Energy Efficient Appliances in a Residential Building
D Kamalakannan, V Mariappan, V Narayanan and N S Ramanathan
Advanced engineering,
Lucas TVS Ltd,
Chennai, India.
kamalakannan.engg@lucastvs.co.in
Abstract— This paper compares various electrical motors being
used in a residential electrical appliances. Most of those motors
are induction/DC/universal motors and their efficiency levels are
very low. It is an urge to develop a motor with higher operating
efficiency. With the recent development in the field of power
electronics and magnet technologies, it would be possible to meet
the above requirements with brushless direct current motor.
Nowadays brushless direct current motors (BLDC) are used in
many applications due to their advantage of high efficiency,
compact size and easy control. In this paper, performance,
efficiency and other features of various household appliance
motors such as motors in refrigerator compressor, ceiling fan, air
conditioner, washing machine, water purifier, mixer-grinder and
air cooler are all compared with those of BLDC motors.
Keywords—BLDC motors, energy efficient homes, smart
buildings
I. INTRODUCTION
The energy consumption of industrial and residential sector
increases day by day due to the population growth. An
additional power generation is needed to meet the increased
demand. As the load demand is not met with the generation
capacity, power shortage is managed by load shedding. Even
during the power availability, due to peak demand, the quality
of power is not good. Interrupted power supply leads to a poor
performance or permanent failure in the operating appliances.
In recent days the concept of micro or smart grid is popular to
address this issue of power shortage. The power demand is met
with solar, wind, diesel- generation and conventional grid
individually or a suitable combination of generation sources.
This system not only reduces transmission and distribution
losses also, it enables the user to manage the generation and
load demand by a proper energy management system. Due to
their limited availability and higher investment costs, it is high
time we use the renewable and non renewable sources
effectively.
In recent days many appliances use BLDC motors because
of their compact size, high efficiency and easy controllability.
Since, BLDC motors require DC power input it would be
possible to operate these motors with a battery or with a
common DC bus system. A separate DC bus electrical output
power is derived from any of the inputs such as renewable
sources of energy like solar, wind, tidal or from the AC grid.
BLDC motors to be used in all the appliances can draw power
from this above DC bus electrical power thereby reducing the
number of components of conversion as well as associated
losses. As mentioned earlier, a 48V DC bus Voltage system
978-1-5090-3498-7/16/$31.00 ©2016 IEEE
has been proposed by Indian Institute of Technology Madras to
address the issues of black out [1]. This project is actively
implemented in many parts of India. The various motors used
in a residential building for both AC as well as DC bus systems
are discussed in the following chapters [2].
II. CURRENT HOUSEHOLD APPLIANCE MOTORS
Electric motors are widely used in many appliances for
converting electrical energy to mechanical energy. Many
applications such as ceiling fan, refrigerator, air conditioner,
water purifier, mixer – grinder and washing machine use either
one of induction, DC and universal motor. The typical power
consumption of these appliances, range between 30W to
1500W.
A. Induction motor
Single and three phase induction motors are used in many
applications due to their simple design, low cost and long life
[3]. It works based on the electromagnetic induction principle.
When an induction motor is energized, a rotating magnetic
field is produced which links the rotor thereby producing a
current in the same. This rotor current produces an opposite
polarity of magnetic field to that of the stator. The integration
of the stator and rotor magnetic field produces a torque in the
rotor. For low power applications, single phase motors are
used. Based on the mechanism used to generate the rotating
magnetic field, induction motors are classified into shaded
pole, resistance start induction run (RSIR), capacitor start
induction run (CSIR), permanent split capacitor (PSC) and
capacitor split capacitor run (CSCR). Each type of motor has
different peak efficiency, starting torque and cost implications.
B. DC motor
Direct current motors consist of a magnetic field (main
field) producing winding in their stator and armature winding
in the rotor. The power supply is given through a brush and
commutator arrangement. DC motors are grouped into shunt
and series motors based on the connection of field winding
with armature winding . Main field can be generated either by
electromagnet or permanent magnet. The machine
construction and speed control is simple as compared to other
motors. However, this motor faces the drawback of limited
life span, poor efficiecy and also requires frequent
maintenance.
C. Universal motor
Universal motor are series wound commutator motor. In
this arrangement, stator winding is connected in series with
rotor winding and is connected through a brush and
commutator. It operates from AC or DC power supplies.
