Reducing Energy Costs in

Electric-Motor-Driven Systems
By Fernando J.T.E. Ferreira and Aníbal T. de Almeida

©ISTOCKPHOTO.COM/SIRAANAMWONG

SAVINGS THROUGH OUTPUT POWER REDUCTION AND ENERGY REGENERATION

ElEctric-motor systEms convErt nEarly half of
worldwide electric energy into the mechanical ener-
gy ultimately used in the final application or process.
Digital Object Identifier 10.1109/MIAS.2016.2600685
Date of publication: 31 August 2017
the integral optimization of electric-motor-driven systems
(EmoDss), including the use of high-efficiency, well-sized
components, is the key strategy to effectively maximize
their overall efficiency. however, the largest energy savings
potential in motor-driven systems is associated with the
reduction of the power required by the driven equipment

84 IEEE Industry Applications Magazine œ J ANUARY/F EBRUARY 2018 1077-2618/18©2018IEEE

through speed/torque control and/or with the partial
reuse of the energy stored in the system. in this article,
the basic principles and some practical examples of out-
put power reduction and energy regeneration in EmoDss
are presented.
Overview of EMODS
currently, electric-motor systems convert 46% of the
world’s electrical energy into mechanical energy, ulti-
mately used in the final application or process. Because
nearly 90% of industrial EmoDss integrate integral-
horsepower, three-phase, squirrel-cage induction
motors (scims), their individual efficiency and reliability
have a significant impact on overall production plant
efficiency and reliability/downtime, ultimately influ-
encing manufacturing performance, quality, and cost.
in industry, EmoDss can use more than two-thirds of
the electrical energy consumed in the industrial sector;
therefore, the improvement of their overall efficiency
may translate into significant ener-
gy savings [1]–[6].
there are four key standards
related to electric-motor and pow-
er-drive system (PDs) efficiency:
in figure 2, the main strategies to reduce energy con-
sumption in EmoDss are depicted, namely, the reduction
of power loss in the energy conversion process (PDs
efficiency increase), the reduction of PDs output power
(reduction of load power by means of process friction/
loss reduction, counterweights use, and speed adjust-
ment), and the reuse of stored kinetic and/or gravita-
tional potential energy (electrical energy regeneration
for direct use in other PDss, injection into the ac mains
grid and/or common dc bus, and/or energy storage in
supercapacitors/batteries).
Output Power Reduction
Motor Speed Adjustment
the system/process output adjustment through motor
speed control has a significant energy savings potential
in relation to other solutions, such as on/off switch-
ing and throttling, in the case of fluid motion systems.
Mains and Mains Cabling

Motor Control Equipment

international Electrotechnical com-

(CDM or Starter)
mission (iEc) 60034-30-1 [7], iEc Feeding Section Motor
60034-30-2 [8], European standard Auxiliaries Starter
CDM

Contactor,
Motor System

50598-2 [9], and iEc 61800-9-2 [10].

Basic Drive Module Soft Starter,
the last three address variable-
PDS

and so on
Extended Product

speed systems and are still under Auxiliaries

development. t he last t wo are
similar. in figure 1, the defini-
tion of the complete drive module Motor
(cDm), motor starter, PDs, motor
system, and ex tended product,
according to iEc standard 61800-9-2,
is presented. Transmission
Due to the adoption of mini - Load Machine Control
mum energy performance stan-
Driven Equipment
dards in the majority of developed
countries, the electric-motor mar-
ket is moving toward premium/iE3
FIGURE 1. The EMODS components according to IEC standard 61800-9-2.
and superpremium/iE4 efficiency
motors [11], [12]. yet the motor is
just one of the components of the Torque
Better Technology
EmoDs, and the overall energy and End-Use
and System Design
efficiency of the latter is strongly Better Pow er Speed
c t I m Device/Application
Quality Im p a ↑η PDS p a ct Control
dependent on the efficiency of all
↑PQ ↓Pout
the system components as well as Input Power PDS Output Power Mechanical
on the process control strategy that Power
offers the largest energy savings Losses
How to Reduce Energy ↓P Stored
potential. a good example is the loss Penergy Energy Energy
Consumption Without
use of variable-speed drives (vsDs) Affecting the Provided Regeneration
in variable-output applications, Useful Energy?
which may lead to large energy sav-
ings [13], [14]. FIGURE 2. The strategies to reduce energy consumption in EMODSs.

