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11 February 2025

50 Pages

A Review of Recent Trends in High-Efficiency Induction Motor Drives

Electrical Engineering Department, Yanbu Industrial College, Yanbu 46452, Saudi Arabia

Abstract

Induction motor (IM) drives are considered one of the important technologies in modern industry. Several industrial applications, such as material handling and food and beverage applications, are driven and operated by modern AC drives. Moreover, modern electric transportation systems such as EVs and e-trucks are based on AC drives. Recently, high-efficiency IM drive systems have been studied as a major opportunity to reduce energy and fuel consumption. This article addresses the recent trends and advancement in high-efficiency IM drives during a particular period (2017–2024), including the development of high-efficiency motors, the utilization of efficient wide bandgap (WBG) semiconductor devices for inverter topology, and commonly used control strategies to achieve high-performance drives. Moreover, the article addresses several manufacturers of industrial IM drives and the corresponding adopted control techniques in their products. A comparison of these control techniques, including their pros and cons, has been conducted as well.

1. Introduction

1.1. Market Size of Electrical Drives

The demand for electric drives (EDs) across various industrial sectors and applications is growing. Owing to the latest published reports [1], the global market size for EDs is estimated at USD 25.51 billion in 2024, and is expected to reach USD 32.70 billion by 2029, growing at a compound annual growth rate (CAGR) of 5.10% during the period of 2024 to 2029 [1].
Meanwhile, the global market size of AC drives accounts for an estimated value of USD 17.9 billion in 2022, and is projected to reach USD 25 billion by 2028 at a compound annual growth of 5.7% [2]. Figure 1 and Figure 2 indicate the global market size of electrical drives and AC drives, respectively.
Figure 1. Estimated global market size of electrical drives.
Figure 2. Estimated global market size of AC drives.

1.2. Electric Drives and UN-SDGs

During the last decade, the demand for efficient electric drives (ED) has increased significantly to reduce energy consumption and enhance environmental conservation in accordance with the sustainable development goals (SDGs) of United Nations (UN), and directly linked to SDGs 7, 9, 12, and 13, which are related to energy efficiency, sustainable and clean industries, and climate action to reduce greenhouse gas emissions, respectively. Owing to the latest published reports [3,4], significant acceleration is still needed to meet the target (see Appendix A to recognize the SDGs goals).
Therefore, high-efficiency AC drives play a considerable role in tackling some of the world’s greatest challenges and achieving a sustainable and equitable future. The high-efficiency drives are characterized by minimal energy consumption and significant energy savings, resulting in less fuel consumption and a significant reduction in carbon emissions. These positive consequences support the transition to more sustainable energy use, aligning with the UN-SDGs. The wide spread of these high-efficiency drives promotes the development of more eco-friendly technologies, enhancing energy efficiency across various sectors. As mentioned before, the utilization of high-efficiency electric drives helps mitigate greenhouse gas emissions, contributing to global efforts to limit global warming [5,6].

1.3. Main Contribution

This paper presents a literature summary of the state-of-the art advancements in high-efficiency induction motor drives during a particular period (2017–2024), including high-efficiency electric motors, low power losses power semiconductor devices, and advanced control techniques that essentially contribute to improving the overall AC drive efficiency in accordance with energy efficiency guidelines and standards. In addition, the paper provides a literature summary of recent regenerative braking methods and energy saving algorithms incorporated with the induction motor control system. Moreover, the article provides a list of well-known industrial IM drives produced by several manufacturers, including their adopted control techniques. A comparison has been made between these control techniques, highlighting their pros and cons.

1.4. Elements of a Typical EDS

The generalized block diagram of a typical electric drive system (EDS) is illustrated in Figure 3. A typical EDS is composed of the following elements: mechanical load, electric motor, power source, power electronic converter (power conditioner), control unit, and measuring devices (sensors and transducers).
Figure 3. Block diagram of a typical electric drive system.
Simply, the main objective of an EDS is to drive a mechanical load at any desired speed/position and torque requirements using an electric motor that is fed from a power source through a proper power electronic converter. The high-performance EDS operates in closed-loop mode, such that the motor can run at the desired speed apart from the load variation or any transient variations in the input voltage that feeds the EDS [7].
Practically, the block diagram of the high-efficiency EDS is like the conventional EDS. The major differences between both systems are considered in the following points:
  • Efficiency classes of the electric motor, where high efficiency and premium efficiency classes are employed;
  • Types of the power semiconductor devices that form the power electronic converter, where a high-efficiency converter that offers minimum power losses is utilized;
  • Control techniques, which can involve energy saving algorithms or guarantee operation at optimum flux level for a wide range of motor speeds.

