Design, analysis and manufacture of IE4 efficiency class new generation synchronous reluctance motor

In this study, it is aimed to design and manufacture a high efficiency, domestic and national new generation Synchronous Reluctance Motor (SynRM) suitable for the IE4 efficiency class, which has just got into the global market, instead of the IE3 efficiency class induction motor used in the industry. For this purpose, a new generation synchronous reluctance motor was designed and manufactured according to IE4 efficiency class, which uses the same stator structure as an IE3 efficiency class 1.1 kW induction motor. The synchronous reluctance motor was analyzed in the ANSYS Maxwell software based on the finite element method. While designing the SynRM rotor, it was tried to find the best solution for the synchronous reluctance motor by considering the flux barrier number, flux barrier and segment widths, flux barrier location, tangential rib and radial rib widths. In the analysis studies, high saliency ratio, efficiency, power factor and low torque ripple were targeted. As a result of optimization studies, the most suitable rotor design was obtained and SynRM with four flux barriers was manufactured. The stator of SynRM, which is designed and manufactured, is taken with the same feature as the induction motor stator. In addition, two different stators with copper and aluminum windings were used. Motor performance analysis of the manufactured SynRM and induction motor were carried out with experimental studies and compared with simulation results. According to the experimental results, it was observed that the efficiency of the induction motor was 85.1%, meeting the IE3 efficiency class, while the efficiency of the SynRM was 87.55%, meeting the IE4 efficiency class standard. In this sense, thanks to the high-efficiency electric motors developed, energy consumption will be reduced and it will be possible to contribute to energy gain, reduction of global warming and healthy life.