economical approach to power losses. Energy saving is certainly of great position to us all, because its
depend on energy for all the day [1]. Energy is generated – this is equal to 2 units of energy created its
save one unit of energy. Saving energy to reduce pollution – generating and utilizing energy accounts
for a large amount of air pollution and extra 83% of greenhouse gas emission productions [26-28]. If
the highest of the ladder for renewable energy. It also reducing the energy costs and potential depletion
of resources. Resource can be conserved by reducing waste and losses, increasing efficiency by
technological changes, and improving the operation.

2. Energy Efficient Strategies on Electric Motor Drives

The manufacturing sector consumes more energy for all other end-use areas and this industry actually
absorbs nearly 20% of the universe total energy supply. Energy is used in the manufacturing area by a
diverse business population, including manufacturing, forestry, mining and construction, and for a wide
range of activities, including production and assembly, room conditioning, and lighting [30]. The various
energy efficient strategies are discussed in figure 3.

Motor
management
Minimizing plan
voltage Maintenance
unbalances

Power Energy Energy

factor Efficient efficient
correction motors
Strategies

Using Rewinding of
Adjustable motors
speed drives
Proper motor
sizing

Figure 3. Energy efficient strategies

2.1. Management Plan of the Motor

An engine controlling system is the important share of a company's energy managing plan. The
implementation of an engine management plan would help companies achieve long-term energy savings
in the engine system, which will ensure efficient and cost-effective control of motor failures.

2.2. Maintenance
Motor preservation objectives remain to extend motor lifetime and anticipate a malfunction in the
engine. Therefore, motor maintenance steps may be considered as either predictive or preventive.
Preventive steps contain minimization of power inequity, awareness of weight, alignment of the motor,
lubrication and ventilation of the engine.

2.3 Energy-Efficient Motors

Efficient power engines minimize the energy consumption by improved construction, improved
products, tighter tolerances and advanced production techniques. Energy-efficient motors can also stay
warmer with proper installation, can also decreasing heat loads on the facility and have extreme duty
numbers, longer containing life, longer life span of insulation and much less noise.

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IOP Conf. Series: Materials Science and Engineering 906 (2020) 012005 doi:10.1088/1757-899X/906/1/012005

2.4. Rewinding of Motors

For certain situations, rewinding a current, energy-efficient engine can be cost-effective, rather than
purchasing a new engine. When repairing or rewinding an engine, it is critical to select an engine facility
center that meets best preparation motor reversing standards to reduce possible losses to performance.
The rewinding is applied efficiency losses are typically reduced less than 1%.

2.5. Proper Size of the Motor

Its common misconception that huge motors, particularly engines working less than 50 percent of the
valued load, are not effective and must be directly changed by energy-efficient components of sufficient
size. In fact, it takes many pieces of information to complete an accurate evaluation of energy saving.

2.6. Adjustable Speed Drives

Its ideally suited to load supplies for engine processes, thereby ensuring the engine energy usage for
customized by particular uses. Because is motors' vitality consumption is about comparative flow rate
cube, relatively small movement decreases, proportional to the pump speed, still result in significant
energy savings.

2.7. Power Factor Correction

Energy metric is really the proportion of power delivered and work-time. That tests how power
generation is being used properly. A high-power factor signifies a successful use of electric energy while
a low-power factor implies inefficient use of electrical energy.

2.8. Minimizing Unbalances in Voltage

An imbalance in voltage reduces the presentation of three-phase engines and shortens their life. A
voltage imbalance produces a current imbalance, resulting in rotation pulses, improved pulsation and
mechanical strain, augmented losses, and motorized warmness, which container minimize the lifetime
of the engine's winding protection.

3. Trends in Energy Saving

Energy efficiency has massive potential to boost financial growth and reduce greenhouse gas emissions,
but a trend which has major impacts on people, companies and the environment is slowing the global
rate of progress. The energy sector continues to turn its attention to energy efficiency with rising
regulations. Industrial energy use remained roughly constant at EU level and since then has fallen rapidly
twice as fast as industrial activity in figure 4[3].

