Global Markets for New Components and Materials in Advanced Electric Motors

Global Markets for New Components and Materials in Advanced Electric Motors

Report ID: 4579521

Use this report to:
- Gain information on the global sales of the components and advanced materials used to manufacture electric motors during the interval from 2016 to 2021.
- Examine current breakthroughs in components and materials used in electric motors.
- Identify entirely new electric motor concepts and applications such as electric airplanes.
- Evaluate and predict which new advanced motor concepts are likely to be commercially successful and for what applications.


Highlights
- The global market for advanced materials and components in electric motors was valued at $33.4 billion in 2015. This market is expected to increase from $33.8 billion in 2016 to $46 billion in 2021 at a compound annual growth rate (CAGR) of 6.4% for 2016-2021.
- Advanced motor controls market is expected to grow from $25.1 billion in 2016 to $33.4 billion in 2021 at a CAGR of 5.9% from 2016 through 2021.
- Electronic material market is expected to grow from $3.1 billion in 2016 to $4.7 billion at a CAGR of 8.7% from 2016 through 2021.



INTRODUCTION

STUDY GOALS AND OBJECTIVES
The purpose of this report is to examine current breakthroughs in components and materials used in electric motors and forecast the related markets over a five-year period when they will begin to enjoy commercial success. For example, improvements in controllers (adjustable speed drives) and newer components such as magnetic bearings, rotor materials and semiconductors are covered. The report forecasts global sales of the components and advanced materials used to manufacture electric motors during the interval from 2016 to 2021. The report also identifies entirely new electric motor concepts and applications such as electric airplanes. The focus throughout is manufacturers and developers of components and materials used in advanced motors. Current commodity motors are not included in the scope of this report.


REASONS FOR DOING THE STUDY
Electric motors are a principal and perhaps the largest consumer of electricity. On a global basis, electric motor-driven systems consume about between 43% and 46% of all electricity purchased. The size of the motor population is staggering. In just the United States, around 90 million electric motors are in use. Approximately 40 million of these motors are used in the commercial and industrial sectors. In the United States, roughly a quarter of total energy demand is attributable to electric motors.

Globally, these numbers are even more significant. The International Energy Agency (IEA) estimates that globally around 230 million motors greater than 0.75 kilowatts (kW) and about 2 billion motors below 0.75 kW are installed. Electric motors are used in countless applications, including fans, blowers, pumps, printers, disk drives, ATMs, industrial and medical machines, automobiles, buses, aircraft control surfaces and hundreds of other applications Electric motors use well-established technology that dates to the 19th century.

Nevertheless, considerable refinements and technology development are still occurring in electric motor technology. The purpose of this report is to look five to 10 years into the future when current breakthroughs in components and materials used in electric motors will start to enjoy commercial success. This report features manufacturers and developers of components and materials used in advanced motors. The purpose is to evaluate and predict which new advanced motor concepts are likely to be commercially successful and for what applications.


INTENDED AUDIENCE
This study will be of interest to electric motor manufacturers, subassembly and component manufacturers, and manufacturers of control systems and ancillaries such as adjustable speed drives and power inverters.


SCOPE OF REPORT
This report covers both entirely new motor technologies and significant component or drive enhancements. For example, improvements in controllers (adjustable speed drives) and components such as magnetic bearings, rotor materials and semiconductors are covered. Currently, much of the electric motor manufacturing industry is engaged in the production of commodity output using well-established technologies. Established technologies comprise most of the approximately $10 billion U.S. motor market. The global market for motors is about $80 billion per year, with much of this amount commodity output. While the magnitude of commodity output and the description of established technologies has been covered in previous market reports, advanced motor technologies and new components that are likely to see greater market penetration in the coming decade have not been thoroughly examined. This report covers what new and novel developments related to finished electric motors and their key components.