Universal motor operates at high speed and high starting torque
as compared to induction motor. The typical requirement of
mixer-grinder application is met with universal motor. This
motor has the drawback of limited life span due to brushes and
commutator, and also has poor efficiency, electromagnetic
interference and sparking due to the mechanical commutation.
However, this will be an inexpensive way to develop a motor
with very high speed.
III. MERITS OF BLDC MOTORS IN HOME APPLIANCES
A. BLDC arrangement
BLDC Motor arrangement comprises of a rotor with
permanent magnets and a 3 phase stator winding. In BLDC
motors, magnets are placed either on the surface of the rotor
which are called as surface mounted permanent magnet (SPM)
or buried inside the rotor iron , called as interior permanent
magnet motor (IPM). The selection of a suitable configuration
is based on the speed and performance requirement of the
application. This motor is controlled by an electronic
controller. It is also called as electronic commutated motor
(ECM).
Based on the control feedback information it is classified
into sensor controller and sensor less controller. Sensor based
controller needs a hall sensor or encoder to provide the rotor
position information, whereas the sensor less controller
predicts the rotor position from voltage and current signal with
the help of a special rotor position sensing algorithm and a high
speed digital controller. Sensor based BLDC controller is easy
to implement but it needs positional inputs for hall sensors
from the rotor of the BLDC Motor. This involves additional
effort to implement hall sensor placement inside the motor.
Whereas sensor less BLDC controller only needs a robust rotor
position algorithm and has the advantage of simple motor
manufacturing process.
Use of sensor and sensor less mode of controller has to be
decided based on the application needs. In compressor
application, sensor less mode is preferred due to the difficulty
in hall sensor placement inside the compressor and its
associated additional wire connections. In high start up load
application such as washing machines, sensor based BLDC can
be implemented. In Fan applications both sensor and sensor
less have trade-off between them regarding the application
construction.
B. Efficiency
The necessary magnetic field for energy conversion process
is available in BLDC motor without any additional excitation.
This reduces the components for main field generation and
their associated losses. The recent advances in the magnetic
material such us neodymium ferro-boron (NdFeB), samarium
cobalt (SmCo) and high energy ferrite magnet helps to achieve
high efficiencies with the reduced size and weight compared to
any other motor types due to their better BH properties.
Further, the addition of low iron loss silicon steel, soft
magnetic composite material and amorphous material helps to
realize a high efficient design with different possible
combinations of BLDC such as axial and radial flux machines.
The concept of concentrated (tooth coil) winding in BLDC
motor aids to achieve a low copper loss because of its less
overhang compared to its distributed winding counterpart. It
also has the advantage of easy manufacturability. The
efficiency curve is almost flat, so the part load efficiency of
BLDC motor is better than the induction motor. Hence it is
more suitable for variable speed operation compared to the
induction motor. The latest development in the electronic
switches and micro controllers enables to achieve a high
efficiency in the controller, as well as to implement a complex
algorithm.
C. Variable speed
The speed control is very much required on any appliance
for having a better user comfort and energy efficient operation
[4]. Since the BLDC motor comes with an electronic controller
it would be possible to control the speed. The same could be
achieved with an induction motor too but it requires an
additional motor control. However, the motor efficiency of the
current induction motor is lesser than the BLDC motor and
thus the overall system efficiency to be less as well. Variable
speed operation plays a major role in achieving a better star
rating with competitive cost. The slow start features of the
BLDC motor helps to reduce the inrush current during the
motor starting. With the field weakening control it would be
possible to run the motor beyond the rated speed of the motor.
But high speed operation is realized with a mechanical gear
arrangement in case of an induction motor.
D. Additional features
Additional benefits in using a BLDC motors are a) the set
speed is maintained despite a dip in input voltage ; b) smart
algorithm adopted within the existing electronics controller
without need of external controller which can enhance the
appliances in a smarter way.
IV. HOME APPLIANCES PERFORMANCE WITH BLDC MOTOR
A. Refrigerator compressor motor
In recent days energy star rating is mandatory for frost free
and direct cool refrigerator [5] [6]. The number of stars is more
for a less energy consumption refrigerator. A refrigerator runs
24 hours a day. The motor used in the compressor should
consume less power for achieving higher star rating. However,
the efficiency of current induction motor is almost saturated
and further improvement is difficult with the available space
and cost constraint. Hence it is required to go with a high
efficiency BLDC motor with variable speed control for
achieving the higher star rating.