J ANUARY /F E BRUARY 2018 œ IEEE Industry Applications Magazine 85

 motor speed and torque control/adjustment can be made
with vsDs, two-speed windings (pole number change),
and stator-winding-phase voltage adjustments. the first
two solutions are the most efficient. the last one is not
efficient because the motor speed decrease is a result of
the slip increase, leading to high rotor losses. the speed
and torque control of synchronous motors has to be made
with vsDs because the slip-based methods apply only
to scims.
two-speed motors are available with two separate
windings or with Dahlander winding (these motors are
smaller and cheaper in relation to those with two sepa-
rate windings) and can provide constant or quadratic
torque output [15], [16]. the Dahlander motors, although
more expensive and less efficient than single-speed
motors, can be an excellent solution when the system
output only has two operating points, particularly
when compared to a vsD-scim solution, in which the
additional vsD and motor losses as well as the rela-
tively large investment in the vsD have to be taken
into account.
Loss Reduction in the End-Use Equipment
Gravity is responsible for the load variation in vertical
or inclined material-handling systems as well as for
the static pressure head in open-loop/open-circulation
pumping systems. in both cases, the higher the grav-
ity effect, the lower the energy savings potential. for
example, in the conveyor belt in figure 3, with a slope
angle a, coulomb friction constant K friction, motor angular
speed ~, gravitational acceleration g, and total moving
mass m mat, the mechanical input power for constant
speed is given by
Pc o n v e y o r . K friction $~$r + m mat $ g $~$r $s i n a.
if the slope is zero (horizontal conveyor), the power
is approximately proportional to the rotational speed of
the motor and independent of the conveyor belt load
(total mass being moved/transported). therefore, reduc-
ing the speed to half and doubling the total load trans-
ported by the horizontal conveyor (e.g., more material
m the relation between constants K 1
M 2
Q and K 2.considering a system with a
m
J 2
v T ,ω
m
h h
F P
m
α
r H
FIGURE 3. The material- and fluid-elevating systems.
86 IEEE Industry Applications Magazine œ J ANUARY/F EBRUARY 2018
per area or smaller distances between containers), the
input mechanical power is reduced to half (50% sav-
ings), and the output is maintained constant. however,
if the slope starts to increase, the savings associated
with the speed reduction are attenuated as it is relatively
small for the extreme case of a 90° slope (which corre-
sponds to an elevator). for example, assuming an initial
mass m mat -i, a friction constant K friction = m mat -i $ g/2, and a
slope angle a = 30°, halving the speed and doubling the
total load/mass lead to a reduction in the mechanical
power of only 25% (for a = 90°, the reduction is 17%).
the escalator systems are very similar to elevating con-
veyor systems.
the same principle applies to the open-loop pumping
systems, where the energy savings with speed control are
largely attenuated. neglecting the pump efficiency varia-
tion, for constant speed, the mechanical power required
by the centrifugal pump in figure 3 is given by (2), where
m fluid is the mass of the fluid moving up:
Ppump . K pump$ K friction $~ 3 + K p u mp $m fluid $ g $~$sin a
= K 1 $~ 3 + K 2 $~$sin a. (2)
if the piping system slope is zero, the mechanical
power is proportional to the cube of the pump rotational
speed, and this situation is equivalent to a closed-loop
pumping system (for constant speed/flow, the mass
effect of the fluids moving up and down is mutually can-
celed), in which the energy savings by speed reduction
are maximized.
in water pumping systems with storage reservoirs,
replacing the on–off flow control (at rated speed) by
variable-speed flow control may also lead to significant
(1) energy savings. however, it is important to take into
account the possible degradation of the centrifugal
pump efficiency when reducing the rotational speed.
typically, the flow reduction should not be more than
20% to ensure that the pump is operating near the best
efficiency point [17]. according to the pump affinity
laws, a reduction of 10% in the rotational speed leads
to a decrease of 19% in the output head and 10% in the
flow rate. yet, according to (2), the
decrease in the mechanical power
required by the pump depends on
30° slope and K 1 = K 2 /2,the power
Pump
decreases 18.6% with a 10% speed
decrease. therefore, increasing the
M1
α pumping time 10% will lead to the
T ,ω
same amount of pumped water but
to 10.5% energy savings.
the possibility of deviating and
extending the pumping period to
the reservoirs to match, as much as
p o s s ible, the off-p e ak power periods (in which the elec- of vsDs or two-speed scims. the heat exchange capac-
tricity is generally cheaper) and reducing the fluid speed ity can also be adjusted by energizing/de-energizing each
to decrease the friction losses in the piping system may of the four subsystems. the combined pump and fan
also be considered. these strategies may require an speed control as a function of the temperature (fig-
increased reservoir capacity and, therefore, additional ure 5), compared with on/off cycling control, leads to a
investment. if the percentage of the power associated more stable temperature in the controlled zone/process
with overcoming the pipe friction is relevant, energy and a more efficient operation, typically decreasing the
savings can still be achieved, although typically less fan energy consumption in the range of 25–50%. such
than in systems without static pressure head (closed- systems can be found, for example, in cooling towers and
circulation systems). rooftop chillers.
Both in closed- or open-circulation systems, consid- in the system in figure 4, if the cooling water circuit
ering a constant flow rate, the increase of the pipes’ is closed and only 50% of the heat dissipation is needed,
diameter may lead to a significant
reduction in energy consumption. in
[5], [13], and [14], the most relevant
Hot Air Hot Air
technical and economic advantag- Pump
M2 Hot Water Cold Water
es associated with speed control in
pumps, fans, compressors, and con- Fan
Cold Air M1 Cold Air
veyor belts are addressed in detail.

Sensors and Process Control

Hot Air Hot Air
Hot Water from the Process Heat Exchange

the use of vsDs for temperature

Cold Water to the Process Heat Exchange

Pump
control in refrigeration pumps/com- M4 Hot Water Cold Water
pressors (e.g., walk-in freezers) can Fan
eliminate the on/off cycling loss- Cold Air M3 Cold Air
es and decrease the temperature
difference between the condens-
er and the evaporator, with large Hot Air Hot Air
energy savings (typically 25%). the Pump Hot Water
M6 Cold Water
control of the difference between Fan
internal and external temperatures Cold Air M5 Cold Air
also improves.
in industrial refrigerators or freez-
ers, the use of ecubes (a low-cost Hot Air Hot Air
measure) fitted in the inner tempera- Pump Hot Water
M8 Cold Water
ture sensor, to simulate the thermal
Fan
inertia of the products being cooled, Cold Air M7 Cold Air
can help the compressor avoid exces-
sive or useless on/off cycling. if the
frozen products still maintain the
recommended conservation tempera-
ture, even when the air temperature
inside the freezer exceeds that value FIGURE 4. A system with four heat exchangers.
during the opening period, there
is no need to start the compressor.
the on/off cycling frequency reduc- VSD
tion leads to a lower energy con- Hot Air Hot Air
Pump
sumption and a longer lifetime of M2 Hot Water Cold Water
T2
the compressor. Fan
M1 Cold Air
in heat-exchanging systems, such Process
T3
as that represented in figures 4 VSD T1 Heat
Cold Air
Exchange
and 5, the pump’s speed may be con-
trolled as a function of the process
or zone temperature and the fan’s
speed as a function of the coolant FIGURE 5. The simultaneous speed control of the pump (M 2) and fan (M 1) of a heat exchanger
water/fluid temperature, by means or chiller, as a function of the process or water and air temperatures (T1, T2, and T3).