METHODOLOGY
Manufacturer-level data for motors is a subset of several North American Industry Classification System (NAICS) codes and is not reported separately. Thus, data in this report represents estimates. Additional data in the report was obtained from the United States Patent and Trademark Office (USPTO) database, Securities and Exchange Commission (SEC) filings and trade journals. While there has been prolific patent activity related to electric motors, as with many areas of technology, not all motor-related innovations turn out to be practical, economical or marketable. Nevertheless, there is a flood of recent patents involving motors and components as well as motor control strategies. This report attempts to make sense of the patent landscape.


INFORMATION SOURCES
Sources include interviews with executives of equipment manufacturing firms, public documents, SEC filings, corporate white papers and other technical documentation for close to a hundred U.S. and international companies directly involved in manufacturing and distributing or directly utilizing advanced electric motors.


ANALYST’S CREDENTIALS
Research analyst Kevin Gainer holds both B.A. and M.A. degrees in quantitative economic analysis and forecasting and has 26 years of economic forecasting, industry intelligence and market research experience. He is the author of six published books and over 100 magazine articles, technical papers, analyses and studies published in conference proceedings as well as many unpublished works produced internally in corporations. He has worked as a Research Editor and Project Analyst at BCC Research since 1985 and has authored numerous BCC technology market research reports.
CHAPTER 1
INTRODUCTION 2
STUDY GOALS AND OBJECTIVES 2
REASONS FOR DOING THE STUDY 2
INTENDED AUDIENCE 2
SCOPE OF REPORT 3
METHODOLOGY 3
INFORMATION SOURCES 3
ANALYST'S CREDENTIALS 3
RELATED BCC RESEARCH REPORTS 4
BCC RESEARCH WEBSITE 4
DISCLAIMER 4
CHAPTER 2 SUMMARY 6
SUMMARY TABLE GLOBAL MARKET FOR ADVANCED COMPONENTS AND MATERIALS IN ELECTRIC MOTORS BY TYPE, THROUGH 2021 ($ MILLIONS) 6
SUMMARY FIGURE GLOBAL MARKET FOR ADVANCED COMPONENTS AND MATERIALS IN ELECTRIC MOTORS BY TYPE, 2015-2021 ($ MILLIONS) 7
CHAPTER 3 OVERVIEW OF THE ELECTRIC MOTOR MANUFACTURING INDUSTRY 9
MOTOR TYPES 9
ENERGY CONSUMPTION OF MOTORS 9
TABLE 1 SHARE OF ELECTRICITY CONSUMPTION BY MOTOR FUNCTION (%) 10
MOTOR SECTORS BENEFITING FROM ADVANCED MATERIALS 10
PUMPING SYSTEMS 10
FANS 10
COMPRESSED AIR SYSTEMS 11
MARKET DRIVERS 11