For a capacity of 180 litre to 330 litre, the typical power
requirement will be in the order of 60W ~ 120W. The speed
and torque of the compressor is 3000rpm and 0.25Nm. Two
retrofitted BLDC motors, one, rated 48V DC, 2A for a solar
based application and the other, rated 300V DC, 0.3A for a 230
V AC (single phase grid connection) are developed. A sensor
less controller is developed to run these motors. It would be
possible to run the motor from 1800 rpm to 4500 rpm based on
the thermal load demand. Refrigerator controller receives
temperature information from the temperature sensor and runs
the motor at a specified speed. The efficiency of a standard
induction motor is 71% whereas in the developed BLDC
motors it is 87%. The refrigerator compressor with a BLDC
motor and an induction motor is shown in fig 1 and 2. It would
be possible to reduce the compressor size and weight. The
inrush current of the BLDC motor is very less as compared to
the induction motor. Further, it could be possible to achieve a
quick chill requirement by running the compressor at a very
high speed.
Fig. 1. BLDC and Induction motor compressor.
Fig. 2. Stator and rotors of indiction and BLDC motor.
B. Ceiling fan
In a residence, a 1200mm sweep ceiling fan is most
commonly used [7]. The required service value (ratio of Air
delivery and the input power) of a 5 star rated ceiling fan
should be greater than 4, at a minimum air delivery of 210
CMM (cubic meter per minute). Hence, the power
consumption of the 5 star rated ceiling fans should not exceed
50W. The best available ceiling fan with an induction motor (in
the market) consumes the power of 50W~ 70 W. Further
improvement of efficiency in an induction motor is difficult.
On the other hand, a BLDC motor based ceiling fan, designed
to meet the air delivery of 210 CMM consumes only 35W of
input electrical power. BLDC motors with two system voltages
are designed: 1) 48V DC, 0.7 A for solar based applications 2)
300V DC, 0.116A for single phase AC grid applications. A
sensor less controller is used to drive the fan. An infra red (IR)
based control is used to increase/ decrease speed or switching
ON/OFF. This developed BLDC motor is 30 ~ 50% efficient
than the induction motor. The developed BLDC fan runs at a
set speed irrespective of the supply voltage (130V ~ 270V AC)
variation. Some more intelligent control algorithm like variable
flow pattern could also be implemented. The developed stator
and rotor assembly and ceiling fan is shown in fig 3 and 4.
Fig. 3. Stator and rotor assembly of ceiling fan.
Fig. 4. Ceiling fan.
C. AC compressor
Air condition (A/C) is one of the major electrical loads in
the home appliances [9] [10]. To achieve a higher star rating,
the compressor efficiency can be increased by changing/adding
refrigerant or by using higher rated compressor or by better
design of evaporator and cooling circuits. However these
methods increase the system overall cost as well. The simple
solution of system efficiency improvement is done by using a
BLDC motor with a variable speed operation. This would be
possible without modifying the compressor and system parts.
The speed and torque requirement of 1.5ton split A/C
compressor is 3000 rpm and 5 Nm. A suitable BLDC motor is
designed to meet the load. Actual fitment dimensions are
maintained as per the existing induction machine. The
dynamometer performance of existing induction motor in a
standard compressor and that of a BLDC motor is shown in fig.
5. It is observed that efficiency of the BLDC motor is better
than the induction motor and also the efficiency is high even at
the part loaded condition. The stator and rotor parts along with
their commercially available compressor assembly are shown
in fig. 6 and 7.
The condenser fan is located on the outdoor unit and runs at
speed of 900 rpm. The typical power consumption with an
induction motor is 105W. A BLDC motor is designed to meet
the above fan load. The developed motor is tested at 900rpm
and it consumes 65W. A 39% power saving with a BLDC
motor can be achieved from the above design. The condenser
BLDC motor and its test arrangement are shown in fig 8 and 9.
Similarly, indoor fan motor is designed for the speed torque
requirement of 1350 rpm and 0.3 Nm. It is observed that 15%
of power saving is possible with BLDC motor. The indoor
BLDC motor is shown in fig 10. Also variable speed operation
helps us to reduce the energy consumption.
