Development of Premium efficiency IE3 class induction Motors Using same stampings of High efficiency ie2 class induction Motors

Government of India issued gazetted notification to use minimum IE2 efficiency class induction motors in all new industrial plants. Presently IE3 class induction motors are being manufactured only by large manufacturers and a few companies in India. Small and medium motor manufacturers are facing challenges to develop and manufacture IE3 class induction motors due to considerable investment in R&D and lack of engineering capabilities for manufacturing. Development of IE2 class induction motor requires basic changes like CRNO steel grade, increased volume of CRNO and increased volume of copper. Whereas development of IE3 class induction motor requires redesigning of windings, stamping profiles, stamping dies, end rings and die cast moulds. Bearings, tooling, patterns of main body, end covers and machine fixtures need to be replaced as per new design. This is a challenge for small and medium manufacturers in terms of time and financial investment.

General difficulties faced by Small and medium motor manufacturers during design and development of IE3 class inductions motors, are covered in this paper. Changes in manufacturing process and precautions in material selection for developing IE3 class induction motors are also discussed. Standard approach of reducing the losses of IE2 class induction motor is followed and how the losses are reduced is also covered.