Electric motors account for over half of the world’s electricity consumption, so boosting their efficiency isn’t just about saving costs — it’s about conserving energy and minimising the environmental impact. While IE5 is currently the official benchmark for motor efficiency, WEG has already set its sights on IE9. But wait — aren’t we still working towards official classification of IE6? In this article, Marek Lukaszczyk from WEG explores what lies ahead for motor efficiency standards.
Motor efficiency has evolved significantly over the years, driven by the International Electrotechnical Commission (IEC) and its efficiency standards. Each new efficiency level has reduced energy losses by about 20 per cent compared to the previous iteration. From the baseline IE1 (standard efficiency) to the IE5 (ultra-premium efficiency), these advancements have helped industries lower costs and cut carbon emissions. Now, the anticipated IE6 (hyper-efficiency) standard promises to push the boundaries even further.
Although official codification of the IE6 standard is still in progress, IE6-rated motors are already making waves in the industry. Several global motor manufacturers have followed the same method used to define previous efficiency classes and have launched IE6-predicted models. In the case of these motors, this translates to a 20 per cent reduction in losses compared to IE5.
IE6 to IE9: A significant jump
In 2024, WEG launched the W23 Sync+ Ultra motor, designed to meet the anticipated IE6 classification. This motor integrates permanent magnet (PM) and magnetic reluctance technologies to achieve this high level of efficiency. PM motors are regarded as one of the best options for achieving high energy efficiency due to their ability to create a magnetic field without the need for current in the rotor. This significantly reduces losses compared to traditional induction motors, delivering superior performance. Since the launch in 2024, this motor range is being widely adopted by industry.
Another example of progress towards higher efficiency levels is the W80 AXgen Axial Flux motor. Using an axial flux design, the motor range meets increasing demand for compact and efficient motor technology. With frame sizes from 250 to 400, the W80 AXgen reaches up to 96.9 per cent efficiency, placing it just shy of the anticipated IE6 efficiency rating.
The development of these motors has laid the groundwork for even more remarkable efficiency achievements from WEG. This includes a recently unveiled prototype of its 500 kW W23 Sync+ Ultra motor which meets a forecasted IE9 efficiency rating.
In this case, the IE9 calculation follows the same methodology used for previous classes, measuring energy losses as a percentage of total power input. With this approach, an IE9 motor would reduce losses by 80 per cent compared to an IE5 motor, achieving efficiency of nearly 99 per cent. The prototype motor demonstrated an impressive 98.8 per cent efficiency at 500 kW, with this result validated through extensive validation and testing by dynamometer.
What future efficiency ratings mean for Industry
Motor technology is evolving at an unprecedented pace, with efficiency improvements outstripping current industry standards. As innovation continues to push boundaries, a robust regulatory framework is essential to keep up with these advancements.
At WEG, we believe it’s important for manufacturers, regulators and industry stakeholders to work together to ensure that efficiency standards evolve in step with technological progress. Whether this means maintaining existing classifications like the current 20 per cent scale or exploring new approaches, it’s essential for the industry to establish forward-thinking standards that reflect the latest advancements in motor technology.
For end users and machine builders, motor efficiency ratings might not be quite as hot of a topic as it is for motor manufacturers themselves. However, opting for the most efficient motor available makes sense on multiple fronts.
Beyond regulatory compliance, the benefits are clear. A more efficient motor reduces energy consumption, which directly translates into lower operational costs over time. Additionally, highly efficient motors tend to have longer lifespans and require less maintenance, further reducing costs. From an environmental standpoint, the advantages against sustainability efforts are obvious.
For WEG, we will continue pushing the boundaries of energy efficiency in motor design and surpassing regulatory requirements. Regardless of how the current efficiency rating system evolves, our IE9 achievement highlights the technical possibilities in motor efficiency.
Discover the W23 Sync+ Ultra motor from WEG.
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