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HO M E > C O NTENT > SELEC TI NG TO RQ U E FO R TO P M O TO R EFFI C I ENC Y

Selecting Torque for Top Motor Efficiency

Robert J. Lawrie | Electrical Construction and Maintenance
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Jan 1, 1999
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Sure, horsepower is an important motor parameter. However, torque is just as important. That said, what
exactly is torque? It really depends on your point of view. If you're the motor, your shaft exerts the torque's
turning effort. As such, we call it motor torque. We commonly measure it in pounds-feet (lb-ft.). If you're
the load, torque is the turning effort you require at your input shaft for your

Sure, horsepower is an important motor parameter.

However, torque is just as important. That said, what
exactly is torque? It really depends on your point of view.
If you're the motor, your shaft exerts the torque's turning
effort. As such, we call it motor torque. We commonly
measure it in pounds-feet (lb-ft.). If you're the load, torque
is the turning effort you require at your input shaft for your
proper operation. In this context, we call it load torque, also measured in lb-ft. Basically,
you should consider torque both as it pertains to the demands of the load you want to
drive, and as it applies to the capabilities of the driving motor.

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Regardless of your point of view, selecting the best and most efficient motor for the job
(based on first-cost and operating costs) depends directly on its torque. Remember, a
motor's operating efficiency falls off rapidly at lower values of torque loading.

these seven facts.

Motor ratings and nameplates are standardized in terms of horsepower and speed,
with no mention of torque. However, you can relate horsepower and torque with the
following equation: Horsepower = Torque (lb-ft) x rpm/5250

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Cost differentials.

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Up-front cost. It's the design torque rating of the motor that most directly affects its
material cost. For example, a 10-hp, 1200-rpm motor costs more than a 10-hp, 1800rpm motor, because the former's rated torque is nearly 50% greater. Likewise, a 10-hp,
900-rpm motor costs even more, because its rated torque is almost 100% greater than
that of an 1800-rpm motor.

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This also helps explain why you don't see motors with synchronous speeds lower than
900 rpm very often; it's usually more economical to use an 1800-rpm motor instead, and
add any necessary gearing or pulleys to obtain the desired speed.

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Operating cost. The operating cost of a motor depends on its efficiency at a given
condition of loading. This applies to existing standard induction motors as well as energyefficient (EE) motors.

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E C&M White Papers

Know Your TCO: A
Look at Medium

Voltage VFDs

For competitive manufacturing-cost reasons, manufacturers generally design motors to

have peak efficiency at or near the full-load nameplate rating. Y ou can see this in the
accompanying diagram, on page 44. Notice how rapidly efficiency deteriorates below the
approximate 50% level of nameplate load. The reason for this decline is: About one-third
of the losses in a typical motor will vary with load torque, while the remaining losses are
essentially constant.
Because of these fixed losses, a large cost penalty occurs if you operate a motor at low
values of loading.

Learn about the intricacies

involved in calculating TCO
and the elements that
affect it....
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Selection guidelines. From the foregoing cost factors, you should focus on two
important selection and application guidelines:

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Buy only as much motor as you need: Avoid oversizing.

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Minimize prolonged operation at light-load conditions.

In some manufacturing plants, preexisting conditions may exist, which may prevent you
from applying these rules. In any case, you must be aware of the cost penalties involved if
you cannot "load-match," size appropriately, or operate the motor you select according to
guidelines.
Y ou can use many different techniques to comply with these two guidelines. It's
important you research the numerous considerations applying to proper motor selection
and operation. We'll cover these in the March issue. Future Motor Facts articles will
discuss how steady-state, acceleration, and starting torque reduce motor operating costs.

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