1.5. Factors Affecting Efficiency of IM Drives

The key factors that affect directly the overall efficiency of the IM drives are related mainly to motor design, operating conditions, environmental conditions, periodic checkup rate, and maintenance status. The breakdown of these factors is summarized in Table 1.
Table 1. Key factors affecting overall efficiency of IM drives.

1.6. Power Losses in IM Drives

The previously mentioned factors of Table 1 can be optimized to achieve a high-efficiency AC drive. Practically, the corresponding items of Table 1 contribute to various power losses across the elements of the AC drive, which altogether affects the overall efficiency of the IM drive. Accordingly, the main types of power losses in IM drives can be summarized in the following points:
  • Copper losses across the motor windings;
  • Magnetic (iron) losses of the magnetic circuit;
  • Losses in rotor windings (in wound rotor) or cage losses (in case of squirrel cage);
  • Iron losses or core losses including hysteresis and eddy currents losses;
  • Mechanical and bearing losses due to friction;
  • Stray losses due to leakage flux, magnetic imperfections;
  • Switching power losses of the inverter;
  • Conduction power losses of the inverter;
  • Cooling system losses due to fans (forced air), liquid cooling and heat sink thermal resistance;
  • Inverter driving circuits power losses;
  • Snubber circuits and passive filters power losses.
Thus, minimization of all these types of losses by optimum design of the AC motors, utilizing efficient power semiconductor devices, optimizing the drive cooling, and adopting proper control strategy permits considerable energy saving and enhances the overall efficiency of the electric drive system.

1.7. Advancement Directions in IM Drives

The advancement in IM drives has many directions. The major trends include:
  • Replacement of conventional IM motors by high-efficiency and premium-grade counterparts [8,9];
  • Utilization of wide bandgap (WBG) semiconductors [10,11];
  • Implementation of modern control techniques such as: direct torque control (DTC) proposed by authors of [12], model predictive control (MPC) [13], and incorporation of regenerative braking and energy saving algorithms to reduce energy consumption [14,15];
  • Utilization of efficient high-speed digital signal processors (DSP) as core processors [16], and involvement of hardware in the loop (HIL) data acquisition cards for rapid prototyping and testing purposes [17,18].
Discussions of such directions are presented in Section 2, Section 3, Section 4 and Section 5 as follows: Section 2 provides an overview of the state-of-the-art advancement in high-efficiency induction motors that are commonly used in IM drives. In fact, induction motors are only considered in this article to limit the study and the article length. Section 3 addresses the major trend in high-efficiency power electronic converters based on (WBG) semiconductor devices. Section 4 presents an overview of the advanced control techniques utilized to achieve high-performance IM drives. Section 5 highlights key manufacturers of induction motor drives and the employed control techniques. In addition, some applications of IM drives are addressed in Section 6.

2. High-Efficiency Induction Motors

In general, motor design plays an important role in achieving higher efficiency [19,20]. Several types of AC motors are commonly used and employed in modern electric drive systems. Thus, obtaining high-efficiency AC drives depends on utilization of high-efficiency AC motors. Induction motors (IMs) are considered the most important rotating machines that remain widely used in the modern industry due to their simplicity and reliability.

2.1. Main Features of High-Efficiency IMs

Compared with the standard types of 3-Φ induction motors, whose cross section of their stator is illustrated in Figure 4, and the rotor of squirrel case types, depicted in Figure 5, the high-efficiency counterparts have the following features:
  • Longer core (motor) length;
  • Thinner core lamination;
  • High grade core material such as grain-oriented silicon steel;
  • Wider stator slots with optimized shapes (based on finite element design and analysis);
  • Thicker stator windings (larger winding cross section area);
  • High temperature electrical insulation class;
  • Larger rotor diameter;
  • Lower resistance rotor bars such as die cast copper rotor;
  • Narrower air gap between the stator and rotor;
  • Larger fan size with optimized aerodynamic;
  • Larger cooling fins and increase cooling surface area;
  • Small bearing size with lower friction losses;
  • Anti-corrosion coating for the motor body.
Figure 4. Cross section of stator of a 3-Φ induction motor.
Figure 5. Rotor of a squirrel cage of a 3-Φ induction motor.
Due to the importance of the topic, several research efforts have been exerted during this decade to improve the performance of IMs in terms of minimizing power losses, improving the starting characteristics, or adopting new approaches for design optimization, such as development of bearingless motors for high-speed applications. Recent improvements in rotor designs and stator winding configurations have led to significant efficiency gains [21,22,23].