Figure 4. Global renewable energy trends (source: https:www.deloitte.com)

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IOP Conf. Series: Materials Science and Engineering 906 (2020) 012005 doi:10.1088/1757-899X/906/1/012005

3.1. Past Trends in Energy Saving

An analysis of these remarkable achievements helps explain both the factors its inspiring the combined
motor drives and contemporary expansions in power electronics expertise that complete those induction
motor drives (IMDs) possible. Such advancements are listed in a roughly sequential instruction to type
it informal to classify the evolution of the expertise that has complete building more advanced IMDs
technologically feasible [11].

3.1.1. Automotive Alternators

Moreover, the industrial inverter chosen for its first instance may not classify as an incorporated drive
system but are included in this segment as it provides an essential reference to the following IMDs.
Additional precisely, in an unregulated full-wave bridge configuration, the power electronics consists
of 6 (or more) diodes short of any measured control buttons required to create variable-frequency ac
power waveforms. The close connection with automotive generators and IMDs relates to the fact that
the diode devices are mounted inside the alternator framework in areas close to the Lundell claw-pole
synchronous alternator assembly, introducing both to a higher heat and vibration factors to follow this
charging design.

3.1.2. Blower Fan Drive Electronically Commuted Motor (ECM)

Some of the initial main IMD devices designed for a residential usage in applications for boiler,
ventilation and air preparing (HVAC), the Electronically-Commutated Engine, primary published as a
creation in 1987. The ECM was intended aimed at usage in housing and bright profitable HVAC devices
such as heater blowers anywhere they offered a way to improve the overall efficiency and comfort of
the furnace system by in case adjustable-speed air flow to the active places rather than traditional on-off
thermostat created regulator through a fixed-speed line.

3.1.3. Submersible Water Pump

Installing the motor and drive in the underground submersible pump unit enabled the control cabling
essential in the well shaft to be reduced although using the impelled water as an abundant then efficient
refrigerant for the motor and electronic drive.

3.1.4. Industrial-Grade Integrated Motor Drives

Modern motor drive manufacturers have produced combined motor drive product lines that are designed
for overall industrial uses such as pumps and fans / blowers that result from adjustable speed operation
in performance improvements and energy cost savings [31].

3.2. Present Trends in Energy Saving

By integrating solar energy systems for hot water and producing electricity, we achieve a further
reduction in energy consumption. Recently there has been an increasing trend in the integration of solar
photovoltaics in buildings.

3.2.1. Design of Energy Efficient Motors

Efficiency has a direct impact on energy consumption and the conservation of energy. Motor charging,
relative to full load, affects the motor's efficiency and overall performance. The efficiency can be
increased by reducing losses which can be a combined effect of decreasing the number of turns,
increasing the size of the conductor and increasing the length of the core causing an increase in the
efficiency [32].

3.2.2. The Generation IMMD with GaN-Based Power Electronics

Its benefit of GaN power devices benefit the third-generation IMMD prototype systems to reduce
inverter form and capacity, with advanced changing frequencies then lesser conductive damages. The

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IOP Conf. Series: Materials Science and Engineering 906 (2020) 012005 doi:10.1088/1757-899X/906/1/012005

prototype IMMD unit also uses a 6-phase ac system like the aforementioned 2nd generation IMMD,
except it is an induction system in this case. Another distinction between the two models is that the 3rd
generation con- figures the sequence of 6 pole-drive elements into binary full-bridge 3-phase inverters,
rather than parallel ones. It allows GaN devices to be used with lower voltage levels, raising the system's
on-state resistance and conduction losses. Since this energy electronics package is placed on the outer
external of the finish bell of the motor designed for easy watching short of disassembly, the energy
electronics has remained suitably reduced towards be compatible by the inserting in the finish bell cavity
of the motor short of at all alteration in the measurements of the housing an evaluation of the 2nd and
3rd group IMMD prototype elements therefore delivers substantial indication of the optimistic effect of
elegant WBG established energy electronics on the forecasts of attaining fixed energy electronics in
upcoming IMDs.

3.2.3. Current Source Inverters enabled by WBG

A stated in Unit V.A, new WBG control semiconductors made from silicon carbide( SiC) and gallium
nitride (GaN) are attractive accessible which can turn additional 10 times earlier than their silicone
equivalents. The research communal is highly optimistic that these new WBG control switches that
bring significant benefits to the uses such as IMDs, which urgently need breakthroughs leading to
smaller , lighter, and more powerful electronics.