DRIVING FORCES BEHIND MOTOR INNOVATION 11
REGULATORY DRIVERS 11
United States 12
Minimum Energy Performance Standards 13
THE SMALL MOTOR RULE 13
CURRENT ESTIMATED MOTOR POPULATION 14
TABLE 2 ESTIMATED POPULATION OF MOTORS BY SIZE, 2016 (BILLION/MILLION/%) 14
CHAPTER 4 MARKET ANALYSIS 16
OVERVIEW 16
TABLE 3 PRIVATE CORPORATE RESEARCH SPENDING ON ELECTRIC MOTORS AND SYSTEMS, THROUGH 2021 ($ MILLIONS) 16
RESEARCH AND DEVELOPMENT 16
DEPARTMENT OF ENERGY FUNDED RESEARCH 16
National Assessment of Motor Energy Savings Potential 16
Next Generation of Electric Machines Project 17
High-Performance Thermal and Electrical Conductor Manufacturing 17
Low-Loss Silicon Steel Manufacturing 17
Superconducting Wire Manufacturing 18
Other Enabling Technologies to Improve Efficiency and Power Density Performance 18
Next Generation of Electric Machines Projects in 2015 19
GENERAL ELECTRIC CO. 20
OHIO STATE UNIVERSITY 20
CLEMSON UNIVERSITY 20
CALNETIX TECHNOLOGIES 20
EATON CORP. 20
NATIONAL AERONAUTICS AND SPACE ADMINISTRATION R&D 20
NATIONAL SCIENCE FOUNDATION RESEARCH 21
NATIONAL RENEWABLE ENERGY LABORATORY 22
CANADIAN RESEARCH PROGRAMS 23
TABLE 4 GOVERNMENT-SPONSORED RESEARCH SPENDING ON ELECTRIC MOTORS AND SYSTEMS IN CANADA, THROUGH 2021 ($ MILLIONS) 23
ADVANCED MOTORS MARKET BY SEGMENT 23
ADVANCED MOTORS IN AIRPLANES AND WATERCRAFT 23
TABLE 5 R &D SPENDING ON MOTORS FOR ADVANCED TRANSPORTATION BY APPLICATION, THROUGH 2021 ($ MILLIONS) 25
ADVANCED MOTORS IN ELECTRIC VEHICLE MOTORS 25
TABLE 6 U.S. PATENTS RELATED TO ELECTRIC VEHICLES, 2014 TO 2016 25
Battery Barrier 26
TABLE 7 GLOBAL SALES OF ELECTRIC VEHICLES BY TYPE, THROUGH 2021 (UNITS) 27
Sales of Motors for Electric and Hybrid Vehicles 28
TABLE 8 GLOBAL MARKET FOR ELECTRIC AND HYBRID VEHICLE MOTORS BY
ELECTRIC VEHICLE TYPE, THROUGH 2021 ($ MILLIONS) 28
Key Raw Materials Issues 28
Raw Materials Alternatives 29
Oak Ridge National Laboratory 29
Momentum Technologies 30
TDK Corp. 30
Carpenter Powder Products 31
ADVANCED MOTORS IN ELECTRIC TRUCKS 31
NEW ELECTRIC VEHICLE MOTOR CONCEPTS 32
2-in-1 Electric Motor 32
Dyson and Electric Vehicle Motors 32
Other New Market Entrants 33
CHAPTER 5 MARKETS BY TECHNOLOGY TYPE 35
VARIABLE SPEED DRIVES 35
ENERGY SAVINGS AS A DRIVER IN THE VSD MARKET 35
MOTOR CONTROLS 35
PRINCIPAL MOTOR CONTROLS VENDORS 35
TYPES OF DIGITAL MICROPROCESSORS FOR MOTOR CONTROLS 36
MAJOR APPLICATIONS OF MOTOR CONTROLS 36
NOTABLE RECENT MOTOR CONTROL PATENTS 36
BRUSHLESS DC MOTORS 38
FUZZY LOGIC 38
ADVANCED MOTOR CONTROLS MARKET SIZE 39