2.2. Research Contributions Related to High-Efficiency IMs

A summary of the major research contributions in high-efficiency IMs during the period of 2017–2024 are presented in Table 2, Table 3, Table 4, Table 5 and Table 6. The survey of core contributions includes the following main areas:
  • Design and manufacturing of high- and premium-efficiency induction motors (Table 2);
  • Optimization techniques and algorithms for high efficiency motor design (Table 3);
  • Efforts in bearingless IMs (Table 4);
  • Modeling, loss analysis, and computational tools (Table 5);
  • Thermal analysis and cooling systems (Table 6).
Table 2. Research contributions related to design and manufacturing of high-efficiency IMs.
Table 3. Research contributions related to optimization techniques for high-efficiency IMs.
Table 4. Research contributions related to development of bearingless IMs.
Table 5. Research contributions related to modeling, analysis, and computational tools for high-efficiency IMs.
Table 6. Research contributions related to thermal analysis and cooling systems for high-efficiency IMs.
Moreover, the efficiency ranges of typical premium efficiency IMs, fabricated by key manufacturers for different power ratings, are presented in Table 7.
Table 7. Technical data and efficiency ranges of typical high-efficiency induction motors.
Table 7 summarizes the corresponding efficiency ranges of typical premium efficiency IMs fabricated by different manufacturers [103,104,105,106,107]. For a power rating between 0.75 kW and 22 kW, the corresponding efficiencies are between 82.5% and 93.6%, while for a higher power rating between 30 kW and 110 kW, the corresponding efficiencies are between 93.6% and 95.8%.

3. Wide Bandgap (WBG) Power Semiconductor Devices

The transition from silicon (Si)-based semiconductor devices to wide bandgap (WBG) semiconductors devices is considered one of the most significant advancements in improving the overall efficiency of the power electronic converters [108,109]. Basically, the bandgap is defined as the minimum energy required to excite electrons, transferring the electrons from the valence band to the conduction band.

3.1. Characteristics of WBG Semiconductors

Compared to the conventional Si-based semiconductors, the WBG semiconductors have a larger (wider) bandgap, approximately three times wider. As illustrated in Figure 6, WBG semiconductors (SiC and GaN) have a bandgap between 3.3 eV and 3.4 eV, allowing the WBG power devices to withstand higher voltages (high breakdown voltage) due to the direct correlation between the bandgap and the critical breakdown (electric) field of a semiconductor. As a typical value, the critical electric field of WBGs semiconductors is approximately ten times greater than that of Si semiconductors (0.3 MV/cm in Si, 3.5 MV/cm in SiC, and 3.3 MV/cm in GaN). Consequently, the breakdown voltage in WBG devices is higher than that of conventional Si devices.
Figure 6. Simplified energy diagram and bandgap energy of Si, WBG, and insulators.
However, there are some main differences in several characteristics of SiC and GaN that make each type more convenient and adequate for certain applications over the other; e.g., GaN has higher electron mobility compared with SiC (GaN:1500 cm2/Vs, Sic: 900 cm2/Vs). This means GaN devices are characterized by high switching frequencies, which makes them more suitable for high frequency applications.
Meanwhile, the greater thermal conductivity of SiC devices (5 W/cmK) compared with that of than GaN (1.3 W/cmK) makes SiC devices transfer heat more efficiently, enabling operation at higher temperatures and allowing higher power densities as well. Thus, the distinct characteristics of each type of WBG devices make GaN suitable for low-power and high-frequency applications, while they make SiC suitable for high-power and high-voltage applications [110,111]. Compared to traditional Si-based devices, WBG devices offer superior performance in terms of higher switching frequencies, lower power losses, and high temperature capability. These advantages have permitted their utilization in various applications such as high-performance industrial drives [112,113], electric vehicles (EVs) [114,115], aircraft propulsion [116], and renewable energy applications [117,118]. The utilization of SiC power devices in motor drives can reduce the overall cost of the drive by decreasing the size of passive components [119,120].

3.2. Main Challenges and Design Issues

Compared with the Si power devices, the WBG power devices face some obstacles and challenges that limit their industrial utilization and delay achieving commercial acceptance and full satisfaction. Some of these challenges are:
  • Higher fabrication and manufacturing cost;
  • Complex fabrication processes to have the final product with good quality;
  • Reliability issue for GaN devices at high temperature;
  • Cooling system design and analysis;
  • Requirement of proper packaging to alleviate electromagnetic interference (EMI).
Fortunately, the fabrication costs of SiC devices are expected to decline as companies move toward the technology of six-inch wafers [120].
Several design issues are taken into consideration during design and testing of WBG-based power electronic converters to achieve successful and reliable operation [121,122,123,124,125]. The main important design issues that are related directly to the successful and reliable operation of the WBG-based power electronic converter are:
  • Gate driving signals (voltage levels), which are different from the well-known and commonly used values of Si devices;
  • The effect of parasitic inductance at operation of high switching frequencies, which requires compact and optimized PCB designs;
  • EMI and electromagnetic compatibility (EMC) concerns due to high dv/dt and di/dt.

