Motor technology: The impact of EPAct

When John A. McFarland joined Baldor Electric Company in 1970, it was about a $20 million business. Last year, Baldor did over $500 million in sales. McFarland, who became president of the company in 1996, attributes that success to a strong focus on the customer. "Our philosophy kind of flies in the face of what they are teaching today in business school about studying your competition, but we just feel very, very strongly that the right way to run a business is to study your customers," says McFarland, "and then act upon what you're hearing from then.

"The Energy Policy Act (EPAct) became effective on October 24, 1997. The law mandates energy efficiency standards for general purpose, three-phase ac industrial motors from one to 200 hp. Industry experts estimate that this class of motors uses more than half the electricity generated in this country. John A. McFarland, president of Baldor Electric Company, shares his insights on the law's impact and trends in motor technology.

Design News: Now that EPAct is effective, what kind of an impact is it going to have on motor suppliers and their customers?

McFarland: EPAct has already had a tremendous impact on our industry. Although Baldor has been improving motor efficiency since the 1970s, in preparation for EPAct we have made substantial investments in new tooling, laminations, production, and testing. These efforts are going to have a substantial, positive impact on engineers, because we think that our motors that comply with EPAct are even better than the motors we made before. They are not only higher in efficiency, but they cost less to operate. They also run quieter and cooler.

Q: What are some of the design strategies for raising motor efficiency?

A: The most effective strategy for making a motor more efficient is to use more and better materials. But you can't just make a better motor and expect the customer to pay any price for it. To help keep costs in line, Baldor has worked very hard to improve its motor manufacturing techniques. We did a lot of research into the processes that go into making a motor, looking for opportunities at every stage along the way to improve both manufacturing efficiency and consistency. For example, one process improvement we made has greatly improved the balance of the motors--they are now dynamically balanced to half NEMA's vibration limit, which will result in a longer motor life. And we're not stopping here--we are going to continue looking for opportunities to improve.

Q: Have you introduced a new line of energy-efficient motors?

A: No, we took a different approach than many of our competitors by improving upon our standard line of motors. Customers were telling us they are happy with this line. So we now refer to our standard line as Baldor Standard-E.

Q: Are all energy-efficient motors equal in performance, and how can engineers avoid a low quality product?

A: No two products are ever really equal. Two motors may be equivalent in efficiency, but that is only one component of quality. Other important indicators of quality are the amount of torque the motor has, the type of bearings, the manufacturing tolerances, the amount of noise generated, and so on.

To ensure a high quality motor, an engineer should work with a company that is reputable. A motor manufacturer should be able to supply data demonstrating that the motors have been tested and that they comply with EPAct. I would also caution designers against any low-ball bids. The only way you're really going to get higher motor efficiency is by using more and better materials--along with good manufacturing techniques--and those things cost money.

Q: So an energy-efficient motor is going to cost more than a standard motor?

A: The answer is yes, but only from the perspective of the upfront purchase price. An energy-efficient motor is actually going to cost less in the long run because it will have lower operating costs and a longer life. And in some cases, a motor with higher efficiency than EPAct may cost even less. To help designers choose what type of motor is most economical for a particular application, we provide a cost-analysis spreadsheet. The user can plug in information on expected duty cycle, power consumption costs, motor purchase price, and so on, to determine what particular motor has the best pay back.

Q: Beyond economics, how can an engineer ensure that he or she has selected the ideal motor for the application?

A: An engineer needs to know as much as possible about the specific application and the motor choices available. While there are ways to analyze this information, we believe that testing should always be done to confirm what the analysis shows.

Q: What can we expect to see in motor technology in the near future?

A: For several years now, we have seen increasing use of electronics. Electronics help motors run more reliably and achieve better performance--all for a lower cost. And electronics are helping to make the technology simpler.