TABLE 9 GLOBAL MARKET FOR ADVANCED MOTOR CONTROLS BY TYPE, THROUGH 2021 ($ MILLIONS) 39
NANOTECHNOLOGY-BASED MOTORS 39
MOLECULAR MOTORS 40
CARBON NANOTUBES 40
NATIONAL SCIENCE FOUNDATION-SPONSORED NANOMAGNETICS RESEARCH 40
CYCLOCONVERTERS 41
PRINCIPLE OF OPERATION 41
PATENTS 42
VENDORS 42
APPLICATIONS 42
MARKET SIZE 43
TABLE 10 GLOBAL MARKET FOR CYCLOCONVERTER SYSTEMS, THROUGH 2021 ($ MILLIONS) 43
NEW MOTOR MATERIALS AND TECHNIQUES 43
METAMATERIALS 43
SIMULATION TOOLS 44
3-D PRINTING 44
COPPER AND COPPER-BASED MATERIALS 44
NEW INSULATING MATERIALS 45
SUPERCONDUCTING MATERIALS 45
MAGNETIC BEARINGS 46
TABLE 11 FIFTY MOST RECENT U.S. PATENTS IN THE FIELD OF MAGNETIC MOTOR BEARINGS, NOV. 2013 THROUGH MARCH 2016 46
POLYTETRAFLUOROETHYLENE IN MOTOR BEARINGS 48
SILICON CARBIDE MATERIALS 48
SOFT MAGNETIC COMPOSITE AND AMORPHOUS MAGNETIC MATERIALS 49
Principal Companies 49
General Electric 49
Mitsubishi Electric 49
Toyota 50
TRANSVERSE FLUX MOTORS 50
HYBRID CYLINDRICAL MOTORS 51
HIGH MEGAWATT DRIVE MATERIALS 51
SWITCHED RELUCTANCE MOTORS 52
APPLICATIONS 52
TABLE 12 SELECTED U.S. PATENTS FOR SWITCHED RELUCTANCE TECHNOLOGY, FEB. 2012 TO MAY 2016 53
SWITCHED RELUCTANCE MOTORS 54
MAJOR PRODUCERS 54
Software Motor Corp. 54
SDT Drive Technology 54
NIDEC Corp. 55
MARKET SIZE 55
TABLE 13 PRINCIPAL GLOBAL PRODUCERS OF SWITCHED RELUCTANCE MOTORS 55
SYNCHRONOUS MOTOR DRIVES 56
MAJOR PRODUCERS 56
ABB/BALDOR Synchronous Motor Innovation 56
QM Power Inc. 56
MARKET SIZE 57
TABLE 14 GLOBAL MARKET FOR SYNCHRONOUS MOTORS, THROUGH 2021 ($ MILLIONS) 58
VARIABLE FREQUENCY DRIVES 58
STANDARDS 58
TABLE 15 REVENUES OF TOP VENDORS OF VARIABLE SPEED DRIVE MOTORS AND CONTROLLERS ($ MILLIONS) 58
SUPPLIERS 59
TECHNICAL ISSUES ASSOCIATED WITH VFD CONTROLLERS 59
OTHER NEW MOTOR TECHNOLOGIES 60
ELECTROSTATIC FORCE VERSUS MAGNETISM AS A MOTOR DRIVER 60
C-Motive Technologies 60
SMART SYNCHRONOUS MOTORS 60
INNOVATIONS IN PERMANENT MAGNET MOTORS 61
MAGNETIC-BASED DRIVES 62
NEWER HYBRID ELECTRIC VEHICLE MOTORS 62
CHAPTER 6 MARKET BY MATERIALS AND DEVICES USED IN MOTORS 65
OVERVIEW 65
MOTOR DRIVER INTEGRATED CIRCUITS 65
TABLE 16 GLOBAL MARKET FOR ADVANCED SEMICONDUCTORS FOR ELECTRIC MOTOR APPLICATIONS, THROUGH 2021 ($ MILLIONS) 65
TABLE 17 GLOBAL MARKET FOR ADVANCED SEMICONDUCTORS FOR ELECTRIC MOTOR APPLICATIONS BY REGION, THROUGH 2021 ($ MILLIONS) 66
GALLIUM NITRIDE 66
TABLE 18 RESEARCH SPENDING ON GALLIUM NITRIDE MOTOR APPLICATIONS BY TYPE, THROUGH 2021 ($ MILLIONS) 67
POWER SEMICONDUCTOR DEVICES USED IN MOTORS 67
APPLICATIONS 67