3.3. Research Contributions Related to WBG-Based Converters and AC Drives

A summary of the major research contributions is presented in Table 8, Table 9, Table 10 and Table 11. The survey of core contributions includes the following main areas:
  • Performance analysis of WBG devices, inverters, and IM drives (Table 8);
  • System design and performance improvement (Table 9);
  • Thermal management and cooling systems (Table 10);
  • Key challenges and solutions (Table 11).
Table 8. Research contributions related to performance analysis of WBG devices and systems.
Table 9. Research contributions related to system design of WBG-based systems.
Table 10. Research contributions related to cooling systems of WBG-based systems.
Table 11. Research contributions related to key challenges and solutions of WBG-based systems.
Moreover, state-of-the-art ratings and main manufacturers of SiC-Base MOSFET power transistors, as one of the WBG power semiconductor devices, are summarized in Table 12.
Table 12. Typical ratings and some manufacturers of SiC power MOSFETs.
Owing to Ref. [204], typical state-of-the-art ratings and main manufacturers of SiC power transistors, as one of the WBG power semiconductor devices, are summarized in Table 12.

4. Main Control Techniques of IM Drives

4.1. Introduction

The most used control techniques applied in industrial IM drives are field-oriented control (FOC) and direct torque control (DTC). FOC, originated by Blaschke in [205], is utilized in IM drives when a precise speed and a high dynamic response are required [206,207,208,209,210,211,212,213,214,215,216,217,218,219,220,221,222,223].
A few decades after inventing FOC, the direct torque control (DTC) technique was proposed by the authors of [12] to provide fast dynamic response and good control of both motor flux and electromagnetic torque [224,225,226,227,228,229,230,231,232,233,234,235,236,237,238,239]. The first industrial DTC-based IM drive was designed and fabricated by ABB in 1996, introduced in [240].
On the other hand, many research activities have been conducted recently aiming to employ the finite control set model predictive control (FCS-MPC) approach to regulate motor speed, torque, and flux based on the dynamic model of the IM.
Moreover, for high-efficiency IM drives, the core control algorithms can involve efficiency optimization task/subroutine (function) to minimize the energy consumption by operating at optimum levels of flux and minimizing the reactive component of the current drawn from the AC supply. Also, adopting regenerative braking approach enhances the overall efficiency of the AC drive by returning to the grid the mechanical energy stored in the motor shaft during braking instants.

4.2. Field-Oriented Control

The commonly used and well-known scalar control methods of IMs provide satisfactory steady performance for economic general purpose AC drives. However, they are neither able to provide high transient response, nor are they suitable for precise operation and applications at low and very low speeds. In addition, scalar methods fail to achieve position control of IMs as servo drives. The field-oriented control, or vector control (VC), technique for IM drives was developed to overcome the main limitations of the scalar control methods
The FOC, or VC, technique aims to emulate the decoupled control features of a conventional separately excited DC motor by decomposing the stator current vector into two orthogonal components: direct component Id and quadrature component Iq. The direct component Id is responsible for air gap flux production, while the quadrature component Iq is responsible for electromagnetic torque production, as illustrated in Figure 7. This way, the FOC emulates the behavior of the DC motor, which results in high dynamic performance and good transient response under sudden load variations, provided that the machine parameters are identified on-line during the motor operation.
Figure 7. Phasor diagram of stator current components with FOC.
The block diagram of the basic scheme of FOC of IM drives is presented in Figure 8.
Figure 8. Block diagram of the basic scheme of FOC of IM drives.
In the VC or FOC system of 3-Φ IM, the reference electromagnetic torque T e m r e f * is computed as the output of the PI-speed controller. The reference stator flux F S r e f * is a function of the reference speed, involving the operation in the field weakening mode for motor operation at speeds above the rated value, as illustrated in the lower part of Figure 8.
Meanwhile, the reference stator currents i S d r e f * and i S q r e f * in the d-q coordinates are generated with the aid of IM parameters owing to the model equations given below:
i S d   r e f * = Φ S   r e f * L S
i S q   r e f * = 4 3   T e m   r e f *   P Φ S   r e f *  
These equations are based on the following assumptions:
1.
The stator flux linkage is typically aligned along the d-axis, and the q-axis flux component is zero. Accordingly: Φ S d * = Φ S   r e f * ; Φ S q * = 0 ;
2.
The reference stator current in the d-axis is directly related to the stator flux linkage;
3.
The rotor is short circuited, where: V r d = V r d = 0 .
The electromagnetic torque is computed using the following equation:
T e m = 3 2 P 2 Φ S d i S q Φ S q i S d
The slip speed is determined using the following relation:
ω s l i p = R r L r i S q i S d
ω s = ω s l i p + ω m
where T e m * is the reference electromagnetic torque (Nm); Tem is the instantaneous electromagnetic torque (Nm); Φ S d and   Φ S q   are the stator flux components in d-q synchronous reference frame (Wb); iSd and iSq are the stator current components of stator current in d-q synchronous frame (A); ω s is the synchronous speed (rad/s); ω s l i p is the slip speed (rad/s); ω m is the motor mechanical speed (rad/s); P is the number of poles; Ls is the stator self-inductance (H); Lr is the rotor self-inductance (H); Rr is the rotor resistance (W); and Lr is the rotor self-inductance (H).
Although the FOC provides good transient performance of the IM, it suffers from several drawbacks. Firstly, the successful operation depends on the accuracy of estimation (computation) of slip speed ( ω s l i p ) and the angle (q), which depend on the rotor time constant (Lr/Rr) that varies with the temperature and level of saturation.
In fact, considerable research efforts have been done in VC and FOC of IM during the period of 1992–2008, with the advancement in DPS and microcontroller technologies. However, the main observed research contributions of FOC of IM drives during the period of 2017 to 2024 are summarized and presented in Table 13.
Table 13. Research contributions in FOC of induction motor drives.

