| With the rapid development of the economy, energy consumption is increasing gradually, and energy crisis is more and more obvious, which makes energy conservation imperative. The Energy efficiency standards of electric machines are proposed by the IEC. The efficiency level of motors is divided into IE1, IE2, IE3, and IE4 in the standard of ICE60034-30. The high efficiency permanent magnet synchronous motor (PMSM) with load developing efficiency of level IE4 used in textile machines is researched in this paper. The main contents are as follows:Firstly, factors affecting motor's losses are analyzed in the study of how to increase its efficiency, and methods decreasing losses are also concluded. Against the big errors of calculating losses in PM motors, the core losses are calculated on the base of analyzing magnetic flux density wave by FEM in this paper, which makes calculation on core losses more accurate. The power factor and the pull-in torque are also studied, together with some methods of improving the performance.Secondly, some key design issues are analyzed considering above factors of the spinning machine. The factor principle of motor design is analyzed, including the structure of the rotor and the slot, and the flux barrier, on the base of which, a high efficiency PM synchronous motor with 15kW and 4 poles is developed. Standard drawings of prototype are accomplished, and the prototype is made.Finally, the type approval test of the prototype is completed, and its efficiency reaches the level of IE4. The prototype is applied to FA502 spinning machine. Compared with the JF03-61A-4/6 asynchronous motor, energy-saving rate of the prototype is 8.97%. So prospective results are attained and the effect of energy-saving is obvious.
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