IE2 to IE4 Transition of Induction Motors for Sustainable Industry: Electromagnetic Performance, Loss Breakdown, Experimental Validation and Cost Analysis
Applied Sciences (Switzerland), cilt.16, sa.13, 2026 (SCI-Expanded, Scopus)
- Yayın Türü: Makale / Tam Makale
- Cilt numarası: 16 Sayı: 13
- Basım Tarihi: 2026
- Doi Numarası: 10.3390/app16136799
- Dergi Adı: Applied Sciences (Switzerland)
- Derginin Tarandığı İndeksler: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Applied Science & Technology Source, Compendex, INSPEC, Directory of Open Access Journals
- Anahtar Kelimeler: experimental validation, finite element analysis, IE2-to-IE4 transition, induction motor, industrial energy efficiency, loss breakdown, sustainability, torque-speed characteristic
- Yıldız Teknik Üniversitesi Adresli: Evet
Özet
High-efficiency industrial motors are increasingly important for reducing energy consumption, operating costs, and indirect carbon emissions. This study presents a comparative evaluation of IE2 and IE4 efficiency class induction motors with the same rated power and frame size through finite element analysis and prototype testing. Two-dimensional transient electromagnetic models were developed in ANSYS Maxwell to investigate magnetic flux distribution, torque behavior, losses, and steady-state performance, and the numerical results were experimentally validated according to IEC 60034-2-1 procedures. The results show that the IE4 motor provides a more balanced magnetic flux distribution, lower local saturation tendency, reduced torque ripple, and lower total losses than the IE2 motor. Experimental measurements confirmed the numerical predictions with good agreement, particularly at the rated operating point. In addition to higher efficiency, the IE4 motor exhibited stronger starting and breakdown torque characteristics, indicating superior load-handling capability. An economic assessment based on a representative duty cycle showed that the relative additional cost of the IE4 motor can be recovered within approximately 0.81 years, while lower annual electricity consumption also reduces indirect CO2 emissions. Furthermore, the IE4 prototype operated at a lower thermal steady-state temperature, supporting longer insulation life and improved long-term reliability. Overall, the findings demonstrate that replacing conventional IE2 motors with IE4 alternatives is not merely an efficiency upgrade, but also a technically robust, economically justified, and environmentally effective strategy for sustainable industrial systems.