4.3. Direct Torque Control

DTC strategy of IM drives controls directly both stator flux and electromagnetic torque by applying instantaneously the optimum inverter switching state which satisfy both torque and flux requirements. Owing to Figure 9, the DTC scheme of 3-Φ IM is composed of the following blocks:
  • Motor transient model to calculate the instantaneous value of the stator flux vector and electromagnetic torque.
  • Two hysteresis ON/OFF controllers: one for the stator flux and the other for the torque.
  • Optimum switching table whose output is the instantaneous values of the inverter switching state, such that the flux and torque track the set points (reference values).
Figure 9. Block diagram of a conventional DTC system of an IM drive.
The DTC strategy of IM drive can have two modes of operation: torque control mode and speed control mode. In torque control mode, the desired electromagnetic torque is the reference signal. In speed control mode, the reference torque is the output of speed controller. The reference flux signal is a function of the motor reference speed. For speeds greater than the rated value, the reference stator flux is reduced, running the motor in field weakening mode. The flux and torque control under DTC can be explained with the aid of Figure 10 and Figure 11, respectively, where the stator flux vector initially lies in sector number one. Each discrete inverter switching state and the corresponding voltage vector has its effect on both electromagnetic torque and stator flux; e.g., if the voltage vector V1 is applied during the sampling period, the magnitude of the stator flux will increase. At the same time, the angle between stator and rotor flux vectors will decrease, which results in a reduction in the instantaneous value of the electromagnetic torque. From the principles of electric machines, the magnitude of the electromagnetic torque is directly proportional to the SINE value of the angle between stator and rotor flux vectors.
Figure 10. Stator flux vector lies in Sector 1.
Figure 11. Control of motor stator flux and torque in Sector 1.
Applying vector V4 instead of V1 results in a reduction in magnitude of stator flux, as illustrated in Figure 10. At the same time, the angle between stator and rotor flux vectors will increase, which results in an increment in the instantaneous value of the electromagnetic torque. From these observations, an optimum switching table is obtained to control simultaneously both stator flux and electromagnetic torque.
Figure 12 summarizes the effects of all inverter voltage vectors on both torque and flux in Sector 1.
Figure 12. Effects of inverter discrete voltage vectors on stator flux and torque in Sector 1.
The ideal trajectory of the stator flux vector is a circular path. Under DTC strategy, the actual path is formed by applying instantaneously the optimum inverter voltage vectors. Such optimum vectors depend on both the current location of the stator flux vector (Sector number 1:6) and the direction of rotation as well.
Figure 13 clarifies and indicates the selection method of the optimum inverter vectors in Sectors ONE and TWO, where:
For CCW rotation in Sector ONE, vectors V2 and V3 are to be mutually applied to follow the desired flux trajectory; while in Sector TWO, vectors V3 and V4 are to be mutually applied to follow up the required stator flux trajectory.
For CW rotation in Sector ONE, vectors V5 and V6 are to be mutually applied to keep track of the desired flux locus; while in Sector TWO, vectors V1 and V6 are to be mutually applied in Sector TWO.
Figure 13. Trajectory of stator flux vector under DTC with conventional two-level VSI.
The stator flux components in the (α–β) stationary reference frame are computed using the following equations:
Φ ¯ S = Φ α + j Φ β
Φ α = 0 T S v α R S i α d t
Φ β = 0 T S v β R S i β d t
where TS is the sampling period of the DTC algorithm in digital implementation.
The magnitude and the location of the stator flux vector are computed by Equations (9) and (10), respectively. They are inputs to the DTC blocks (hysteresis flux controller and the inverter switching table), as shown in Figure 9.
Φ S = Φ α 2 + Φ β 2
Ψ S = t a n 1 Φ β Φ α
The electromagnetic torque produced by the IM is calculated using Equations (11) and (12):
T e m = 3 2 P 2 Φ ¯ S   x   I ¯ S
T e m = 3 2 P 2 Φ α i β Φ β i α
where P is the number of magnetic poles of the AC motor.
The stator current components in the (α–β) stationary reference frame are determined using Equations (14) and (15):
I ¯ S = i α + j i β
i α = 1 3 2 i a i b i c
i β = 1 3 i b i c
The major advantages of DTC are the quick response of both torque and flux, as well as dependency of the DTC algorithm on a machine model with a moderate degree of complexity, unlike FOC, which is based on a sophisticated machine mode.
However, the main drawbacks of the DTC are the requirement of online identification of stator resistance to achieve high performance at low speeds, and the conventional scheme is not applicable for position control and servo applications.
In fact, considerable research activities in DTC drives have been carried out during the period of 1997–2017. The main observed research contributions of DTC for IM drives during the period of 2017 to 2024 are summarized and presented in Table 14.
Table 14. Research contributions in DTC technique of induction motor drives.

