Energy-Efficient Drive Systems for Industrial Automation: Design, Implementation, and Performance Analysis

Abstract

Industrial automation requires high-performance electric drive systems while minimizing energy consumption and operational costs. This paper investigates energy-efficient drive systems, including variable frequency drives (VFDs), permanent magnet synchronous motors (PMSMs), and brushless DC (BLDC) motors. Emphasis is placed on optimization techniques, such as sensorless control, torque optimization, and regenerative braking integration. Simulation and experimental studies demonstrate energy savings of 15–25%, improved dynamic response, and reduced harmonic losses. The paper concludes that optimized drive systems significantly enhance industrial productivity while reducing carbon footprint.

KEYWORDS: Energy-efficient drives, Industrial automation, VFD, PMSM, BLDC, Torque optimization, Regenerative braking.