3.3. Future Trends in Energy Saving

Evaluates or findings that suggest an operator change and to analyse driver patterns to have a sense of
where the industry is going, EPRI will track developments on a routine basis, finding significant changes
that may suggest a major effect on scenarios, drivers, global perspectives, or the Interconnected Energy
Network.

3.3.1 Ultra-efficient Heat Pumps

Stepping up energy efficiency will be needed as global demand for energy continues to rise. The
technology chances are endless and possible real investments, but so far customers and values have
remained measured to capitalize in the maximum economical, energy-efficient machineries. In-use
houses, electrical equipment, and devices' energy efficiency is well short of what is theoretically
achievable.

3.3.2 Variable Speed Drives

The AC induction motors translate the electrical energy into mechanical and other types of usage.
Therefore, about two-thirds of the electrical energy is fed to the world's motors for this reason. And the

(a)
(b)
Figure 5. Pump energy curves (a) Power savings using VFD, (b) Pump Affinity Laws

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IOP Conf. Series: Materials Science and Engineering 906 (2020) 012005 doi:10.1088/1757-899X/906/1/012005

big restriction is energy efficiency for motors. And this energy saving is accomplished largely by the
use of variable frequency power. In general, three types of major load applications are classified as
variable torque type load, constant torque type load and constant Horsepower type load [29]. VSD
control, using inverter technology, it allows the regulation of starting inrush currents, the management
of specific fixed speeds, quick change of speed and the reversal of AC motors. Such types of electric
motors are responsible for a significant part of energy usage in manufacturing, operating in combination
with fluid-moving machinery such as pumps, fans, compressors etc [33]. Most variable torque drives
have Proportional Integral Differential (PID) capability for fan and pump an application, which allows
the drive to hold the set point based on actual feedback from the process, rather than relying on
estimation. High levels of accuracy for other applications can also be achieved through drives that offer
closed-loop operation. Closed-loop operation can be accomplished with either a field-oriented vector
drive, or a sensor less vector drive. The field-oriented vector drive obtains process feedback from an
encoder, which measures and transmits to the drive the speed and/or rate of the process, such as a
conveyor, machine tool, or extruder. The drive then adjusts itself accordingly to sustain the programmed
speed, rate, torque, and/or position Variable speed drives, on the other hand, gradually ramp the motor
up to operating speed to lessen mechanical and electrical stress, reducing maintenance and repair costs,
and extending the life of the motor and the driven equipment[6].In variable torque applications, the
torque required varies with the square of the speed, and the horsepower required varies with the cube of
the speed, resulting in a large reduction of horsepower for even a small reduction in speed[7] [8].The
motor will consume only 12.5% as much energy at 50% speed than at 100% speed as shown in Figure
5 (a) and (b).

3.3.3 Energy Efficient Motors

IE3 & IE4 Motors have high efficiency at any ambient temperature. Hence these are costly than IE2
Motors. The materials cost of the motor is increased by a few percent. While trying to reduce copper
losses, we end up increasing core loss. Hence the starting current of motor is high, it may increase fault
levels and in turn cable size. The disadvantages are overcome as the payback period for the customer
can be as little as six months for a continuously loaded motor. Through improving architecture,
improving materials and improving production techniques, the energy-efficient electrical motors
decrease energy losses. Replacing an engine may be defensible based on the fuel cost savings resulting
from an energy-efficient model. It is correct if the engine is constantly running, the power levels are
great, the engine is overweight for the mission, or damage or past rewinds have reduced its nominal
performance.
IEC60034-30-1
magnet motor
Variable

Permanent
speed

Regularization
IE5: Gold Standard } Deliberation 11/4 -
95.0
Motor Efficiency (%)

IE4: Super premium

93.9
EU
U.S JPN CHN
Induction Motor

CAN KOR IE3:Premium

Constant

92.1
speed

KOR EU 15 Energy Saving Law

U.S IND IE3,IE2 + Inverter
CHN IE2: High Efficiency
AUS

IE1: Standard
88.7
-99 00 10 11 12 13 14 15 16 17 (Year)
IEC: International Electro technical Commission, JIS: Japanese Industrial Standard

Figure 6. Movement of regulation of motor efficiency

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IOP Conf. Series: Materials Science and Engineering 906 (2020) 012005 doi:10.1088/1757-899X/906/1/012005

