Current state of the heavy Electrical equipment Industry
Machines are driven by motors, therefore they have been given the title of "Heart of Industries". According to International Energy Agency (IEA)’s analysis, industrial machines powered by motors are the most power-hungry equipment in the industry, including drills, pumps, air compressors and blowers. Collectively, they account for approximately 46% of the global power consumption. In Taiwan, motor power consumption accounts for 68% of all industrial power consumption. The staggering amount of power consumed by motors means that "energy-saving" has become a key consideration during new product development. In addition to increasing emphasis on the performance of motors, the application of inverters to expand system has also been widely accepted, further increasing efficiency and performance. According to estimates by European Committee of Manufacturers of Electrical Machines and Power Electronics (CEMEP), the ratio of motor + inverter applications will rise from 22% in 2012 to 45% in 2020.
Development of TECO’s high efficiency motors
The chart below shows the roadmap for development of high efficiency motors for major global markets including America (NEMA), Europe (IEC), China (GB), Japan (JIS), and Taiwan (CNS). Relevant product series were completed prior to enactment of IE2 and IE3 related laws and regulations in each market. Despite the fact that no concrete timetable for the implementation of the higher efficiency rating standards IE4 and IE5 exists in these countries, TECO has already completed development of the first aluminum die-cast rotor IE4 high-efficiency induction motors in the world as well as IE4 high-efficiency permanent magnet motors integrated with inverter drives to achieve maximum energy conservation and emission reduction effects for customers and improve the company’s technical capabilities In addition, the company uses no or very little rare-earth magnet for its IE4 synchronous reluctance motors and magnet-assisted synchronous reluctance motors. Even the most efficient IE5-grade permanent magnet motors have already been deployed.
In 2017, the sales of high performance energy-efficient motors below 300hP (224kW) (IE3+IE4) accounted for 61.27% and 37.91% of TECO's sales revenue and volume, respectively. Total energy savings reached 606 million kWh of electricity (please refer to the charts below):
High-efficiency motor roadmap Roadmap
Green Product Performance
Sales ratios of high performance energy-efficient motors below 300hP (224kW) in 2017 (IE3+IE4)
Compared to IE1-rated motors, high performance and energy-efficient motors (IE3+IE4) sold by TECO all over the world in 2017 generated annual electricity savings of roughly 606 million kWh and emission reductions of 335,800 tCO2e.
Energy-Efficient Inverters and Green Energy Solutions
In addition to high-efficiency energy-saving motors, TECO also actively develops industrial low- and medium-voltage inverters and servo drives to pursue business opportunities in the field of energy conservation. In response to global trends of energy conservation, carbon emission reduction, and eco-friendliness, and production automation as the mainstream in global industrial development of, the main focus of electric control business development lies on the development of products that meet demands for high-efficiency, energy conservation and precise control for mechanical systems. On the foundation of the "TECO GO ECO" vision, the company has also developed control components for motors, such as inverters, servo drives and other perimeter protection low voltage products to meet industry needs for safe electricity usage, automation, and energy conservation.
The TECO 510 industrial control series inverters features the 4 initials L, E, A, F, symbolizing the core spirit of harmony and symbiosis with nature and achieving the dual objective of higher energy efficiency and better energy conservation. Optimized inverter design results in reduced environmental burdens, and the use of eco-friendly materials that conform to RoHS and REACH management standards ensures that no injuries or secondary pollution are generated. The company also actively promotes an environmental safety and health management system and has acquired the ISO14001 and TOSHMS/OHSAS 18001 certifications with the goal of maintaining the safety of work operations and minimizing environmental impacts. The 510 series features a complete range of solutions from entry-level to high-end with different specifications and a high cost-performance ratio as far as horsepower is concerned. This series represents a major breakthrough in domestically produced energy-saving inverters in terms of powerful features and application breadth.
The A510s and F510 series is not only capable of controlling induction motors but has also achieved significant progress in the control of highly complex synchronous motors, breaking through the bottleneck of inverter energy conservation efficiency with an average efficiency of 45%.
Future Development of Heavy Electric Business
Era of permanent magnet motors
As the motor development trend advances from IE2 to IE3, there is also increasing market scale for permanent magnet motors. Compared to traditional induction motor, permanent magnet motor has advantages such as simple structure, compact size, lightweight and minimal wear. Furthermore, the cost of rare earth material used for permanent magnet motor has decreased significantly recently, making it more cost-competitive. Moreover, its efficiency is able to exceed IE4 regulations. Not only so, since it needs to work in conjunction with an inverter, the overall energy-saving performance is also improved. TECO’s permanent magnet motors are divided according to the application needs of different speeds; in particular, the DVLS series focuses on the 3,000~6,000 rpm market segment, including air compressors and water pumps, achieving a maximum energy-saving of 30%. In the future, permanent magnet motors designed for wind and hydraulic power applications will facilitate TECO’s developments in motor products for higher speed applications.
TECO not only strives to refine product performance on an ongoing basis, it also engages in the development of system integration solutions, providing power system modules integrating motors, inverters and gear reducer motors. The Company also proactively listens to the clients’ service needs. TECO has implemented motor health examination service for its clients based on the smart equipment monitoring technology. Also known as QRC (Quick Response & Repair Center), the purpose of this initiative is to provide customers with outstanding aftersales service over the long run.
The creation of QRC provides customers with expeditious repair, guarantee, technical modification and replacement services.
Motor repair and maintenance service can be expanded to other equipment replacement opportunities in order to offer one-stop service: inverter, gear reducer motor, switchboard, busway, diesel generator, wind and hydraulic power units, on-site disassembly/modification project and new repair and maintenance monitoring system.
Development of a Smart Microgrid
TECO actively deploys Industry 4.0 through IoT data and integration of the power grid and storage and release management of green energy. The company has the ability to conduct self-monitoring and power consumption allocation and combine power grid supply with supplementary renewable energy sources including solar energy, small-scale wind turbines, and fuel cells in a flexible manner. Grid-connected operations generate carbon emission reductions. This system can also operate independently and serve as a large-scale mobile power supply to provide emergency or backup power for the military, power companies, data centers, medical units, emergency rescue units, etc. as well as remote areas or outer islands without stable power supply. Business owners can access the status of power supply at any time through the mobile APP with TECO's smart micro-grid system and cloud-based smart monitoring system. The smart micro-grid utilizes a smart cloud monitoring system. A firm grasp of power supply conditions is maintained through a mobile APP.
Development status of the smart micro-grid
In 2017, TECO has collaborated with its subsidiaries to win the bid for New Taipei City’s smart community micro-grid demonstration project. Furthermore, efforts are being made to secure micro-grid projects in areas or countries where electricity is less accessible, including Indonesia, Philippines, remote townships in Taiwan and smart communities.