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How can you measure the energy efficiency of a motor?

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Energy efficiency is a key factor in choosing and using a motor for any mechanical engineering project. It affects the performance, cost, and environmental impact of the motor and the system it powers. But how can you measure the energy efficiency of a motor? In this article, you will learn about some common methods and tools for assessing the energy efficiency of a motor, as well as some tips and best practices for improving it.

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Dewantara Akbar

Branch Manager at ofi
Kyrylo Sokolovskyi

Mechanical Engineer.
Daniel Mitchell

Delivering the Value in Industrial, Commercial, Institutional, & Multi-Unit Residential projects - Building/Contracting…

1 What is energy efficiency?

Energy efficiency is the ratio of output power to input power of a motor. It indicates how well the motor converts electrical energy into mechanical energy. The higher the energy efficiency, the less energy is wasted as heat, noise, or vibration. Energy efficiency is usually expressed as a percentage or a decimal fraction. For example, a motor with an energy efficiency of 90% or 0.9 means that 90% of the input power is delivered as output power, while 10% is lost.

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2 Why is energy efficiency important?

Energy efficiency is important for several reasons. First, it affects the operating cost of the motor and the system it powers. A more efficient motor consumes less energy, which means lower electricity bills and less carbon emissions. Second, it affects the performance and reliability of the motor and the system it powers. A more efficient motor runs cooler, quieter, and smoother, which means less wear and tear, maintenance, and downtime. Third, it affects the design and sizing of the motor and the system it powers. A more efficient motor can deliver the same output power with a smaller size and weight, which means less space and materials required.

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3 How can you measure energy efficiency?

There are two main ways to measure the energy efficiency of a motor: direct and indirect. Direct methods measure the input and output power of the motor directly, using instruments such as power meters, torque sensors, and speed sensors. Indirect methods estimate the input and output power of the motor indirectly, using parameters such as voltage, current, power factor, and efficiency curves. Direct methods are more accurate and reliable, but they require more equipment and skills. Indirect methods are simpler and cheaper, but they have more uncertainties and assumptions.

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Dewantara Akbar

Branch Manager at ofi
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Simplified method to measure and calculate motor efficiency: 1. Measure input voltage (V) and current (I) using multimeter 2. Calculate input power (P input) as P = V*I (assuming PF = 1) 3. Measure output rotational speed (RPM) using tachometer, and convert it to rad/s (ω) 4. Measure output torque (τ) using torque meter 5. Calculate output power (P output) as P = ω*τ 6. Calculate motor efficiency as η = (P output/P input)*100

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4 What are some tools for measuring energy efficiency?

When measuring the energy efficiency of a motor, there are various tools available depending on the method and purpose. For instance, power analyzers measure voltage, current, power, and power factor to calculate energy efficiency. Additionally, torque meters measure the torque or force applied by the motor to its load and can be either static or dynamic. Tachometers measure rotational speed of the motor or its load and can be contact or non-contact. Efficiency testers combine the functions of a power analyzer, a torque meter, and a tachometer in one unit to measure input and output power in real time.

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Kyrylo Sokolovskyi

Mechanical Engineer.
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Once, I had a small, old Soviet motor without a plaque on it, and I needed to determine its characteristics to understand whether it was suitable for my needs. I didn't have any special equipment, so I used what I had: a dynamometric wrench and a timer on my phone. I did not have the goal to measure energy efficiency, but if I had, I would have used an ammeter additionally, and after some simple calculations, I could have found it out

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5 What are some tips for improving energy efficiency?

There are several ways to improve the energy efficiency of a motor, depending on the type, condition, and application of the motor. For example, it's important to select a motor that matches the load and speed requirements of the system. Additionally, you should perform regular inspections, cleaning, lubrication, and alignment of the motor and its components. Furthermore, you can optimize the system by adjusting the load and speed of the system to match the optimal operating point of the motor. You can also reduce any losses or friction in the system by using sensors, controllers, or feedback mechanisms to monitor and regulate the system parameters. By following these methods, tools, and tips, you can measure and improve the energy efficiency of a motor for your mechanical engineering project and enjoy its benefits.

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Daniel Mitchell

Delivering the Value in Industrial, Commercial, Institutional, & Multi-Unit Residential projects - Building/Contracting & Managing High Performance Multi-Discipline design and delivery teams.
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I have found it helpful to collect IR images of motors under known load conditions. Resample on a regular interval and compare the latest images to the first. When the images start diverging you know you need to investigate why. Institute a motor program. Identify motor replacements ahead of time. Select the most energy efficient and fit for purpose replacements. Tag your motors (in your information model and in the field) with the replacement data. Should a failure occur the crews know what to replace that motor with, where to get it, and what the energy savings are.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Daniel Mitchell

Delivering the Value in Industrial, Commercial, Institutional, & Multi-Unit Residential projects - Building/Contracting & Managing High Performance Multi-Discipline design and delivery teams.
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Document your existing motor, the new motor, and calculate its payback, GHG reductions, and use your savings to upgrade your other motors. This adds up fast. An 8% increase in efficiency on a 600V 150HP motor can pay for the replacement in under a year and a half.

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How can you measure the energy efficiency of a motor?

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4

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6

1 What is energy efficiency?

2 Why is energy efficiency important?

3 How can you measure energy efficiency?

4 What are some tools for measuring energy efficiency?

5 What are some tips for improving energy efficiency?

6 Here’s what else to consider

Mechanical Engineering

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How can you measure the energy efficiency of a motor?

1

2

3

4

5

6

1 What is energy efficiency?

2 Why is energy efficiency important?

3 How can you measure energy efficiency?

4 What are some tools for measuring energy efficiency?

5 What are some tips for improving energy efficiency?

6 Here’s what else to consider

Mechanical Engineering

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