It also has good performance as under loaded as compared with the IM, and has higher torque density
and overload capacities the movement of regulation of motor efficiency are shown in figure 6. When
less heat is produced inside, it is easier to refrigerate. Syncrel has another important benefit when it is
required to substitute the normal motors with energy efficient ones. Since the high efficiency IMs at the
same parameters are larger than the regular ones, the high efficiency SyncRels have the same height of
the centerline shaft as those to be replaced. The upgrade is therefore simple and quick, without the need
for mechanical modifications [35]. SynRel and PMSM engines it can be provided as a possible
additional to the induction engines in applications where speed variation is required, realizing in
consistency and outstanding in performance. Such machines run at synchronous speed, minimizing rotor
losses and are thus able to achieve very high performance levels, often reaching IE5 standards. The
better assets of these machineries be able to similarly remain used to greatly decrease the complete size
and mass of the engine, meaning that the design of the engine needs less materials.

3.3.4 Soft Starter with Energy Savers

The Soft Starter offers a consistent and cost-effective solution to these difficulties by supplying the
motor with a measured power issue, resulting in phase smooth, less acceleration and deceleration. As
damage to the windings and rollers decreases, motor life will increase. In 3 step units, Soft Start & Soft
Stop offers guided start and stop with a range of ramp times and current limit settings to match all
applications [34].

3.3.5 Bidirectional Converter for Energy Recovery

Most applications driven by electric drive, such as lifts, tooling machines, packaging machines, etc., are
branded by frequent stops / starts with erratic duty rounds; thus, significant energy-saving capacity exists
through the recovery of extreme kinetic energy during braking intermissions. Though, modern variable
frequency drives do not support regenerative braking, since they are normally provided by bridge diode
rectifiers. The renewed kinetic energy is thus degenerate in case of assistance of decelerating devices. It
can result in a considerable amount of vitality wastages, particularly once there are frequent stops /
starts.

3.3.6 Internet of Things (IOT)

Energy management system for commercial and industrial spaces through the Internet of Things. Using
the data that comes from a network of on-site sensors and meters, the system offers saving steps to
minimize energy usage and increase productivity. IoT can help to improve the various processes to be
more quantifiable and measurable by the large amount of data collected and processed. IoT could
potentially improve quality of life in various spheres including medical services, smart cities,
construction, Agriculture, water, and the energy sector [36].

3.3.7 Digital Twin Technology

Digital twins are used in the energy sector to optimize the functioning and maintenance of physical
assets, systems, and manufacturing processes. The digital twin is used through the visualization of
change over time to track construction and identify problems. This capability helps the team to
immediately respond to changes on-site.

Table 2. Comparison of past, present and future energy saving techniques of industrial drive
Components Past Present Future
Motor Normal motor Energy efficiency motor Light weight motor
Converter Power electronics Advanced power Silicon carbide switch
switches electronics switches
Drives Industrial-Grade IMD Adjustable speed drive VSD with digital twin
technology
Load Normal load Pump and fan load IOT based connected load

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IOP Conf. Series: Materials Science and Engineering 906 (2020) 012005 doi:10.1088/1757-899X/906/1/012005

4. Conclusion
Most developed countries have adopted legislation close to those of the European Union on energy
efficiency. Motors representing 40–50 per cent of total global energy usage are becoming the largest
appliance requiring high-efficiency standards. Currently the most common program in the motor
industry is the research and technological production of DC brushless motors. Certain R&D products
include refining motor design, enhancing silicon steel sheets electromagnetically, encouraging the
advantages of permanent magnetic fields, adjusting wire-winding technology, and developing the
electronic control system. The emerging energy saving and carbon cuts issues as well as the high-energy
price age approach have led to the rapid production and popularization of high-efficiency engines. There
is a trend towards increasing efficiency inside the electrical machine itself, but the greatest system-level
improvements occur when the machine is coupled with an electronic power converter to produce a
variable speed drive. The key drawbacks to this lie in the initial expense of a variable-speed motor, but
the payback period is very limited in many situations. Future technological developments will reduce
the cost of capital of the drive and thus existing markets will expand and new markets will open
up[10].The motor is the sector's most energy-using part. Promoting high-efficiency motors is conducive
not only to improving industrial productivity but also to reducing greenhouse gases. Several countries
have thus been discussing the enhancement of motor-efficiency requirements in their energy and
industrial policies in recent years.

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