High-efficiency drive solutions for maximum energy savings and sustainability in your company.
What is the main advantage of an IE5 synchronous motor over older motors (e.g., IE3)?
IE5 synchronous motors offer significantly lower energy losses – up to 20% less than IE4 and sometimes over 40% less than IE3 motors. This leads to substantial energy savings und higher efficiencies, especially in partial load operation.
How quickly is the investment in an IE5 synchronous motor paid back?
The payback period (ROI) for an IE5 synchronous motor can often be within 1-2 years , depending on operating hours and energy prices. The significant energy savings and potentially lower maintenance costs contribute significantly to this.
Are IE5 synchronous motors suitable for all industrial applications?
Yes, IE5 synchronous motors are very versatile. They are ideal for applications with long operating times or variable loads, such as in intralogistics, food and beverage industry as well as in general mechanical engineering and in pump and fan applications.
What role does the IE5 synchronous motor play in reducing the CO2 footprint?
Due to their high energy efficiency IE5 synchronous motors significantly reduce electricity consumption . A 0.75kW IE5+ motor can, for example, save around 0.15 tons of CO2 per year compared to an IE3 motor at 4,000 operating hours.
Does ATEK also offer complete drive systems with IE5 motors?
Yes, ATEK Drive Solutions is a system provider and supplies complete drive trains. These consist of highly efficient IE5 synchronous motors, compatible gear boxes and brakes that are optimally coordinated to ensure maximum system efficiency .
How does ATEK assist in the selection and design of an IE5 synchronous motor?
ATEK offers comprehensive technical consulting by experienced engineers. We support you in the detailed design, optimization and selection of the right components for your specific application to achieve maximum energy savings and performance.
What does ‘Ultra Premium Efficiency’ mean in the context of IE5 motors?
IE5, or ‘Ultra Premium Efficiency’, is the highest internationally standardized energy efficiency class for electric motors according to IEC 60034-30-1. It characterizes motors with the currently lowest energy losses on the market.
Are IE5 motors also efficient in partial load operation?
Yes, a key advantage of IE5 synchronous motors, especially permanent magnet synchronous motors (PMSM), is their consistently high efficiency even at partial load. This is crucial for applications with varying loads, to continuously and effectively save energy.
IE5 synchronous motors achieve the highest energy efficiency class and reduce energy losses by at least 20% compared to IE4 motors, leading to significant direct energy savings .
The use of IE5 motors enables a significant reduction in operating costs through lower energy consumption – often the investment is paid back within 1-2 years – and makes an important contribution to the reduction of CO2 emissions.
ATEK Drive Solutions offers as a system provider tailored drive solutions mit highly efficient IE5 synchronous motors, optimally combined with gear boxes and brakes and supported by competent technical consulting for system design..Discover how ATEK Drive Solutions with IE5 synchronous motors lowers your operating costs while protecting the environment. Learn more about the benefits, application areas, and saving potentials of this innovative technology.
Are you ready to reduce your energy costs while contributing to environmental protection? The high-efficiency IE5 synchronous motors from ATEK Drive Solutions offer you the opportunity to do so. Contact us at this link, to find out how we can help you.
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Introduction to high-efficiency IE5 synchronous motors.
The importance of energy efficiency in industrial drive technology
Drives are often major consumers of electricity in the industry. Increasing energy efficiency is becoming rapidly important in light of global climate goals and rising energy prices. Modern, high-efficiency drive technology can often reduce energy consumption and thus energy costs by 15% or more, which represents a significant energy saving . Optimized drive systems, such as the highly efficient IE5 synchronous motor for energy saving, are therefore not only ecologically sensible but also economically necessary.
The growing demand for energy-efficient solutions
Companies are increasingly under pressure to operate more environmentally friendly and resource-efficient. EU regulations, such as the Ecodesign Directive and EU Regulation 2019/1781, continuously tighten the requirements for the energy efficiency of motors. The early use of the highest efficiency classes, as represented by the IE5 synchronous motor , secures sustainable competitive advantages and avoids later, costly retrofitting. Der Energy-saving calculator for motors clearly illustrates the potentials for energy saving.
Presentation of the IE5 synchronous motor as an answer to increasing demands
IE5 synchronous motors represent the current peak of energy efficiency, achieved through innovative designs and the use of high-quality materials. They achieve significantly higher efficiencies compared to older efficiency classes; for example, they enable a loss reduction of about 20% compared to IE4 motors. The IE5 technology is a key to significantly reducing energy consumption and the associated CO2 emissions, thereby realizing a maximum energy saving .What is an IE5 synchronous motor and why is it so efficient?
