At Came, we developed the winding for a high-efficiency 1.5 kW, 2-pole motor that is MEC 80 in size
The project was initiated with a view to reducing overall dimensions and costs compared to the existing MEC 90 size solution
The three-phase version achieved efficiency level IE3 with an efficiency of 84.8%
The single-phase version achieved efficiency level IE2 with an efficiency of 81.6% and a starting torque of 32%
A specific request: 1.5 kW in MEC 80
The project began in July 2024 at the request of a customer in the surface and pool pump sector, who asked us to develop a winding solution for a high-efficiency 1.5 kW, 2-pole motor, with single-phase IE2 and three-phase IE3 versions.
The main constraint was size: the product had to be MEC 80 rather than the MEC 90 initially proposed and already developed, so that the customer could use a smaller pump with a B5 MEC 80 flange coupling.
More compact and lower cost
The aim was to reduce the size and cost of the final solution, while also achieving savings by reducing the size by one step. The planned supply included an asynchronous wound stator in a machined Came casing, and a rotor with a shaft, with the aim of achieving 1.5 kW in MEC 80 while maintaining efficiency, starting torque and reliability.
Development from the existing Came base
We started from a high-efficiency winding design already developed by us at Came with a size of MEC 80: a 1.1 kW solution with a lamination pack height of 90 mm. From this base, we developed the 1.5 kW version, increasing the lamination pack height to 110 mm and creating both the single-phase IE2 and three-phase IE3 versions.
The decisive technical choices
During the project, we identified the maximum lamination pack height that was compatible with the rear shield, casing and flange, and chose a low-loss magnetic lamination to achieve the efficiency target. Another key point was the starting torque of the single-phase motor, which had to be 30%. We achieved this by introducing a dedicated rotor process.
The three-phase IE3 version achieved an efficiency of 84.8%.
After dimensioning and making samples, bench tests confirmed that the required targets had been met.
The three-phase IE3 version achieved an efficiency of 84.8%, compared to a nominal reference value of 84.2%, while the single-phase IE2 version achieved 81.6%, compared to the minimum required value of 81.3%.
The starting torque of the single-phase motor was also on target, with a measured value of 32%.
A saving of 22% compared to the larger size
Compared to the larger size version, there was a saving of 22% in the total supply cost. The saving was achieved mainly by reducing the copper weight, which has a significant impact on the overall cost of the solution.
The best choice is the result of balance
Reducing the size does not just mean reducing the product dimensions, but finding the right balance between power, efficiency, available space, materials, starting torque and final cost.
In this project, by changing from size MEC 90 to MEC 80, the customer obtained a more compact and economical product while maintaining the required efficiency targets.
At Came, we help the customer develop asynchronous windings and custom technical solutions, when performance, project control and attention to the final cost are required.
Contact us to make your next product more efficient.
Fabrizio Bardelli
Came Research and Development Expert
consulting@came-italy.com
+39 0444 488282