4.4. Model Predictive Control

Recently, finite control set model predictive control (FCS-MPC) has been applied in IM drives as an advanced control approach [241,242,243,244,245,246,247,248,249,250,251,252,253,254,255,256,257] to minimize the torque and flux ripples and achieve other goals, such as minimization of switching frequency.
In the FCS-MPC technique, the future behaviors of the controlled variables (stator flux and electromagnetic torque in case of IM drives) are predicted for a finite time frame of one or more sampling period. Accordingly, the optimum future control action is applied to the motor to satisfy a customized goal function, where the FCS-MPC algorithm repeatedly checks the future behavior at every sampling period. Therefore, in addition to the main speed control (regulation) task, other goals can be achieved, such as minimization of flux and torque ripples, minimization of inverter switching frequency, minimization of stator current ripples, or minimization of active and reactive power ripples. Accordingly, the cost function can accommodate all these terms and more, owing to the performance requirement of the IM drive as demonstrated in Equations (16)–(19):
J 1 = T e m * T e m k + 1 + Φ S * Φ S k + 1
J 2 = T e m * T e m k + 1 + Φ S * Φ S k + 1
J 3 = i S α * i S α k + 1 + i S β * i S β k + 1
J p q 1 = P r e f P k + 1 + Q r e f Q k + 1
The absolute value functions of the previous equations can be replaced by square functions for minimizing the terms of the formulated cost functions.
Moreover, each term can have a weight factor (wp and wq) to prioritize some term(s) during operation, as given by Equation (20):
J p q 2 = w p P r e f P k + 1 2 + w q Q r e f Q k + 1 2
The block diagram of FCS-MPC of IM drives is shown in Figure 14. The control system has three main parts:
  • Speed control loop and reference signals generation of torque and flux. The output of the PI speed controller represents the desired electromagnetic torque, while the reference stator flux is kept constant at the rated value for the entire range of speed from zero to the rated value. Above the rated value, the flux is reduced inversely to verify field weakening mode.
  • Computation of stator currents and stator voltages components in the (α–β) stationary reference frame.
  • FCS-MPC algorithm, which is composed of several blocks and functions, such as prediction of stator currents and stator flux components in the stationary reference frame (α–β) one sample ahead, and prediction of electromagnetic torque one sample ahead as well. Finally, in FCS-MPC, the customized cost function is calculated and checked for all inverter switching states. Then, the optimum inverter switching state that instantaneously provide minimum cost function is chosen and applied to the IM.
Figure 14. Block diagram of FCS-MPC system of IM drive.
The FCS-MPC approach requires a high-speed DSP unit to implement the several functions and subroutines related to the sophisticated algorithm. The accuracy of stator flux and electromagnetic torque prediction depends on the machine parameters plugged into the model. Thus, any deviation from the real values, which are affected by temperature and saturation level of the machine, negatively affects the performance of the IM drive, and maybe the stability as well.
Recently, several research efforts have been exerted in applying and investigating the IM drive under the FCS-MPC approach. The summary of main research contributions during the period of 2017 to 2024 is presented in Table 15.
Table 15. Research contributions of MPC technique of induction motor drives.
In addition, a comparison between these control techniques, including advantages and disadvantages has been made. Table 16 summarizes the pros and cons of these control techniques. Each technique has its own advantages and suffers from some limitations. Therefore, each technique is more convenient in specific applications; e.g., scalar control (SC) is adopted in scalar drives for general purpose applications such as pumping and ventilation purposes, while FOC is utilized in servo applications and high-performance AC drives. DTC is preferred when the industrial process considers the torque as a controlled variable rather than the motor speed. An example of this application is the tension control of wires and paper rolling. Such required operation can be met by using the DTC drive in torque control mode instead of the speed control mode.
Table 16. A comparison between control techniques of IM drives.
Regarding the MPC, the industrial adoption is limited due to the requirement of high computational speeds and the processing capability of the digital control unit. Also, MPC needs an accurate model and is sensitive to motor parameter variations.