MAJOR PRODUCERS 68
DENSO and Toyota 68
Hitachi and Infineon 68
Vincotech 68
SELECTED PATENTS IN THE POWER SEMICONDUCTOR FIELD 69
POWER SEMICONDUCTORS IN THE AUTOMOTIVE AND ELECTRIC VEHICLE MOTOR MARKET 70
TABLE 19 GLOBAL MARKET FOR ELECTRIC VEHICLE IGBTS, THROUGH 2021 ($ MILLIONS) 70
Major Producers 71
Infineon Technologies 71
ST Microelectronics 71
Freescale Semiconductor 71
NXP Semiconductor 71
Texas Instruments 71
MAJOR POWER ELECTRONICS SUPPLIERS 71
Artesyn 72
Astec 72
AVX 72
Bergquist Co. 72
Bosch Rexroth 72
Coilcraft 72
Delta Electronics 72
Fairchild Semiconductor 73
Infineon Technologies 73
International Rectifier 73
IXYS 73
Linear Technology 73
Maxim Integrated Products, Dallas Semiconductor 73
Micrel 74
Microsemi 74
Motorola Semiconductor Products Sector: Freescale Semiconductor 74
Motorola Semiconductor Products Sector: ON Semiconductor 74
Microchip Technology 74
National Semiconductor 74
Philips Semiconductors 74
Power Integrations 75
Power-One 75
Pulse 75
Rockwell Automation (ElectroCraft and Allen-Bradley) 75
STMicroelectronics 75
Supertex 75
SynQor 76
Texas Instruments 76
Toshiba 76
Vicor Corp. 76
Vishay Intertechnology (Siliconix) 76
CHAPTER 7 PATENT ANALYSIS AND COMPANY PROFILES 78
OVERVIEW 78
SELECTED RECENT PATENTS 78
COMPANY PROFILES 83
TABLE 20 PRINCIPAL MANUFACTURING ACTIVITIES WITHIN NAICS CODE 335312: MOTOR AND GENERATOR MANUFACTURING 83
ABB LTD. 85
ADVANCED MOTORS AND DRIVES 85
ACTOM (PTY) LTD. 85
ALLIED MOTION TECHNOLOGIES INC. 86
ALTRA INDUSTRIAL MOTION 86
AMETEK INC. 86
ARC SYSTEMS INC. 87
ASMO CO. LTD. 87
BALDOR ELECTRIC CO. 87
BAUER GEAR MOTOR 88
BROOK CROMPTON UK LTD. 88
BROSE FAHRZEUGTEILE GMBH & CO. KG 89
CROMPTON GREAVES LTD. 89
DANAHER MOTION 89
DENSO 90
FRANKLIN ELECTRIC CO. INC. 90
GENERAL ELECTRIC CO. 90
HITACHI LTD. 91
INCREMOTION ASSOCIATES INC. 91
HYOSUNG CORP. 91
JOHNSON ELECTRIC HOLDINGS LTD. 91
KIRLOSKAR ELECTRIC CO. LTD. 92
KLD ENERGY TECHNOLOGIES 92
LEESON ELECTRIC 92
MINEBEA CO. LTD. 93
MITSUMI ELECTRONICS CO. LTD. 93
MOOG ANIMATICS 93
NANYANG EXPLOSION PROTECTION GROUP CO. LTD. 93
NIDEC CORP. 94
ORIENTAL MOTOR 94
PANASONIC CORP. 94
REGAL BELOIT CORP. 95
ROBERT BOSCH GMBH 95
ROCKWELL AUTOMATION INC. 95
SANYO DENKI AMERICA INC. 95
SHINANO KENSHI CORP. 96
SIEMENS AG 96
SOFTWARE MOTOR CORP. 96
SOMFY GROUP 97
TECO-WESTINGHOUSE MOTOR CO. 97
TOSHIBA CORP. 97
TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORP. 98
WEG ELECTRIC CORP. 98
WOLONG HOLDING GROUP 98
ZHEJIANG WOLONG HOME APPLIANCE 99
ZHONGSHAN BROAD-OCEAN MOTOR CO. LTD. 99


