High-efficiency three-phase asynchronous motors play an important role in the industrial field. Their advantages over ordinary motors are largely due to the design differences in their internal structures. These differences are not simple local improvements, but systematic optimization from materials, electromagnetic design to mechanical structure, which makes high-efficiency motors significantly surpass ordinary motors in energy efficiency, performance and reliability.
From the material level, the core difference between the two is reflected in the selection of silicon steel sheets. Ordinary motors usually use conventional silicon steel sheets, which have relatively low magnetic permeability and material purity, and are prone to large hysteresis losses and eddy current losses when the motor is running. High-efficiency three-phase asynchronous motors use higher-grade cold-rolled silicon steel sheets, which are thinner and have a higher silicon content. They can effectively reduce energy losses in the iron core and make the motor consume less electricity under the same working conditions.
In terms of electromagnetic design, ordinary motors often focus on meeting basic operating requirements, and the optimization of magnetic field distribution and winding layout is insufficient, resulting in large excitation currents during operation and low energy utilization efficiency. High-efficiency motors undergo refined electromagnetic design. By adjusting the number of turns, wire diameter and arrangement of the stator winding, and optimizing the rotor slot shape and size, the magnetic field distribution inside the motor is made more uniform and reasonable. Such a design can not only reduce the no-load loss of the motor, but also improve the power factor of the motor, greatly improving the efficiency of converting electrical energy into mechanical energy.
In terms of winding technology, the winding manufacturing process of ordinary motors is relatively simple, mostly wound by manual or semi-automatic methods, the wire arrangement is not tight enough, and the end length is long, which not only increases the resistance of the winding, but also affects the heat dissipation effect of the motor. High-efficiency motors use advanced automated winding equipment and precision molds. The windings are arranged neatly and tightly, and the end length is effectively controlled, which reduces the use of copper materials and winding resistance. It is also conducive to heat dissipation and further improves the overall performance of the motor.
The rotor structure is also an important difference between the two. The rotor of an ordinary motor is usually a conventional cast aluminum cage structure, which has certain limitations in starting performance and operating efficiency. High-efficiency three-phase asynchronous motors will adopt a variety of rotor designs according to different application scenarios. For example, cast copper rotors have better electrical conductivity, which can effectively reduce rotor resistance and reduce operating losses; there are also rotors with special slot designs, which can improve the starting characteristics of the motor and improve operating stability by optimizing the shape of the rotor bars and end rings.
In terms of bearings and mechanical structures, the bearings used in ordinary motors are generally standard models, with relatively basic designs in terms of lubrication and sealing, which are prone to wear and heating problems when running at high speed for a long time. In order to ensure low friction and long life operation, high-efficiency motors will use high-quality bearings with low friction coefficients, and adopt more advanced lubrication systems and sealing structures. In addition, the base and end covers of high-efficiency motors have higher processing accuracy, and the rotor dynamic balancing treatment is more refined, which significantly reduces the vibration and noise of the motor during operation, and greatly enhances the mechanical reliability.
The difference in heat dissipation systems should not be ignored either. The heat dissipation of ordinary motors mainly relies on the natural cooling of the heat dissipation ribs on the surface of the base, or is combined with a simple fan for air cooling. The heat dissipation efficiency is limited. When running at high load for a long time, the internal temperature of the motor is easy to rise, affecting performance and life. High-efficiency motors are equipped with a more complete heat dissipation system. By optimizing the shape and layout of the heat dissipation ribs, the forced air cooling effect is enhanced, and even independent water cooling systems are used in some high-power motors to ensure that the motor can maintain a low operating temperature under various working conditions.
High-efficiency three-phase asynchronous motors build a set of efficient, energy-saving, stable and reliable operating systems through structural optimization in materials, electromagnetic design, winding technology, rotor structure, bearing machinery, heat dissipation system, etc. These differences not only reflect the progress of motor manufacturing technology, but also provide strong support for energy saving and efficiency improvement in industrial production.
