The Design and Application of Latest Generation PM Machines

Transcription

1 The Design and Application of Latest Generation PM Machines Steven Stretz Regal Beloit Corporation Motor and Drives Conference

2 The Induction Motor from where we came The origin of the induction motor dates back to the late 1800s The design was a natural fit allowing technological changes in materials and processes to be easily incorporated. It (and others such as DC) quickly became the way to convert electric power into motion. Mikhail Dolivo-Dobrovolsky, 1890 cage rotor Walter Baily, 1879 Galileo Ferraris, Nikola Tesla, 1885, 1887 Charles Bradley, 1887 Motor and Drives Conference

3 The Need For Standardization For acceptance, usage and ultimately the market to grow, some standardization was needed. NEMA was created in 1926 U-Frame motor dimensions and ratings weren t established until However T-frame standards followed quickly in 1964 Standards not only dictated the physical dimensions but also the operating characteristics such as torque, temperature limits and other criteria. Motor and Drives Conference

4 Controlled Growth and Years of Stability TEFC, TEAO, TEWAC. Close Coupled Hydraulic Pump. Special purpose Multiple sseeds Medium Voltage Inverter Duty. Class A, B, F, H P-Base T-Frame IP, IC Codes. Splash Proof NEMA D Continuous Duty Water Proof Definite Purpose NEMA Premium U-Frame NEMA B NEMA C Intermittent Duty High Efficiency NEMA E * Not intended as an accurate event timeline Motor and Drives Conference

5 Drivers of Change, creating gaps Power Electronics, Variable Frequency Technology Advances Efficiency Standards Electric Vehicles & Propulsion Special purpose TEFC, TEAO, TEWAC. IP, IC Codes Inverter Duty Customer Demands Internet of Things Cost Manufacturing Scale T-Frame P Base High Efficiency Integration Splash Proof Continuous Duty Water Proof Definite Purpose NEMA Premium IE 4 IE 5 NEMA B Intermitte nt Duty Nema E High Speed Traction Connectivity which are opportunities Motor and Drives Conference

6 Technology Fills The Gaps but how Magnets, what type, what configuration, cost? Replace Induction with General Purpose PM motor? Electronics, where, how? Change entire motor form or topology? The process of diversity, standardization and growth may be starting over again. Motor and Drives Conference

7 Understand The Need, purpose for the change NICE! 1 Programmable 2 No maintenance 3 Increase product capability 4 Nice to Have Stated 1 Meets standards 2 Higher efficiency 3 Affordable 4 Stated Obvious 1 Quality 2 Reliability 3 Available 4 Obvious What topologies make sense? Motor and Drives Conference

8 Understand The Gaps How large is the gap-between current and what is needed Is the gap perceived or real, are we solving the right problem. The application can drive technology/topology, but Technology/topology can revolutionize the application Motor and Drives Conference

9 Next, A Systematic Design Approach Design optimization needed to truly evaluate topology differences Manual efforts can lead to false conclusions Computationally efficient techniques exist Multiple objectives and constraints can be implemented Material cost and manufacture complexity can be considered Torque Ripple [%] Goodness [Nm/sqrt(W loss )] Shaft Torque [Nm] The contributions of the colleagues at Marquette University, University of Wisconsin Milwaukee, ANSYS Corp. and Motor Design LTD are gratefully acknowledged. Motor and Drives Conference

10 Combined Electromagnetic and Thermal Initial optimization excellent for comparing topologies but only when cooling mechanism similar Pure multi-physics transient analysis can be computationally challenging, there are other ways Methods using computationally efficient electromagnetic and fast solving thermal circuit analyses has produced excellent results The contributions of the colleagues at Marquette University, University of Wisconsin Milwaukee, ANSYS Corp. and Motor Design LTD are gratefully acknowledged. Motor and Drives Conference

11 Noise and Vibration yet another thing to consider Noise unfamiliar sounds Cogging Ripple torque Radial forces Carrier frequency Resonances Inherent machine characteristics Magnet variation Air gap Shaping Manufacturing variation The contributions of the colleagues at Marquette University, University of Wisconsin Milwaukee, ANSYS Corp. and Motor Design LTD are gratefully acknowledged. Motor and Drives Conference

12 Obstacles to Change not always technical Fear of permanent magnets, cost, availability, stuff sticks to them? What do you mean it only works with certain drives? (availability, compatibility of commercial drives and machines) Change MY design? Drive programming knowhow Reliability of integrated electronics Cost, payback for whom? Motor and Drives Conference

