Ensuring Electric Motor Efficiency and Quality of Overhauls & New Purchases
This blog presents a selection of Motors and compares No Load Results
Introduction
Induction motors are widely used in industrial and commercial applications due to their robustness, reliability, and efficiency. However, like all electrical machines, they experience energy losses even when operating without a mechanical load. These losses, known as no-load losses, occur due to various factors such as magnetic hysteresis, eddy currents, mechanical friction but also defects in Manufacture or Overhaul.
Understanding no-load losses is crucial for optimizing motor efficiency and reducing energy consumption.
What Are No-Load Losses?
No-load losses refer to the power consumed by an induction motor when it runs at rated voltage and frequency without any external mechanical load. These losses are present regardless of whether the motor is driving a load or not and consist of:
1. Core Losses (Iron Losses)
- Hysteresis Loss: Caused by the repeated magnetization and demagnetization of the stator core. This loss depends on the magnetic properties of the core material and the frequency of the AC supply.
- Eddy Current Loss: Occurs due to circulating currents induced in the iron core by the alternating magnetic field. Laminated cores are used to minimize this loss.
2. Mechanical Losses
- Friction Loss: Results from bearing friction and rotor windage (air resistance).
- Windage Loss: Caused by air resistance as the rotor spins inside the motor.
3. Stray Load Losses (Minor)
- These are additional losses due to leakage fluxes and harmonic effects, though they are relatively small under no-load conditions.
Why Are No-Load Losses Important?
- Energy Efficiency: Even when idle, motors consume power due to no-load losses. Reducing these losses improves overall efficiency.
- Heat Generation: No-load losses contribute to motor heating, affecting insulation life and reliability.
- Cost Implications: Continuous no-load operation increases electricity bills, making it essential to minimize losses.
How to Measure No-Load Losses
No-load losses can be determined by conducting a no-load test on the induction motor:
1. Run the motor at rated voltage and frequency without any load. (Nothing Connected to the Shaft)
2. Measure a Single Phase of Current with EmPower Motor Current Signature Analysis.
3. Since there is no load, the input power equals the no-load losses (neglecting small stator copper loss).
The no-load power factor is typically very low (high reactive power) because most of the input power is used to magnetize the core rather than perform useful work.
How to Reduce No-Load Losses
1. Use High-Quality Core Materials: Amorphous steel or high-grade silicon steel reduces hysteresis and eddy current losses.
2. Optimize Air Gap: A properly designed air gap minimizes magnetizing current and core losses.
3. Efficient Cooling Systems: Proper ventilation reduces windage and friction losses.
4. Premium Efficiency Motors: Motors designed with lower no-load losses (e.g., IE3 or IE4 class) offer better performance.
5. Avoid Unnecessary Idling: Turning off motors when not in use prevents continuous no-load losses or Lightly loaded application should size the Motor to 80% of rated current.
More importantly conduct Acceptance Testing of Motors upon Purchase or Overhaul, as defects like Bearings, Rotor Quality, Air Gap variations, Winding defects, Core Loss all effect Efficiency and Poor Quality Winding Practice.
Conclusion
No-load losses in induction motors represent an inherent inefficiency that impacts energy consumption and operational costs. By understanding these losses and implementing strategies to minimize them, industries can enhance motor efficiency, reduce energy waste, and improve overall system performance. Investing in high-efficiency motors and proper maintenance ensures long-term savings and sustainability.
Real World Testing
I have searched the internet on this topic and while a number of articles are quite interesting to read few or none actually publish figures and examples.
3Phi Reliability represent EmPower in Europe which was released to market early 2025. I have had the opportunity to conduct testing in multiple Overhaul facilities and a Motor Manufacturer for No Load Testing.
The vast majority of testing with EmPower has been at end users operating at load.
Seven Motors have been Analyzed with EmPower
No Load Rated Current No Load % Defect
1. 250kW 4 Pole 60.61 Amps RMS 437 Amps 13.86% Rotor
2. 30kW 4 Pole 9.7 Amps RMS 53.8 Amps 18.02% Dynamic Ecc
3. 37kW 2 Pole 8.71 Amps RMS 63.5 Amps 13.71% Rotor/Static Ecc
4. 500kW 2 Pole 77.28 Amps RMS 865 Amps 8.93% Rotor/Static Ecc
5. 800kW 4 Pole 196.2Amps RMS 1390 Amps 14.11% Rotor/Bearing
6. 200kW 67Hz wound 17.34 Amps RMS 346 Amps 5.01% Pass
7. 1090kW 6 Pole 40.11 Amps RMS 1106 Amps 3.62% LowBearing Pass
An Example of the defect in 37kW 2 Pole Motor 2
Findings Results: Possible severe rotor bar defect
Unbalance or Misalignment detected
Static Eccentricity
Dynamic Eccentricity
Reviewing the Results: As Motor sizes increase the Efficiency also follows, and the speed also makes a difference. Slower speed motors have less windage losses.
These results show that Rotor Quality and Static Eccentricity (Build Quality) dominate the Efficiency losses. The example of Motor 5 with a suspect Rotor defect is consuming approx 8% more no load loss.
Rotor Defects are proportional to Load so this loss of 8% is likely to remain at load.
EmPower calculates the Energy lost for each type of defect. In this case Motor 7 with 3.62% No Load Current, shows Bearing Defect as the highest loss.
I would recommend running this motor for an hour and retaking the data to give time for any lubricant to fully distribute.
Additional Data: PPF: 0.143 Hz, 93.660 W
Speed: 19.573 Hz, 33.566 W
Stator Slot Base: 939.493 Hz, 17.787 W
Rotor Bar Base: 19.573 Hz, 33.566 W
DE OR: 61.302 Hz, 251.015 W
DE IR: 95.124 Hz, 15.862 W
DE Cage: 7.653 Hz, 31.724 W
DE Ball: 42.982 Hz, 34.407 W
ODE OR: 60.989 Hz, 302.834 W
ODE IR: 95.593 Hz, 29.715 W
ODE Cage: 7.614 Hz, 28.162 W
ODE Ball: 42.101 Hz, 39.100 W
Total Watts: 911.399 W
Estimated Load (%): 3.627
Estimated Energy (kW): 39.530
Would you like a more detailed analysis on any specific aspect of Acceptance Testing Motors? Let me know in Contact Us.
#EnergyEfficiency #EmPower #MotorLosses #NoLoadLosses
EmPower in Europe contact
Mark Gurney Motor Analyst
www.3phi-reliability.com/contact-us
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