J ANUARY /F E BRUARY 2018 œ IEEE Industry Applications Magazine 87


P1
Valve Valves
P2 Control
Fan
Pressure P
2 Sleeve
Sensor Air Filter
M1
M2
VSD P1
Waste
FIGURE 6. The industrial cleaning suction system optimization [18].
Plastic Mold
Granules Hopper Heater Cavity Mold
Reciprocating Barrel Nozzle Moveable Platen
Screw
Injection Clamping
FIGURE 7. The injection-molding machines.
th e speed reduction of the fans and the pumps should
be optimized providing that, in the end, the overall
thermal resistance between the process to be cooled
and the environment is kept at 50% to maintain a con-
stant temperature for half of the heat loss production.
the fan and pump speed decrease will lead to a cubic
reduction in the required power.
if the amount of heat to be extracted from the pro-
cess cooling system in figure 4 is reduced to 75, 50, or
25%, assuming independent closed-circulation piping
systems, the user may switch off one, two, or three heat
exchangers (pumps and fans), leading to a reduction of
25, 50, and 75%, respectively, of the required hydraulic/
pneumatic power. alternatively, reducing the pump
and fan speed of the pump and fan in the four heat
exchangers to 75, 50, and 25%, by means of vsDs, leads
to a reduction of 57.8, 87.5, and 98.4%, respectively, of
the required hydraulic/pneumatic power. instead of
vsDs, another less expensive option is to use two-speed
motors, also leading to large savings. in this case, the
solution for 75, 50, and 25% cooling load can be two
exchangers at 100% speed plus two exchangers at 50%
speed, four exchangers at 50% speed, and two exchang-
ers at 50% speed plus two exchangers switched off,
respectively. this leads to a reduction of 43.8, 87.5, and
88 IEEE Industry Applications Magazine œ J ANUARY/F EBRUARY 2018
93.8%, respectively, of the required
Compressed Air to hydraulic/pneumatic power. the
Clean the Filter pumpside savings will be lower
if independent open-circulation
elevating systems are considered.
in this case, the power reduction
P1 Pressure Suction Air
Sensor Ducts depends on the static pressure head
Negative Pressure
share in the overall output pump
pressure head.
in industrial exhaustion/suction
systems, the overall optimization
may also lead to significant energy
Variable Number of Work Posts savings. in figure 6, a real case of
a foundry exhaustion system is
presented, with a variable num-
ber of deburring work posts with
individual exhaustion/suction points.
When a work post is not being used, the respective suc-
tion point is closed using a valve.
originally, the PDs of the main exhaustion fan (M 1
in figure 6) was of fixed speed, and when the air input
of one or more of the individual suction points was
closed, there was an increase in the suction air duct’s
system resistance, leading to an increase in the negative
pressure (varying between −0.0206 and −0.0245 bar).
the direct-online (Dol) single-speed 90-kW scim driv-
ing the exhaustion fan was then replaced by a 90-kW
permanent-magnet synchronous motor (Pmsm) with
vsD, with closed-loop control of speed as a function
of the filter input pressure (P1, measured with pressure
transducers/sensors), to maintain the suction negative
pressure in the work posts (. –0.0206 bar) approximate-
ly constant, regardless of the number of open-state suc-
tion points. Energy savings between 15 and 25% were
obtained in the exhaust fan (the higher the number of
closed-state suction points, the higher the energy sav-
ings potential), which is a combined result of the motor
efficiency improvement and the system pressure control
[18]. moreover, the sleeve filter was cleaned periodi-
cally by means of clock-based on/off switching of the
compressed-air injection system output electrovalves
and the waste output rotary valve, driven by a motor
(M 2 in figure 6). this part of the system was optimized
by implementing a control strategy based on filter input
and output pressures (P1 and P2), largely reducing the
number of filter cleaning cycles, leading to additional
energy savings in the compressed-air system and waste-
output rotary valve motor [18].
in hydraulic injection-molding machines (figure 7),
energy savings between 15 and 55% (on average, 35% [18])
is possible with speed and torque control of the electric
motor driving the hydraulic pump, as a function of the
actual hydraulic power required by the machine/process.
in figure 8, a real example of input power reduction in
a plastic injection machine by means of installing a vsD
in the hydraulic pump motor is shown, in which it was
89 IEEE Industry Applications Magazine œ J ANUARY /F E BRUARY 2018

FIGURE 8. The input power in a plastic injection machine driven by an IE2-class 37-kW SCIM: (a) without VSD and (b) with VSD [19].