Fig. 5. Effieicency comparison of inductionand BLDC motor.
Fig. 6. BLDC stator and rotor for A/C compressor .
Fig. 7. Retrofitted BLDC motor with a stadard compressor.
Fig. 8. A/C condenser fan BLDC motor.
Fig. 9. Outdoor fan with a BLDC motor.
Fig. 10. Indoor fan BLDC motor.
D. Washing machine
In conventional washing machine, a mechanical gear and
belt arrangement is used along with a single phase induction
motor to achieve a) wash cycle requirement of high torque at
low speed and b) spin cycle requirement [10]. This additional
mechanical system causes performance and reliability related
issues. With a suitable design of BLDC motor with field
weakening control capability, it would be possible to achieve
the wash and spin cycle requirement. The expected speed
torque profile of washing machine is shown in fig. 11. Figure
12 shows the top loading washing machine with a BLDC
motor. The prototype motor is illustrated in fig. 13. The
efficiency of a standard induction motor that is used in a
washing machine is 55% ~ 60%, whereas the developed BLDC
motor provides 70%. There will be an additional loss in the
mechanical system (gear and belt), but same is absent in the
BLDC motor.

Fig. 11. Speed torque profile for washing machine.
Fig. 12. top loading washing machine with a BLDC motor
Fig. 13. BLDC washing machine motor.
E. Water purifier
The commercially available RO water purifier comes with
a rating of 24V DC 0.8A, 17W brushed DC motor. The life of
the motor is restricted by brush and commutator arrangement.
A sensor less BLDC motor and controller designed with the
following specification of 48V DC, 0.32 A consumes 15W.
The life and efficiency is better as compared standard brushed
DC motor. The developed RO pump with a BLDC motor is
shown in fig. 14.
Fig. 14. Water purifier pump with a BLDC motor
F. Mixer grider
The motor used in a residential mixer-grinder comes with
universal motor and its power consumption is 480 W
(typically). A suitable BLDC motor with a sensor less control
designed at both 300,48V AC/DC systems with 0.8, 5A current
rating consumes 240W. This motor runs at a constant set speed
irrespective of load condition. Since the inrush current is very
less (close to rated current) as compared to the universal (12A),
it would be possible to operate with battery backup system or
solar based as well. The stator and rotor and mixer-grinder
assembly is shown in fig. 15 and 16.
Fig. 15. Stator and rotor of mixer grinder motor.
Fig. 16. Mixer-grinder assembled with BLDC motor.
G. Air cooler
In a regular air cooler application, fan is driven by a single
phase induction motor. At the maximum air flow condition
induction motor consumes power in the range of 140 W ~ 180
W and cost of the motor varies accordingly. Cost of the system
increases further if it uses a drive for making the speed control.
By using a BLDC, it would be possible to improve the motor
efficiency and implement speed control with a marginal
incremental cost. The developed BLDC motor is shown in fig.
17 and it consumes 90W power with the same blade and at
same speed (1300 rpm). Since efficiency curve of BLDC motor
is almost flat, for a lower speed, power consumption is lesser
than a standard induction motor.
Fig. 17. Air cooler motor.
 V. CASE STUDIES
The comparison of parameters such as motor power and
efficiency of conventional and BLDC motors, used in
different applications is shown in table 1. The power
consumption of various electrical household appliances using
both conventional and BLDC motors has been classified into
three major power ranges (200W, 600W and 3000W) to study
the energy saving potential in each group. As in a consumer
selected power range (either 200W or 600W or 3000W), the
power consumption of all the required appliances (excluding
lighting loads and other electrical accessories) using
conventional motors is more than the BLDC counterparts as
seen in table. 2.
TABLE I. POWER AND EFFICIENCY COMPARISON OF MOTORS USED IN
APPLAINCES
VI. CONCLUSION
Thus, BLDC motors for various applications like refrigerator
compressor, ceiling fan, air condition system, mixer-grinder,
washing machine, water purifier and air cooler were developed
and their performance parameters were compared against their
existing induction/universal motor counterparts. It is observed
that the efficiency in BLDC motors in all the appliances have
been better compared to their existing counterparts. Also it
facilitates the flexibility in designing BLDCs for both 230V
AC and 48V solar DC system as well as for different
load/applications.
TABLE II. ENEERGY SAVING POTENTIALS IN APPLAINCES
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