LIST OF TABLES
SUMMARY TABLE GLOBAL MARKET FOR ADVANCED COMPONENTS AND MATERIALS IN ELECTRIC MOTORS BY TYPE, THROUGH 2021 ($ MILLIONS) 6
TABLE 1 SHARE OF ELECTRICITY CONSUMPTION BY MOTOR FUNCTION (%) 10
TABLE 2 ESTIMATED POPULATION OF MOTORS BY SIZE, 2016 (BILLION/MILLION/%) 14
TABLE 3 PRIVATE CORPORATE RESEARCH SPENDING ON ELECTRIC MOTORS AND SYSTEMS, THROUGH 2021 ($ MILLIONS) 16
TABLE 4 GOVERNMENT-SPONSORED RESEARCH SPENDING ON ELECTRIC MOTORS AND SYSTEMS IN CANADA, THROUGH 2021 ($ MILLIONS) 23
TABLE 5 R &D SPENDING ON MOTORS FOR ADVANCED TRANSPORTATION BY APPLICATION, THROUGH 2021 ($ MILLIONS) 25
TABLE 6 U.S. PATENTS RELATED TO ELECTRIC VEHICLES, 2014 TO 2016 25
TABLE 7 GLOBAL SALES OF ELECTRIC VEHICLES BY TYPE, THROUGH 2021 (UNITS) 27
TABLE 8 GLOBAL MARKET FOR ELECTRIC AND HYBRID VEHICLE MOTORS BY ELECTRIC VEHICLE TYPE, THROUGH 2021 ($ MILLIONS) 28
TABLE 9 GLOBAL MARKET FOR ADVANCED MOTOR CONTROLS BY TYPE, THROUGH 2021 ($ MILLIONS) 39
TABLE 10 GLOBAL MARKET FOR CYCLOCONVERTER SYSTEMS, THROUGH 2021 ($ MILLIONS) 43
TABLE 11 FIFTY MOST RECENT U.S. PATENTS IN THE FIELD OF MAGNETIC MOTOR BEARINGS, NOV. 2013 THROUGH MARCH 2016 46
TABLE 12 SELECTED U.S. PATENTS FOR SWITCHED RELUCTANCE TECHNOLOGY, FEB. 2012 TO MAY 2016 53
TABLE 13 PRINCIPAL GLOBAL PRODUCERS OF SWITCHED RELUCTANCE MOTORS 55
TABLE 14 GLOBAL MARKET FOR SYNCHRONOUS MOTORS, THROUGH 2021 ($ MILLIONS) 58
TABLE 15 REVENUES OF TOP VENDORS OF VARIABLE SPEED DRIVE MOTORS AND CONTROLLERS ($ MILLIONS) 58
TABLE 16 GLOBAL MARKET FOR ADVANCED SEMICONDUCTORS FOR ELECTRIC MOTOR APPLICATIONS, THROUGH 2021 ($ MILLIONS) 65
TABLE 17 GLOBAL MARKET FOR ADVANCED SEMICONDUCTORS FOR ELECTRIC MOTOR APPLICATIONS BY REGION, THROUGH 2021 ($ MILLIONS) 66
TABLE 18 RESEARCH SPENDING ON GALLIUM NITRIDE MOTOR APPLICATIONS BY TYPE, THROUGH 2021 ($ MILLIONS) 67
TABLE 19 GLOBAL MARKET FOR ELECTRIC VEHICLE IGBTS, THROUGH 2021 ($ MILLIONS) 70
TABLE 20 PRINCIPAL MANUFACTURING ACTIVITIES WITHIN NAICS CODE 335312: MOTOR AND GENERATOR MANUFACTURING 83



LIST OF FIGURES
SUMMARY FIGURE GLOBAL MARKET FOR ADVANCED COMPONENTS AND MATERIALS IN ELECTRIC MOTORS BY TYPE, 2015-2021 ($ MILLIONS) 7
Country=World Industry=ElectricalEquipment ParentIndustry=Manufacturing Date=201701 Topic=MarketReport Publisher=BCCResearch Price=6000