Input Power (W) Input Power (W)

10,000
15,000
20,000
25,000
30,000
35,000
40,000
45,000
50,000

10,000
15,000
20,000
25,000
30,000
35,000
40,000
5,000

5,000
0

0
10:53:40 8:25:27

With VSD

Without VSD
10:53:41 8:25:29
10:53:43 8:25:31
10:53:45 8:25:33
10:53:47 8:25:35
10:53:49 8:25:37
10:53:51 8:25:39
10:53:53 8:25:41
10:53:55 8:25:43
10:53:57 8:25:45
10:53:59 8:25:47
10:54:01 8:25:49
10:54:03 8:25:51
10:54:05 8:25:53
10:54:07 8:25:55
10:54:09 8:25:57
10:54:11 8:25:59
10:54:13 8:26:01
10:54:15 8:26:03
10:54:17 8:26:05
10:54:19 8:26:07
10:54:21 8:26:09
Operating Cycle

10:54:23 8:26:11
10:54:25 8:26:13
10:54:27 8:26:15
10:54:29 8:26:17
10:54:31 8:26:19
10:54:33 8:26:21

Operating Cycle
10:54:35 8:26:23
Time

Time

10:54:37 8:26:25
(b)

(a)

10:54:39 8:26:27
10:54:41 8:26:29
10:54:43 8:26:31
10:54:45 8:26:33
10:54:47 8:26:35
10:54:49 8:26:37
10:54:51 8:26:39
10:54:53 8:26:41
10:54:55 8:26:43
10:54:57 8:26:45
10:54:59 8:26:47
10:55:01 8:26:49
10:55:03 8:26:51
10:55:05 8:26:53
10:55:07 8:26:55
10:55:09 8:26:57
10:55:11 8:26:59
10:55:13 8:27:01
10:55:15 8:27:03
10:55:17 8:27:05
10:55:19 8:27:07
10:55:21 8:27:09
10:55:23 8:27:11
10:55:25 8:27:13
10:55:27 8:27:15
10:55:29 8:27:17
10:55:31 8:27:19
10:55:33 8:27:21
10:55:35 8:27:23
10:55:37 8:27:25
 the hydraulic oil and the mechanical
and hydraulic components as well as
100% Output lower acoustic noise. moreover, the
Flow Flow
speed control is extremely important
Input 225 r/min to ensure that an adequate quantity
Power Fan of plastic is being fed into the mold
100% and to maintain even pressures for
consistent flow. in the extruders, the
37 kW DOL
speed control can lead to average
SCIM-IE2

Gear Box
Driveshaft savings of 15% [18].
in grain storage silos, it is also
Disk Coupling Disk Coupling possible to save a significant amount
of energy by controlling the speed of
the dehumidification system blower
Savings Variable Speed Fixed Speed Savings (which blows air into the bottom of
47% 5.5% the tank/silo) as a function of the
(a)
hygrometric state of the air in the
top of the tank. typically, the blow-
29% Time Share: 100% Flow 100% ers are operated at a constant speed,
Output Flow Flow
71% Time Share: 90, 80, 70, 60, 50% Flow regardless of the actual humidity
225–112.5 r/min 225 r/min
level of the stored grains, which is a
Fan
quite inefficient strategy.
Input Power
53% 94.5% Combined Efficient Technology
and Process Control
VSD a good example of the combined
PMSM

35 kW use of efficient technology and pro-

cess control resulting in large ener-
gy savings is in the fan system for
(b) cooling towers. replacing the typi-
cal fan motor system, by integrating
FIGURE 9. The optimization of the fan motor system in a cooling tower [19], [20]: (a) a direct- a four-pole Dol scim, disk cou-
drive variable-speed fan system and (b) a conventional fixed-speed fan system. plings, a driveshaft, and a gear box
[figure 9(a)] with a high-efficiency
motor system and integrating a verti-
cal mounted (with special rear flange) direct-drive Pmsm
Table 1. The percentage of energy consumption controlled by a vsD [figure 9(b)], may lead to significant
for three fan motor systems [19] energy savings [19]–[21]. in [19], energy savings of 5.5%
for full-load, fixed-speed operation and 47% for variable-
Fan Motor System Energy Consumption* speed operation are reported (figure 9). in such systems,
DOL IE2-class SCIM + gear box 100% (reference) if an iE2-class scim is replaced with an iE3-class scim,
the expected energy savings are about 1.4%, but if the
DOL IE3-class SCIM + gear box 98.6%
fixed-speed geared system with an iE2-class scim is
VSD + IE4/5-class PMSM (gearless) 62.5% replaced with a variable-speed direct-drive (gearless)
*Assuming an average speed of 75% of the maximum value of the operating system with a Pmsm, the expected energy savings are
cycle. approximately 37.5%, assuming an average speed of 75%
of the maximum value of the operating cycle, as can be
seen in table 1 [19].
possible to obtain an energy consumption reduction of the Pmsm is cooled by the driven fan flow, thus
. 50%. the energy savings potential depends on the not integrating a self-cooling fan. Besides the econom-
hydraulic load cycle profile and the mold quality. in gen- ic advantage of the Pmsm direct-drive solution, there
eral, the higher the cooling time share in the machine are also other important advantages, such as mainte-
operating cycle, in which the required hydraulic power nance cost reduction (eliminates gear-box maintenance),
is relatively low or not necessary, the higher the energy reduced downtime/improved reliability (fewer mechani-
savings [18]. in plastic injection machines, the speed cal components, such as a gear box), and lower acoustic
control of the hydraulic pump also leads to longer use of noise. another advantage is from a safety perspective

