Revolutionizing industrial applications: Latest advancements in low-power AC drive

In today’s fast-paced industrial landscape, efficiency, sustainability, and performance are essential. One technology driving this change is low-power AC drive technology. Variable frequency drives (VFDs), also known as AC drives, play a crucial role in industrial automation by offering precise control over electric motors. 

Manufacturers have been optimizing their performance, lowering operating costs, and contributing to sustainability.  Low-power AC drives, their sophisticated operating mechanism, and their integration into smart systems enable companies to achieve energy efficiency.

Role of low-power AC drives 
Low-power AC drives are essential in industrial automation for controlling the electric motor speed and torque. Recent developments have also improved the reliability and energy efficiency of these drives. As a result, industries are rapidly adopting them to optimize performance, lower costs, and enhance sustainability. 

AC drives ensure process enhancement, energy productivity, and green objectives. They can help reduce downtime and improve process control in applications such as conveyor systems, small pumps, and fan control. This technology boosts operational efficiency and reduces environmental impact.

The AC drives market in India is projected to reach approximately USD 471 million by 2025, growing at a CAGR of 7%. This growth is driven by rapid industrialization, urbanization, rising demand for energy-efficient solutions, and the adoption of advanced technologies like Industry 4.0 and IoT. 

Local manufacturing under the “Make in India” initiative plays a pivotal role, encouraging suppliers to establish domestic production units that boost cost competitiveness and supply chain resilience. Supported by government-led PLI schemes, this localization strengthens India’s industrial value chain. 

Technological innovations and digitalization are further enhancing the appeal of low power AC drives. Together, these factors are transforming India's automation and industrial landscape. 

This push toward localization is transforming India's industrial landscape, Global suppliers of low power AC drives are investing in domestic manufacturing to not only reduce production costs and improve supply chain resilience, but also to align with national priorities for self-reliance and sustainable growth. The increase in localized production is enhancing market accessibility and boosting India’s industrial value chain.

Energy efficiency and sustainability
The Indian market for energy efficiency, which was estimated to be worth $13 billion in 2024, is anticipated to reach $21 billion by 2029 thanks to government initiatives and heightened industry knowledge. By promoting sustainability and energy efficiency, low power AC drives are significantly changing sectors. 

By modifying motor speeds, variable frequency drives (VFDs) can optimize performance and efficiency in variable-speed applications while reducing energy usage by up to 50%.

Advanced control and performance enhancements
Advanced control features present in low power AC drives greatly improve the performance and efficiency of the motor. (Modern drives utilize technologies like sensor less vector control (SVC) and field-oriented control (FOC) to achieve precise speed and torque control, optimizing overall system performance.) 

More specifically, SVC offers accuracy without needing additional sensors, resulting in cost-effectiveness and making it ideal for high-precision tasks such as conveyors and robotics. These drives also minimize harmonic distortion, which allows for smoother motor operation, reduced vibration, less mechanical stress, and ultimately results in a more reliable system, extended motor lifespan, and lower maintenance costs.

As per the recent industry report by India AC Drives Market Report and Forecast 2023-2028, the Indian advanced AC drive control technologies market is projected to grow at a CAGR of 8.9% from 2024 to 2028, to touch INR 7709.7 crore by 2028. The growth is attributed to the rising adoption of Industry 4.0 and the focus on energy efficiency and sustainable manufacturing practices across industries.

Integration with IIoT and smart automation
Low-power AC drives have evolved with IIoT, incorporating sensors and cloud connectivity to monitor and optimize performance. Real-time tracking and analytics enable predictive maintenance, while AI-based diagnostics fine-tune drive settings for greater efficiency. 

These advancements align with the digital transformation across industries, where IIoT and smart control systems drive sustainable, high-performance operations. As a result, AC drives are crucial in enhancing operational efficiency and environmental impact.

Compact design and enhanced durability
Space limitations and environmental demands in industries have spurred the increasing development of low-power AC drive design. But modern drives started getting smaller and smaller, making them good for tight space without sacrificing performance. 

Designed for rugged environments, these systems often include protective enclosures, cooling systems, and are heat-resistant to maintain reliable operation in demanding industrial scenarios.

In addition, the move to fan-less designs means less maintenance, because there are fewer moving parts that have the potential to fail over time. These properties of low power AC drives provide extreme durability and reliability, which allow them to meet the requirements of even the harshest industrial conditions.

Future trends and innovations
The future of low power AC drives looks promising, with several exciting innovations on the horizon. Wireless and cloud-connected AC drives are becoming more common, enabling remote monitoring and control via mobile devices and centralized systems. This flexibility and mobility are crucial as industries increasingly seek adaptive solutions for modern operations.

Enhanced cyber security features are also being incorporated into modern AC drives to protect industrial networks from cyber threats. As more systems become connected, securing these critical components from breaches is essential.

AI-powered self-learning drives are set to be a major breakthrough. These drives will adapt their performance based on usage patterns, continuously optimizing their operation for maximum efficiency and reliability. This innovation will enable further improvements in energy savings, performance, and predictive maintenance.

Conclusion: Road ahead
Low-power AC drive applications, ranging from 0.1kW to 500kW, are the backbone of industrial automation. These drives are optimizing energy efficiency, lowering expenses and furthering sustainability objectives, ultimately building a greener and more productive future. 

Low-power AC drives will continue to deliver operational efficiency across industries with smart features, energy recovery systems, and increased control ability. Energy recovery systems, for example, capture and reuse energy during motor deceleration, further enhancing efficiency.

-- Dr. Sanjeev Srivastava, Head of Industrial Automation, Delta Electronics India.