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Here is where metallurgy comes into play. A motor rich in magnetically soft material will be more efficient, producing more work with less heat. And since the magnetic capacity of a motor also is influenced by the amount of active material (more core, more laminations), the tendency might be to try to add as much magnetically soft material to your design as possible.

Without getting into a lengthy physics lecture, this process of reversing polarity produces heat (or wasted energy). This is known as hysteresis loss. And that helps explain why increasing the voltage into the motor will not necessarily increase the output. Instead, it can fight the resistance of magnetic materials to reverse polarity--and simply heat iron.

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Motor cables are defined as long when the motor frame is not bonded close enough to the drive panel to be considered a single ground plane. To be considered a single ground plane, the parts must be connected by a surface which is no longer than ten times its width.

It is important to keep this struggle between performance and cost in mind when you talk to customers about energy-efficient motor-driven equipment. Yes, efficiency is probably more important to homeowners now than ever, but that efficient operation comes at a price. And motor manufacturers will keep working to strike that balance between motor performance, efficiency, and cost.

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