90 IEEE Industry Applications Magazine œ J ANUARY/F EBRUARY 2018

b e c a use the vsD allows a trickle cur- the two-speed scims also reduce
rent to be injected into the motor to maximum starting loss power in
prevent fan rotation during standby A good example of relation to single-speed Dol scims.
(an antiwindmill feature), which can
be caused by exterior wind condi-
the combined use of Because the starting duration may
not be significantly extended (up to
tions or by another tower’s airflow. eficient technology two times longer than that for Dol
this trickle current also produces starting), it is possible to reduce
enough heating in the motor to pre- and process control the overall starting loss energy in
vent condensation (eliminating the
need for space heaters). the direct-
resulting in large the motor.
in applications with a high num-
drive option also leads to lower energy savings is in ber of starts per minute, iE3/iE4-
installation and maintenance costs class scims are not recommended
by eliminating alignment issues of the fan system for due to the rotor’s larger inertia [26]–
mechanical components and cooling
water contamination due to gear-box
cooling towers. [28], which may lead to significantly
longer starting periods and, there-
oil leakage. fore, to higher starting loss energy
the fan efficiency can also be in the stator and rotor. however, if
improved by adjusting the blade pitch. in fact, [21] reports the extra kinetic energy can be recovered during the
a case study on the improvement of a large fan motor stopping process, this might be a minor problem.
system in a cooling tower, including the fan blade a longer starting period leads to higher thermal stress
pitch adjustment. in the windings, which can shorten the insulation life-
time. after starting the motor, if there is no need for
Motor Starting and Intermittent Operation voltage and/or frequency adjustment, it should operate
soft starting of scims is important to reduce the respec- directly from the grid to avoid its own extra harmonic
tive starting and in-rush currents as well as the mechani- losses (e.g., due to the harmonic distortion) and the
cal stress of some motor and load parts, such as bearings, losses of the starting device. the larger rotor inertia of
shafts, and blades. the duration of the motor starting high-efficiency motors will also contribute to extending
period depends on the acceleration torque (motor torque the starting and reversing time in Dol motors or limit
minus load/braking torque) and the moment of inertia dynamic performance of the motor when it is controlled
of the system [22]–[25]. the number of losses associated by a vsD.
with the rotor cage and stator-winding circuits during the regarding the intermittent operation of high-effi-
motor starting period are quite different depending on ciency motors, there are some limits after which they
the starting method [5], [13]. figure 10 shows the kinetic lose their extra efficiency advantage because the extra
energy stored in the rotating system (motor plus load) and starting losses/energy over the typical duty cycle ex-
the approximate variation of the motor joule losses and ceed the reduction of losses/energy in steady state [29],
line current, as a function of the motor speed, during the as depicted in figure 11. the estimated minimum du-
starting period, for different starting methods. the typical ration of the steady state in seconds that ensures high-
duration of the starting period is also indicated [per unit efficiency motors lead to energy savings is presented
(p.u.), Dol starting period as reference]. in figure 12.
the most efficient soft-starting method for scims is
using a vsD because the motor slip is minimized dur- Energy Regeneration
ing all the starting process and, therefore, the respective Energy regeneration is an interesting option in systems
rotor and stator joule losses are low [5], [13]. Electronic in which a significant amount of kinetic and/or gravi-
soft starters can significantly reduce the scim maximum tational potential energy can be stored. such energy
loss power during the starting period (due to the current can be supplied to the motor-driven systems during the
limitation), but, because the starting duration becomes starting/acceleration and/or ascending/upward move-
longer, the overall starting loss energy in the motor may ment periods.
still be relatively high. the same applies to star-delta When an electric motor is decelerating and/or brak-
starting. [typically, the duration of the motor starting ing, it can operate as a generator in the second and
period with an electronic soft starter is two to four times fourth quadrants, converting mechanical energy into
longer than that for Dol starting, depending on the total electrical energy. in such cases, when a regenerative
system inertia, load torque-speed curve, and starting vsD is used to control the motor, the kinetic energy
mode selected in the soft starter (voltage ramp or current and/or the gravitational potential energy stored in a
limitation; in the voltage ramp mode, the motor starting system can be partially recovered/reused. [the regen-
time depends on the preset initial value and duration of erative vsDs can convert electric power in both direc-
the voltage ramp).] tions (bidirectional converters) and maintain the input

J ANUARY /F E BRUARY 2018 œ IEEE Industry Applications Magazine 91

 1.2 1.2 1.2
DOL Star-Delta Two-Speed
Starting Period: 1 p.u. Starting Period: 3...5 p.u. Starting Period: 1...2 p.u.
Power (p.u.; DOL Starting Losses as Reference)

Power (p.u.; DOL Starting Losses as Reference)

Power (p.u.; DOL Starting Losses as Reference)

1.0 1.0 1.0

0.8 0.8 0.8

Stored Stored
0.6 Kinetic 0.6 0.6 Kinetic
Energy Energy
(Area) Stored (Area)
Kinetic
0.4 0.4 Energy 0.4
(Area)
Rotor and Rotor
Stator and
Joule Losses Stator
0.2 0.2 Rotor and 0.2
(Curve) Joule
Stator
Losses
Joule Losses
(Curve)
(Curve)
0.0 0.0 0.0
0 0.5 1 0 0.5 1 0 0.5 1
Speed (p.u.; ωNas Reference) Speed (p.u.; ωNas Reference) Speed (p.u.; ωNas Reference)
(a) (b) (c)

1.2 1.2 7.0

Soft Starter VSD DOL
Starting Period: 2...4 p.u. Starting Period: 2...4 p.u.
Line Current (p.u.; N ominal Current as Reference)

6.0
Power (p.u.; DOL Starting Losses as Reference)

Power (p.u.; DOL Starting Losses as Reference)

1.0 1.0

5.0
0.8 0.8
Two
Speed
4.0

0.6 0.6
Stored Stored
Kinetic Kinetic 3.0 Soft
Energy Energy Starter
0.4 (Area) 0.4 (Area)
Start-
2.0 Delta
Rotor and Stator
0.2 Joule Losses 0.2 VSD
(Curve) Rotor and Stator 1.0
Joule Losses
(Curve)
0.0 0.0 0.0
0 0.5 1 0 0.5 1 0 0.5 1
Speed (p.u.; ωNas Reference) Speed (p.u.; ωNas Reference) Speed (p.u.; ωNas Reference)
(d) (e) (f)

FIGURE 10. The approximate variation of the SCIM joule losses (p.u., DOL starting losses as reference) and line current (p.u., nominal current
as reference), as a function of the motor speed (p.u., nominal speed ~ N as reference), during the starting period, for different starting
methods: (a) DOL, (b) star-delta, (c) two-speed constant-torque Dahlander winding, (d) soft starter, (e) VSD, and (f) motor line current.