Functioning and technology of synchronous motors
Synchronous motors, especially the highly efficient IE5 synchronous motor, are characterized by their rotor rotating without slip and hence synchronously to the stator’s rotating field. This design avoids principle-related losses. Permanent magnet synchronous motors (PMSM) utilize permanent magnets in the rotor to achieve even higher efficiency and thus more energy saving . The precise and low-loss operation is fundamental to the outstanding IE5 efficiencies and the high potential for energy saving. Further information on the power factor is also relevant.
- Rotate without slip and synchronously to the stator’s rotating field, which due to design avoids losses and significantly contributes to energy saving .
- Use permanent magnets in the rotor (as permanent magnet synchronous motors, PMSM) for significantly higher efficiency, a core feature of the highly efficient IE5 synchronous motor.
- Permanent magnets generate the necessary rotor field without energy consumption and thus eliminate ohmic rotor losses, maximizing energy saving and increasing the efficiency of the motor.
- Enable a high power density and thus more compact designs compared to other motor types, making the IE5 synchronous motor particularly versatile.
- Maintain high efficiencies even in partial load operation, which is particularly advantageous for continuous energy saving .
- IE5, defined as ‘Ultra Premium Efficiency’ according to IEC 60034-30-1, stands for the currently lowest motor losses (at least 20% less than IE4), which distinguishes the highly efficient IE5 synchronous motor as a leader in energy efficiency.
Permanent magnet synchronous motors (PMSM) in detail
PMSM, a typical design of the highly efficient IE5 synchronous motor, have rotors that are equipped with high-energy permanent magnets (often based on rare earths). These magnets generate a strong magnetic field without additional energy expenditure, allowing for a high power density and compact motor dimensions. The elimination of rotor losses significantly improves the energy balance of the motor and leads to significant energy saving.
The role of permanent magnets for high efficiency
Permanent magnets in the rotor generate the magnetic field without electrical energy, thereby completely eliminating ohmic rotor losses as seen in asynchronous motors. In contrast to asynchronous motors, PMSMs, such as the IE5 synchronous motor, maintain their high efficiencies even in partial load operation. This is particularly advantageous for the energy saving in applications with variable load profiles.
IE5 as an efficiency class: definition and advantages
The international standard IEC 60034-30-1 defines IE5 as ‘Ultra Premium Efficiency’. This class characterizes motors with the lowest energy losses, which are at least 20% lower than those of IE4 motors. The switch to a highly efficient IE5 synchronous motor sustainably reduces energy costs through maximum energy saving and makes an important contribution to CO2 reduction. While IE3 motors already provide good efficiency, the IE5 standard represents a significant improvement.Advantages of the IE5 synchronous motor for companies
Energy savings and CO2 reduction
Highly efficient IE5 synchronous motors enable significant energy saving and thus directly contribute to the reduction of CO2 emissions. For example: A 0.75kW IE5+ motor, as a representative of the highly efficient IE5 synchronous motors, can save around 0.15 tons of CO2 per year compared to an IE3 motor with 4,000 operating hours. In large industrial plants with many drives, these savings add up considerably. Every kilowatt hour of electricity saved reduces the CO2 footprint and conserves valuable resources. energy saving gesparte Kilowattstunde Strom senkt den CO2-Fußabdruck und schont wertvolle Ressourcen.
Cost efficiency and return on investment (ROI)
Although IE5 synchronous motors initial costs may be higher at first purchase, they often pay off quickly due to the achieved energy saving and the resulting lower energy consumption. A return on investment (ROI) can for example be achieved after about 13 months. Additionally, lower maintenance efforts and a longer lifespan are often possible. A comprehensive total cost of ownership (TCO) analysis clearly demonstrates the economic viability of the highly efficient IE5 synchronous motor.
Contribution to sustainability and environmental protection
Sustainable operations are increasingly becoming a decisive success factor for companies. The implementation of highly efficient IE5 synchronous motors makes an important contribution to environmental protection. The IE5 synchronous motor reduces energy and raw material consumption (e.g., through optimized use of copper and rare earths) due to its superior efficiency, which supports efforts towards energy saving and positions companies as responsible players.Application areas of the IE5 synchronous motor
Intralogistics and conveyor technology
In intralogistics, where drives often operate continuously or at partial load, highly efficient IE5 synchronous motors particularly advantageous for the energy saving. Typical applications include conveyors and sorting systems. IE5+ motors, an advanced variant of the IE5 synchronous motor, can maintain efficiencies of up to 95% even in partial load conditions. This leads to significant energy saving and reduced operating costs in logistics centers.
- Intralogistics and conveyor technology, where they enable maximum energy saving performance (e.g., in conveyors and sorting systems, ideal for the highly efficient IE5 synchronous motor).