4.5. Regenerative Braking and Energy Saving

Applying regenerative braking is one of the important strategies that are employed in industrial AC drives and EVs, because it is an effective and efficient energy recovery technique that minimizes the overall energy consumption and provides quick stopping of the electric machine [258,259,260,261,262,263,264,265,266,267,268,269,270].
In the case of EVs, this energy is utilized to charge the battery, increasing the distance range of the EV. In medium- and high-power ranges, AC drives apply the regenerative braking technique to return the shaft kinetic energy to the electric grid during braking instants, as in electric trains [14,15].
Research contributions in regenerative braking and energy saving of IM drives during the period 2017 to 2024 are presented and summarized in Table 17.
Table 17. Research contributions in regenerative braking and energy saving of IM drives.

5. Manufacturers of Industrial IM Drives

A summary of the well-known industrial AC drive manufacturers (ordered alphabetically) and the employed control techniques in their products are summarized in Table 18. Most manufacturers produce scalar V/F drives and vector control (VC) drives (with position/speed encoder or sensorless drive), while few players adopt DTC technology.
Table 18. Industrial AC drive manufacturers.
The major observation is that MPC has not yet gained industrial acceptance. However, the PowerFlex® 750 AC drive series, with totalFORCE® technology from Allen-Bradely provides adaptive control of position, velocity, and torque for AC motors [290,291].

6. Modern Applications of IM Drives

Induction motor drives have been employed in many industrial applications for a long time. Recently, they are utilized in modern applications such as:
  • Industrial automation and robotics arms;
  • Electric vehicles, trucks, and buses;
  • High-speed electric trains;
  • Energy saving HVAC systems and inverter-based home air conditions;
  • Drilling rigs in oil and gas industry;
  • Flywheel energy storage systems;
  • Electric propulsion systems in marine applications;
  • Multi-motor conveyor systems;
  • Hoist and crane control to achieve a safe and high-performance operation in terms of anti-sway, including the possibility of regenerative braking to provide quick stopping.

7. Conclusions

Various modern industries depend on induction motor drives, retaining their importance despite the utilization of synchronous motor drives and other types. This article aims to provide a literature summary of the recent trends in high-efficiency induction motor drives during the period of 2017–2024. In addition, the article addresses recent regenerative braking methods and energy saving algorithms incorporated into the induction motor control system. The article is considered as a review guide to junior researchers whose area of interest are AC drives in general, and induction motor drives in specific. Also, the article can help researchers who are interested in power electronics to recognize the recent advancement in WBG-based converters applied in AC motor control. Accordingly, the paper introduces the state-of-the-art publications related to the topic. The novelty of the paper is considered in the topic itself (high-efficiency IM drives), introducing and addressing the recent core contributions related to the topic.
The selected period is narrowed to only the last seven years to include the state-of-the art research activities that have been carried out. However, considerable respectable research publications covering the same topics have been published during the previous two decades, and the pioneer contributions during the last three decades cannot be ignored and have been addressed through the correspondingly covered topics in the article.
The main conclusions and findings are summarized in the following points:
  • Development and adoption of high-efficiency AC drives, especially IM drives, is an important opportunity in the modern industry to reduce energy consumption in different sectors, in accordance with energy efficiency standards and restrictions.
  • Design and implementation of high-efficiency and premium-efficiency IMs have commercial acceptance, as many manufacturers fabricate considerable products covering a wide power range serving multiple applications.
  • Design of high-efficiency IMs using evolutionary optimization techniques and modern analysis tools such as finite element design has received great interest from academia and industry.
  • Many recent research papers are interested in studying and investigating thermal equivalent circuits of IMs to optimize and enhance motor cooling system and increase their efficiency.
  • WBG power semiconductor devices are gradually being incorporated into the development of commercial IM drives due to salient advantages; e.g., SiC devices are suitable for high power applications, while GaN is convenient for low voltage/low power application/very high frequency applications.
  • Some fabrication challenges of WBG power devices still exist; however, considerable research efforts are tackling these obstacles and finding solutions to most of them. Thus, the prices of WBG devices are decreasing with the time to get commercial acceptance.
  • The industrial IM drives still depend on scalar control techniques for general purpose application. Meanwhile, vector control IM drives are used when high-performance drives are required.
  • Until now, few industrial drive manufacturers have adopted or fabricated DTC-based drives since the development of the first drive by ABB in 1996.
  • MPC have not received commercial or industrial acceptance until recently. However, considerable research papers have adopted and recommended the utilization of FCS-MPC in high-performance IM drives.
  • Modern IM drives have the option of regenerative braking to provide quick stopping and motor braking. Moreover, regenerative braking participates in a reduction in the overall energy consumption of AC drives. In EVs and electric transportation systems, regenerative braking extends the distance range of the vehicle battery by trickle charging during EV speed reductions and stopping.