92 IEEE Industry Applications Magazine œ J ANUARY/F EBRUARY 2018

power factor close/equal to unity. the overall PDs per- the interest/suitability of the second solution depends
formance during driving and braking depends signifi- on the balance between the driving and braking operat-
cantly on the control strategy of the regenerative drive/ ing modes of the motor systems connected to the com-
vsD.] the efficiency of a motor system operating in mon dc bus. if all the energy generated by the systems
regenerative mode is equal to the product of the indi- in braking mode is not immediately consumed by the
vidual efficiencies of all the system
components, namely, the motor,
when it is operated as a genera- Additional
Power
tor ^P mech " P ele -ach, the inverter of Because of Power Consumption P
P
the vsD, when it is operated as a Higher Pa → Acceleration (I)
Energy Saving
controlled rectifier ^P ele -ac " P ele -dch, Moment of P → Constant Speed (II) Because of Higher
c
Inertia Degree of Efficiency
and the integrated/built-in active Pb → Deceleration (III)
front-end (back-to-back topology)
or the external/separated regen- t t
erative module, which are con-
nected to the dc bus and allow for Additional Losses
(I) (II) (III) Because of Higher (I) (II) (III)
injecting energy into the ac grid
Moment of Inertia
^ Pele -dc " Pele -ac h. therefore, the effi-
ciency of the energy regeneration
process varies with the technolo-
FIGURE 11. The SCIM power consumption in intermittent operation [29].
gies and control strategies being
used. in conventional nonregenera-
tive vsDs, the energy generated by 8
the motor is dissipated as heat in a 7
Minimum Constant

braking resistor, connected to the 6

Speed Time (s)

dc bus through a chopper circuit. 5

the energy (re)generated by the
4
motor system can be (re)used by
3
means of three different solutions:
1) injected directly into the ac grid, 2
2) injected into a common dc bus, 1
or 3) stored in supercapacitors and/ 0
0.75

1.1
1.5

2.2
3

5.5

7.5
9.2
11
15

15

18.5
22
or batteries for further use. these
solutions can be combined. the first Rated Power (kW)
and second solutions are depicted
in figure 13. FIGURE 12. The minimum steady-state time to justify the investment in a high-efficiency SCIM
the first solution is widely used, with higher rotor inertia [29].
and the amount of regenerated
energy is limited by the maximum
power/current that can be handled Common
ac Grid
by the regenerative drive and the ac R ST
dc Bus
Losses
grid in the point of connection. for + –
a given amount of stored energy, the Power Flow
average power to be injected into
dc-Bus
VSI

the ac grid is inversely proportional

to the duration of the regeneration
dc-Bus

Regenerative
VSI

period. if there are no restrictions Module

regarding the time to stop/deceler-
VSI
ate, the user can design the regen-
erative system for a smaller power.
dc-Bus

dc-Bus
VSI

VSI

the regenerative system power will

VSI

be halved if the deceleration time

window is doubled, leading to a sig- Back-to-Back VSI
nificant reduction in the system cost. Topology
this should be a tradeoff between
time to stop and system cost. FIGURE 13. The different energy regeneration solutions. VSI: voltage-source inverter.

J ANUARY /F E BRUARY 2018 œ IEEE Industry Applications Magazine 93

 oth er motor systems (as braking power higher than driv-
ing power), a regenerative module has to be connected
between the dc bus and the ac grid to handle the excess
generated energy. in any case, when excessive energy is
likely to be injected into the dc bus, a braking resistor
associated with a chopper circuit has to be installed to
dissipate that energy. if the energy regeneration period
is relatively long, supercapacitors and/or batteries may be
used to store part of the regenerated energy and inject it
back into the motor system during the next starting or
acceleration period.
in general, it is possible to recover/reuse/save sig-
nificant amounts of energy with regenerative drives
in applications with frequent and/or long braking/
deceleration operations; high-inertia loads (e.g.,
machine tools, lathes, flywheel presses and crushers,
and large circular or band saws); high-speed loads
(e.g., industrial centrifuges and high-speed lathes with
an automatic feeder); and high-mass vertical, inclined,
or horizontal linear-motion applications (e.g., lifts,
cranes, trolleys/carriages, conveyors, and escalators).
yet, energy regeneration is only possible when the
mechanical system is bidirectional, i.e., allowing the
power to flow in both directions. there are a number
of motor-driven systems using worm gears that, in
most cases, are unidirectional, not allowing energy
recovery. for technical or safety reasons, such unidi-
rectional systems can be found in some elevators and
cranes. in such systems, the use of counterweights
reduces consumption. in systems with direct coupling,
planetary or helical cylinder/conic gears, pulleys/belts,
and chains/sprockets, regenerative PDss can effec-
tively be used.
Kinetic Energy Recovery
the stored kinetic energy is given by (3) for linear-motion
systems and by (4) for rotating systems, where mis the
mass, vthe linear speed, Jthe moment of inertia, and
~ the angular speed. the kinetic energy varies with the
square of speed:
E k_v = 1 m $v 2, (3)
2
E k_~ = 1 J $~ 2 . (4)
2
in high-inertia and/or high-speed rotating systems,
independently of the motor inertia, the stored energy
can be very high, and, therefore, the investment in a
regenerative system may be a good option. in such sys-
tems, during starting/acceleration periods, a significant
amount of energy is stored, which may be partially
recovered during system stopping if a regenerative drive
is installed. the cost-effectiveness of such solu-
tions largely depends on the system on/off cycling.
actually, in most of the industrial motor-driven systems
without regenerative capability, users avoid the respective
shutting down in the operating cycle’s no-load periods to
save time and energy associated with the system starting
process as well as to avoid frequent mechanical stresses
that can shorten the lifetime of some of the system
components (gears, bearings, shafts, and fan blades).
for example, in large wood trunk saws (figure 14),

