How to reduce electric motor losses

In the process of converting electrical energy into mechanical energy, electric motors experience losses. This means that when a motor is activated, energy that is not converted into mechanical power dissipates as heat. This heat causes the temperature of the windings to increase, which can in turn lead to the insulation melting. This ultimately results in a short circuit and failure of the motor.

There are three main causes of electric motor losses:

Core (iron) losses

Heat dissipated during core losses further degrades the core, causing greater core loss and more heat – a vicious cycle! Losses can be reduced by lengthening the core and using thinner laminations.

Stator losses

Stator losses occur as current flows through the winding – remedies include using thinner insulation and increasing the volume of wire (which will require stator slot design changes).

Rotor losses

These losses take place in the rotor conductive bars, which may be made bigger to increase the size of the cross section. Larger end rings can also reduce resistance.

Reducing losses improves your motor’s efficiency and extends its service life, saving you money both now and in the long term. We’ve been rewinding and repairing electric motors for 45 years, so for information on how Gibbons can help you cut your losses, give us a call on 01621 868138 or email info@gibbonsgroup.co.uk.