Sensorless Motors Bring Servo-Like Control to Automation

Adroit Technologies is releasing the Mitsubishi Electric EM-A Series across the African market, introducing a class of permanent magnet synchronous motors designed to enhance speed and position control in industrial automation. The hardware targets material handling, conveyor automation, medical equipment, and packaging machinery by providing servo-level precision without the associated integration complexity.

Eliminating Encoders via Sensorless Vector Control
Traditional servo systems rely on mechanical encoders to dictate rotor position, which requires additional wiring, components, and maintenance. The EM-A Series replaces this physical mechanism with patented sensorless vector control technology. By utilizing an adaptive magnetic flux observer embedded within the accompanying FR-E800 inverter, the system continuously calculates motor position and speed. This architecture eliminates physical encoders, reducing hardware dependency while maintaining the positional accuracy required for demanding applications such as textile equipment, lift systems, and gravimetric dosing.

Torque Delivery and IE5 Efficiency Standards
The permanent magnet motors generate up to 200% starting torque from zero speed, maintaining operational precision during sudden load variations. Operating within these parameters, the motors achieve IE5 energy efficiency ratings, surpassing standard IE3 induction motors to minimize electrical consumption and carbon emissions. The integration of the FR-E800 inverter adds native programmable logic controller (PLC) capabilities, allowing for direct point-to-point positioning and motion control without requiring external logic programming. The units operate across a power range of 0.1 kW to 7.5 kW and are configurable with or without holding brakes.

Bridging Induction and Servo Motor Capabilities
The technological configuration positions the EM-A Series between standard induction motors and full servo systems. Dave Wibberley, Director at Adroit Technologies, noted that removing the encoder lowers the total cost of ownership by decreasing component count, wiring, and maintenance requirements for machine builders and system integrators. Furthermore, Marco Clerici from the Export Factory Automation Division at Mitsubishi Electric Europe stated that combining permanent magnet technology with advanced control enables high efficiency under varying load conditions, supporting industrial modernization and sustainability objectives.

Additional Context
This section details technical specifications and competitive benchmarking not included in the original news release.

In the sensorless permanent magnet motor market, the Mitsubishi EM-A Series competes with platforms such as the Siemens SIMOTICS S-1FK2 (when operated in sensorless mode via SINAMICS drives) and the SEW-EURODRIVE CMP series. The primary benchmark for sensorless synchronous motors is the accuracy of the magnetic flux estimation algorithm at near-zero speeds, a metric where traditional induction motors experience significant slip and control degradation. By achieving an IE5 "Ultra-Premium Efficiency" rating—defined by the IEC 60034-30-2 standard—these motors demonstrate energy losses approximately 20% lower than IE4 standards. This makes the architecture highly competitive in continuous-duty industrial automation applications, where lifecycle energy consumption costs drastically outweigh initial capital expenditures.

Edited by Aishwarya Mambet, Induportals Editor, with AI assistance.

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