Funding

This research received no external funding.

Conflicts of Interest

The author declares no conflicts of interest.

Abbreviations

ASICApplication specific integrated circuit
BLDCBrushless DC motor
CAGRCompound annual growth rate
CCWCounterclockwise
CWClockwise
DAQData acquisition system
DSPDigital signal processor
DTCDirect torque control
EDElectric drives
EDSElectric drive system
EMCElectromagnetic compatibility
EMIElectromagnetic interference
EVElectric vehicle
FCS-MPCFinite control set model predictive control
FOField orientation
FOCField-oriented control
FPGAField programmable gate array
GaNGallium nitride
HILHardware in the loop
IMInduction motor
MPCModel predictive control
PMPermanent magnet
PWMPulse width modulation
PEPower electronics
RISCReduced instruction set computer
SCScalar control
SDGsSustainable development goals
SRMSwitched reluctance motor
SVMSpace vector modulation
SiCSilicon carbide
SRMSwitched reluctance motor
THDTotal harmonic distortion
WBGWide bandgap
UNUnited nations
VCVector control
VSIVoltage source inverter

Appendix A

Appendix A.1. Sustainable Development Goals of the United Nations

Goal 1: End poverty in all its forms everywhere.
Goal 2: End hunger, achieve food security and improved nutrition, and promote sustainable agriculture.
Goal 3: Ensure healthy lives and promote well-being for all at all ages.
Goal 4: Ensure inclusive and equitable quality education and promote lifelong learning opportunities for all.
Goal 5: Achieve gender equality and empower all women and girls.
Goal 6: Ensure availability and sustainable management of water and sanitation for all.
Goal 7: Ensure access to affordable, reliable, sustainable, and modern energy for all.
Goal 8: Promote sustained, inclusive, and sustainable economic growth, full and productive employment, and decent work for all.
Goal 9: Build resilient infrastructure, promote inclusive and sustainable industrialization, and foster innovation.
Goal 10: Reduce inequality within and among countries.
Goal 11: Make cities and human settlements inclusive, safe, resilient, and sustainable.
Goal 12: Ensure sustainable consumption and production patterns.
Goal 13: Take urgent action to combat climate change and its impacts.
Goal 14: Conserve and sustainably use the oceans, seas, and marine resources for sustainable development.
Goal 15: Protect, restore, and promote sustainable use of terrestrial ecosystems, sustainably manage forests, combat desertification, halt and reverse land degradation, and halt biodiversity loss.
Goal 16: Promote peaceful and inclusive societies for sustainable development, provide access to justice for all, and build effective, accountable, and inclusive institutions at all levels.
Goal 17: Strengthen the means of implementation and revitalize the Global Partnership for Sustainable Development.

Appendix A.2. Summary of Sustainable Development Goals of the United Nations

  • No Poverty.
  • Zero Hunger.
  • Good Health and Well-Being.
  • Quality Education.
  • Gender Equality.
  • Clean Water and Sanitation.
  • Affordable and Clean Energy.
  • Decent Work and Economic Growth.
  • Industry, Innovation and Infrastructure.
  • Reduce Inequality.
  • Sustainable Cities and Communities.
  • Responsible Consumption and Production.
  • Climate Action.
  • Life Below Water.
  • Life on Land.
  • Peace, Justice and Strong Institutions.
  • Partnerships for the Goals

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