ABB Expands IE6 SynRM Motors and Automation Extended

ABB has expanded its IE6 Hyper-Efficiency synchronous reluctance motor range up to 450 kW and introduced Automation Extended to modernize distributed control systems. The magnet-free SynRM motors offer improved efficiency, reduced CO₂ emissions, and drop-in compatibility with standard induction motor footprints. Automation Extended enables phased digital upgrades by separating mission-critical control from advanced analytics and AI environments. Together, the initiatives support industrial decarbonization, energy savings, and low-risk digital transformation across energy-intensive operations.

ABB’s IE6 Hyper-Efficiency synchronous reluctance motor range now extends up to 450 kW. Image used courtesy of ABB

IE6 SynRM Motors Expand into Large Frame Sizes

ABB’s magnet-free IE6 Hyper-Efficiency SynRM motors are now available in frame sizes 280 and 315, covering a power range from 110 to 450 kW and speeds up to 3600 rpm. The expansion builds on ABB’s earlier introduction of IE6 SynRM technology and makes hyper-efficiency motors accessible across a broader set of mainstream industrial applications.

ABB IE6 Hyper-Efficiency SynRM motors installed in a pumping application. Image used courtesy of ABB

The motors are designed to deliver measurable gains in energy performance compared to both IE4 induction motors and IE5 ultra-premium efficiency alternatives. ABB estimates a total cost savings or cost avoidance of €51,200 and a reduction of approximately 92,200 kg of CO₂ emissions when upgrading from IE4 to IE6 over a 20-year service life in a 110 kW application running continuously at 75 percent load. Moving from IE5 to IE6 represents an additional 76 percent improvement in savings and emissions reduction, with a reported return on investment of approximately eight months.

Unlike permanent-magnet motor designs, SynRM technology eliminates the use of rare-earth metals and permanent magnets. The motors are 98 percent recyclable and are included in ABB’s EcoSolutions portfolio with verified Environmental Product Declarations (ISO 14025 Type III). Designed to match the dimensions of standard induction motors, the IE6 SynRM range enables drop-in replacement in pumps, fans, compressors, and other industrial applications, particularly when paired with ABB variable speed drives.

Automation Extended Enables Modernization

Complementing its hardware efficiency expansion, ABB has also introduced Automation Extended. The program is designed to help industries modernize existing automation infrastructure without interrupting production or replacing trusted systems. Automation Extended builds on ABB’s installed DCS platforms. Rather than requiring full system replacement, the program enables progressive adoption of advanced analytics, AI, and IoT capabilities while preserving core control integrity.

ABB’s Automation Extended architecture separates mission-critical control from a digitally enabled environment for analytics and AI integration. Image used courtesy of ABB

The architecture is based on a separation-of-concerns model that divides the automation ecosystem into two interconnected environments. The control environment maintains deterministic, mission-critical process control. The digital environment, securely connected to the control layer, supports advanced analytics, artificial intelligence, edge applications, and real-time decision support without interfering with core operations.

An open, modular framework supports interoperability and scalability through technologies such as OPC UA backbones and cloud-native architectures, leveraging containerization and orchestration. This approach enables industries to introduce new capabilities, including predictive analytics, condition monitoring, and anomaly detection.

Coordinated Approach to Efficiency and Decarbonization

Industrial operators are facing increasing pressure from energy costs, regulatory demands, cybersecurity risks, and workforce transitions. ABB’s expanded IE6 motor range addresses energy consumption at the equipment level, while Automation Extended provides a structured pathway for digital transformation at the system level. ABB is positioning itself to support both immediate energy savings and long-term improvements across energy-intensive industries by combining high-efficiency motor technology with modular automation architecture.