M2 Trunk Saw

M2 Trunk Jsaw

M2 Trunk M2
J2
Carriage Loading System

Trunk M2
Carriage Carriage Starting:
v Backward m F m1 Forward v, F Driving Mode
1
Braking Driving Stopping:
M1 M1
J4 J1 J4 J1 Braking Mode

Dissipated Energy Regenerated Energy Consumed Regenerated

Energy Energy
Braking Resistor ac Grid
ac Grid
Consumed
Energy

FIGURE 14. A wood saw with a trunk-feeding carriage.

94 IEEE Industry Applications Magazine œ J ANUARY/F EBRUARY 2018

in b etween trunks or carriage move-
ments, the user lets the saw keep
running. the same happens in large fly-
wheel presses and crushers. in such
systems, in the light or no-load peri-
ods when they are driven by scims, the
motor torque or magnetizing flux can
be adjusted by means of regulating line
voltage or changing the stator-winding
connection mode [30], [31].
a typical conveyor carriage feed-
ing trunks/logs to a saw in a sawmill
(figure 14) is a good example of a lin-
ear-motion system where it is possible
to recover part of the stored kinetic
energy during the deceleration period of the backward
movement. in such systems, the carriage pushes the
trunk that was placed on top of it into the saw over
4–10 s and then the carriage returns back for repo-
sitioning of the trunk or to be loaded with a new
trunk. the return back time of the carriage should
be as short as possible to optimize the sawing process
time. such a carriage may have a mass of 2–5 t, and its
way back may have 5–15 m, depending on the plant. to
minimize the time of the return trip, the carriage has
to be accelerated as much as possible and stopped in
the shortest time and distance possible. for example,
assuming that v = 15 m/s and m = 5,000 kg in the
very instant before braking the carriage, the stored
2
kinetic energy is E k_v = 0 . 5 # 5 ,000 # 15 = 562, 500 J =
562.5 kW.s = 0.16 kWh. assuming 500 return trips per
day, this leads to 78.13 kWh/day of energy that can be
partially recovered by a regenerative system, which,
over 300 days/year, translates into 23,437.5 kWh/year.
considering an overall efficiency of 50% for the regen-
erative system and €0.075/kWh, nearly €879/year, can
~ = 1,500 r/ min = 157.1 rad/s. i f
a rotating system with an equal
In general, the moment of inertia and angular
higher the overall speed starts and stops 6,000 times
per year, neglecting the regenera-
power eficiency tive system efficiency, the energy
savings potential is 10,280 kWh/
of escalators, the year. considering an overall effi-
higher the energy ciency of 50% for a regenerative
system and €0.075/kW h, this
savings associated translates into €386/year.
with regeneration. Gravitational Potential
Energy Recovery
the gravitational potential energy
is given by (5), where m is the mass, gis the gravity
acceleration, and his the height:
E p = m $ g $ h. (5)
the direct mechanical energy spent to lift a mass m is
m $ g $ h,which remains stored in that mass and can be
partially recovered during a descent movement if a regen-
erative drive system is used. for example, if a load with a
1-t mass is lifted at a 10-m height, the stored gravitational
potential energy is E p = 98,100 J = 27.25 Wh. if that load
is moved up and down 6,000 times per year, there is an
energy savings potential of 163.5 kWh/year. consider-
ing an efficiency of 50% for the regenerative system and
€0.075/kWh, this translates into €6.13/year.
automatic storage systems (such as the four-quadrant
operation in figure 15) are good examples of where both
gravitational potential energy and kinetic energy can be
reused to reduce the overall energy consumption over
the entire operating cycle. in a single elevator, the energy
recovered from the elevator motor (M 2 in figure 15)

be saved. however, as previously mentioned, the maxi- during the heavily loaded downward movement can be
mum power that can be injected into the ac grid may reused to simultaneously supply the translation motor
force the user to extend the deceleration period (to ^M 1 h through a common dc bus. if possible, it can also

reduce the injected power) and/or install a braking be used to partially supply the motors of another lightly
resistor in the dc bus to dissipate
the part of the energy that cannot
be injected into the ac grid. the
first option leads to an increase in m1 Braking
the carriage returning time. the F
M2
second option lowers the energy J2
Regenerated v
saving potential associated with
Energy
Regenerated

the regeneration. in principle, the

Energy

energy injected into the grid is m2 F, v F, v F, v

immediately consumed by nearby M4 Regenerated
J4 Energy
electric loads.
a s a n ex a mple, t he s tor e d Driving
M3 M
kinetic energy is E K_~ = 6,168.5 kJ = J3 Driving Driving J 1
1
1.71 kWh in a solid cylinder with a 1-t Automatic Storage System
mass and a 1-m radius ^ J = 0.5 #
1,000 # 1 2 = 500 k g.m 2 h, rotating at FIGURE 15. An automatic storage system with two moving elevators.