- food and beverage industry, particularly through special designs of the IE5 synchronous motor in hygienic design (protection class IP69K), meeting the highest cleanliness standards.
- Filling and packaging machines, which benefit from both the high efficiency and the potential of the energy saving as well as the hygienic properties of the IE5 synchronous motor profit.
- Electric vehicles and hybrid drives, where the highly efficient IE5 synchronous motor is considered a key technology for environmentally friendly mobility due to its outstanding power density and efficiency.
- Applications with frequently changing load profiles, as IE5 synchronous motors excellent efficiencies can also be achieved in partial load conditions, thus maximizing the energy saving over the entire operating cycle.
- Industrial applications in general that want to utilize the efficiency advantages and technologies of the highly efficient IE5 synchronous motor from e-mobility to implement comprehensive energy saving .
- Pump and fan applications, where accurate control and maximum energy efficiency through the IE5 synchronous motor are required to achieve significant energy saving .
food and beverage industry
Specifically for the food and beverage industry with its stringent hygiene requirements, there are special designs of the highly efficient IE5 synchronous motor in what is known as hygienic design, often with protection class IP69K. The combination of outstanding energy saving through efficiency and uncompromising hygiene makes the IE5 synchronous motor ideal for use in filling and packaging machines.
Electric vehicles and hybrid drives
highly efficient synchronous motors, including the IE5 synchronous motor , are a key technology in electromobility due to their high power density and excellent efficiency, as demonstrated by examples such as the BMW i3 or the VW ID. This technology, consistently designed for energy saving and high performance, has the potential to make numerous industrial applications more efficient and economical. See also the article on the permanent magnet synchronous motor for charging infrastructure.ATEK Drive Solutions and the IE5 synchronous motor
ATEK as a system provider for the complete drive train
ATEK Drive Solutions positions itself as a system provider for complete drive trains and has decades of experience in the development and production of gearboxes, brakes, and servomotors. A comprehensive modular system allows for millions of configuration options. This system competence ensures the optimal coordination of a highly efficient IE5 synchronous motor, gearbox and brake for maximum energy saving and system efficiency.
The IE5 synchronous motor offering from ATEK
ATEK’s portfolio includes highly efficient IE5(+)-high-performance servomotors, specifically developed for maximum energy saving, highest dynamics and precision. These motors can be optimally combined with gearboxes and brakes from the ATEK program into compact and customized drive units. Customers thus receive a perfectly matched, energy-efficient solution from IE5 synchronous motor a single source.
Technical advice and support in design
The correct selection and design of the drive is crucial for its performance and efficiency. ATEK’s experienced engineers assist customers in detailed design, optimization, and selection of the appropriate highly efficient IE5 synchronous motor as well as the accompanying components. An online configurator for gearboxes further facilitates initial selection. Our expertise ensures a drive solution that enables maximum energy saving and is also reliable, durable, and economical.Challenges and future perspectives
Competition and market development
The market for drive technology, including highly efficient IE5 synchronous motors, is dynamic and requires continuous innovation as well as a strong customer focus. Adapting to technological change, for example through investments in servo and digital competencies, is essential for providers. The goal is to offer technologically leading and economical drive solutions that significantly contribute to the energy saving for users.
Technological advancement
The development of electric motors, even beyond the standard of highly efficient IE5 synchronous motor , is continuously progressing; research on IE6 motors is already underway. New materials, innovative motor designs, and advanced electronics promise further efficiency increases and thus even greater potentials for energy saving. An example of this is synchronous reluctance motors. ATEK closely follows these developments to always provide state-of-the-art technologies. Information on alternative technologies can be found, for example, in our article on the synchronous reluctance motor for industrial vacuum cleaners.
The role of digitization
Digitization offers numerous opportunities for optimizing drives and drive systems. Condition monitoring and predictive maintenance increase availability and efficiency. IE5 synchronous motors can be excellently integrated into Industry 4.0 concepts thanks to their modern technology, where motor sensor data can be used for intelligent monitoring and predictive maintenance. Connected drives with the highly efficient IE5 synchronous motor increase overall plant effectiveness, support efforts for energy saving and lower operating costs.
Highly efficient IE5 synchronous motors offer enormous potentials for reducing energy costs through sustainable energy saving and promoting ecological sustainability. A comprehensive system view of the entire drive train is essential to fully exploit the advantages of the IE5 synchronous motor . The expertise of specialists helps to find optimal and future-proof solutions, thereby strengthening competitiveness. Individual advice on the possibilities of the highly efficient IE5 synchronous motor for energy savings is always available.
