In the European Union, the average load factor of electric motors in both industrial and tertiary sectors is estimated to be less than 60%. However, in some industrial sectors, the average load factor for some motor power ranges can be as low as 25%. Most oversized three-phase induction motors operate with low efficiency and power factor, which is by far the most important cause of poor power factor in industrial installations. In the low-load operating periods, motor performance can be improved both in terms of efficiency and power factor if the magnetizing flux is properly regulated. In this paper, a multi-flux level, three-phase, squirrel-cage induction motor is proposed, in which the efficiency and power factor can be both maximized as a function of load. The flexibility of the proposed motor system can be a surplus value in Industry, particularly for variable load applications in which significant energy savings can be obtained. The proposed motor can also be used as new or rewound general-purpose spare motor (with several levels of voltage, magnetizing flux and/or power). The proposed motor has a stator winding with two sets of turns, sharing the same positions in the stator slots (which can be connected either in series or in parallel). Among all the possible stator winding connections, six modes were selected and analysed (two of which are new). The basic principles for proper connection mode change are discussed. An electronic device and a contactor concept for automatic connection mode change are proposed.
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