13 Simple Conversion to PM Typically for larger machines Design challenges, mentioned earlier: Systematic design approach identifies best design choices considering design constraints. Design choices can greatly affect cost and performance. Sound and noise can become a challenge depending on operating frequency. Manufacturing variations can have a different affect on performance. Performance is affected by electronic drive (setting) Motor and Drives Conference

14 Application Story Sometimes it is all about efficiency and it can be measured Multiple motor and control manufacturers products tested to identify / demonstrate savings potential Worked through a number of setup challenges and bugs to complete testing Energy savings of 3-18% over test speed range, 8-9% in normal operating range, converting from induction to PM motors and controls Test method: measure total input power required (in kilowatt hours) for each pound of material produced Original DC Induction motor PM motor motor & drive with modern VFD with PM VFD Motor and Drives Conference

15 Synchronous Reluctance Including PM Assisted Technology with long history of academic interest and practical application. Product introductions as far back as 1950s. Very popular in late 1970s and 1980s in textile industry for nylon and polyester fabric production and where synchronous speed was main requirement. Became used in other interesting applications. Renewed interest more recently as a way to improve machine efficiency Efficiency opportunities through reduction in rotor losses but can have relatively low power factor Unique control method required to optimize performance, sensitive to machine design Scatter plot of 10,000 candidate designs quantifying the theoretical improvement in performance achieved from adding PM Motor and Drives Conference

16 Integrating Motor and Drive targeted applications Low acceptance of early attempts reliability concerns, infrastructure dependencies Technology advances has improved integration Integration key to achieving desired benefit (integration for a reason) Key features often software driven Product evolution relies on advances in electronics and motor technologies Evolution of an idea as technology advances Motor and Drives Conference

17 Application Story Energy savings from variable speed and high efficiency are well documented, both consumer and industrial, HVAC and pumping. One industrial example achieved an energy savings of % from induction to PM Test method: measure input power vs speed, then measuring power meter differences for typical cycle (programmed) Motor and Drives Conference

18 Topology Change for a reason, one example Axial technology allows the designer to create a shorter machine, a pancake vs a sausage Axial designs one of the most effective uses of material Design challenges, mentioned earlier: Systematic design required to reach the proper design Cooling is much different Radial forces become axial and axial forces become radial Noise generating platform much different in shape Manufacturing variations present different challenges than radial Motor and Drives Conference

19 Combining Ideas, Technologies Axial and integration.. Tremendous advantages from combining machine topologies and electronics in different ways, for different products. Scaling size opens new opportunities Motor and Drives Conference

20 Further Integration, into the application As integration goes deeper there are more challenges, vibration and noise mitigation for example There are also opportunities for new levels of product / application performance. Customer and even user input and cooperation even more important. New flexibility in design for customers Motor and Drives Conference

21 Modularity another approach to integration and flexibility Modularity can apply to the machine only or to levels of integration with electronics. Scalability beyond size to different operating characteristics, such as speed / number of poles Combination of machine types possible Motor and Drives Conference

22 Internet of Things talking motors? Is it a motor, a sensor, both? Is it all about software or will it affect the base design of the machine? How are features and functionality distributed among the product, subsystem, users and cloud? Excellent opportunities to motorize products previously not! Motor and Drives Conference

23 Conclusions Lessons learned from the history of the induction motor may be a good guide for future machine development. Understanding the needs of the application is key to developing the best product. The application does drive the solution but new machine technologies can also revolutionize the application. A systematic design approach is required to compare different machine topologies; to find the best solution Consider both real and imaged challenges moving from concept to final design. There are many exciting approaches to new machine development, each with unique benefits It s an exciting time for machine (and power electronic) design Motor and Drives Conference

24 An Exciting Time For Innovation even in PM machines Thank You Motor and Drives Conference

25 Acknowledgements and References References: Greg Heins, Dan Ionel, Mark Thiele, Winding Factors and Magnetic Fields in Permanent Magnet Brushless Machines with Concentrated Windings and Modular Stator Cores, IAS 2015 Yi, Wang, Dan M. Ionel, Minjie Jiang, Steve J. Stretz, Establishing the Relative Merits of Synchronous Reluctance and PM Assisted Technology Through Systematic Design Optimization. Acknowledgements: Dan Ionel, Chief Design Engineer, Regal Beloit Alan Yeadon, Senior Application Engineer, Regal Beloit Students and Colleagues, Marquette University Students and Colleagues, University of Wisconsin Milwaukee ANSYS, for their project support Motor Design LTD., for their project support Motor and Drives Conference