Magnetic materials improve efficiency of motors

Researchers from the University of Adelaide are using new magnetic materials to develop energy-saving electrical motors and generators. Their research has been funded through two different Australian Research Council Linkage project grants.

Lead researcher Associate Professor Nesimi Ertugrul, from the university’s School of Electrical and Electronic Engineering, noted, “In the developed world, more than 50% of all energy generated is used by electrical motors”, a significant portion of which are used to drive water pumps.

“This leaves a lot of room for efficiency gains.”

The researchers have used two emerging magnetic materials - soft magnetic composite (SMC) and amorphous magnetic material (AMM) - and two novel production techniques to form the ‘stator’ within the electrical motor or generator. The stator is the stationary and magnetic part of a motor surrounding the rotor which turns.

“Currently all commercial motors are made by pressing very thin metal sheets of silicon iron together and then stamping out the shape of the stator from the metal,” said Associate Professor Ertugrul. “This process is wasteful of the metal sheeting and also limits the best use of available space for the copper wire needed in motors.

“We’ve produced new stators using SMC with no need for machining, no scrap metal and improved space utilisation for copper wire for greater power output.”

Both production techniques have been successfully developed and tested with patented prototypes, showing substantial energy efficiency gains - up to 90% energy efficiency in small motors compared to 60-70% in conventional motors. Using SMC material and working with industry partner Intelligent Electric Motor Solutions (IEMS), the team developed motors that operate at low speed with high power output and with low production costs, suitable for swimming pool and similar pumps.

The researchers are now looking for further investment partners to commercialise the technology.