J ANUARY /F E BRUARY 2018 œ IEEE Industry Applications Magazine 95

 l o a d e d e l e v a t o r ( M 3 a n d M 4) . B ec au se in this type of lift drive system with a two-speed scim and a worm gear,
application the motor rotation reversing frequency is high,
the inertia of motors ^ J 1, J 2, J 3, and J 4 h should be as low
as possible. Because motors M 2 and M 4 are lifting them-
selves, they should have a low weight, particularly if there
is no regeneration system installed.
in the case of elevators (a four-quadrant operation due
to the use of counterweights, such as in figure 16), when
they are moving downward and the load weight (people
inside) is larger than the counterweight, the motor torque
is in the opposite direction to the rotational speed, i.e., the
motor is braking and energy regeneration is possible if
the motor is controlled with a regenerative vsD. the same
applies when the elevators are moving upward unloaded.
Because of the existence of a counterweight, the eleva-
tor drive systems operate in the four quadrants. in gen-
eral, the use of regenerative drives in elevators can lead to
energy savings of 40–50%. When considering replacing a
ac Grid or dc Bus
M1 M2 M3 M4
J1 J2 J3 J4
Driving
without regeneration capability, with a vsD-fed scim or
Pmsm, with helical gear or direct drive, the energy savings
can be up to 80% [13]. in the elevators, the simple use of
two call buttons (up/down) in each stage instead of only
one (undifferentiated up/down) also allows saving energy
because the elevator may only stop if the moving and call
directions are coincident.
an interesting solution for facilities with multiple ele-
vators and escalators [see figure 17 (ascendant escalators:
a one-quadrant operation without the possibility of ener-
gy regeneration; descendent escalators: a two-quadrant
operation with the possibility of energy regeneration)]
operating simultaneously, one part in driving mode and
another in braking/generating mode, is to have a com-
mon dc bus for direct electric energy transfer among the
respective motor systems. the use of a common dc bus
may avoid the use of regenerative modules to inject ener-
gy into the ac mains. the cost of such solutions is likely
to be relatively low because most vsDs are prepared to
be connected to a common dc bus. however, as previous-
ly mentioned, if excessive energy is injected into the dc
bus, it has to be dissipated as heat by a braking resistor
and/or injected into the ac grid by a regenerative module.
most commercial vsDs are prepared for the connection
of an external braking resistor. hence, such dissipation

m1
systems can easily be implemented.
F, v mc m4
in descendant escalators, the friction loss share is typi-
v
Braking

Braking

cally large, limiting the energy regeneration potential. in

Driving

m2 m F, v
F mc c F general, the higher the overall power efficiency of escala-
v tors, the higher the energy savings associated with regener-
m3 mc ation. the drive system speed and/or on/off/standby control
as a function of people upon or approximating the escalator
System with Multiple Elevators
also has a significant impact on its energy consumption.
the same principles apply to hoists and cranes, except
FIGURE 16. A system with multiple elevators (four-quadrant operation). that there is no moving counterweight and energy regen-
eration is only possible when the
handled load is moving downward.
in large cranes (a two-quadrant
operation), some manufacturers are
ac Grid or dc Bus already offering integrated regenera-
tive drives for the downward move-
ments in two different forms: 1)
Regenerated Regenerated regenerative braking for energy stor-
Energy Energy ing in supercapacitors, to be used
Second
Floor in the next driving mode operation,
M2 M3 and 2) regenerative braking for ener-
J2 J3 gy injection directly into the ac grid.
F, v F
Driving First Floor Braking v the first strategy is quite interest-
M1 M4 ing because it saves energy and, at
J1 J4
F
same time, shaves the motor-starting
F, v
Driving Ground Floor Braking v peak power in the very beginning
of the upward movement operation,
System with Multiple Escalators
which can be an issue when mul-
tiple cranes are operating simultane-
FIGURE 17. A system with multiple escalators (one- or two-quadrant operation). ously, as happens in large harbors

96 IEEE Industry Applications Magazine œ J ANUARY/F EBRUARY 2018

with container handling. the same principle can be
applied in facilities with multiple elevators.
Conclusions
the largest energy savings potential in EmoDss is
associated with speed control and energy regeneration,
which can be several times higher than that associated
with the integration of high-efficiency, well-sized tech-
nologies into the motor system. Process-based motor
speed control and energy regeneration solutions, when
applicable, may allow energy savings as high as 80%.
speed control/adjustment should be considered when
a system/process requires a variable output and the
gravity effect in the output power is relatively low.
Energy regeneration is particularly interesting when
a significant amount of kinetic and/or gravitational
potential energy can be stored in the system/process.
Both speed control and energy regeneration in motor
systems can be easily implemented using regenerative
vsDs, potentially offering a short payback time in suit-
able applications.
in applications requiring frequent direct-online start-
stops, the user should evaluate both the motor starting
method and the rotor moment of inertia and check if
a high-efficiency motor is appropriate or if it will lead
to an increase of the energy consumption due to the
larger starting losses and longer starting time. in such
applications, the use of vsDs allows for smooth motor
acceleration/deceleration, a sharp reduction of the motor
rotor losses, and, if provided with regeneration capabil-
ity, recovering part of the stored kinetic energy when the
load/application stops.
Author Information
Fernando J.T.E. Ferreira and Aníbal T. de Almeida
(adealmeida@isr.uc.pt) are with University of coimbra,
Portugal. ferreira and de almeida are senior members of
the iEEE. this article first appeared as “overview on
Energy saving opportunities in Electric motor Driven
systems—Part 2: regeneration and output Power reduc-
tion” at the 2016 iEEE ias industrial and commercial
Power systems conference. this article was reviewed by
the ias Energy systems committee.
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