What s New & What s Driving New Motor Technologies. Dan Jones Incremotion Associates
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1 What s New & What s Driving New Motor Technologies Dan Jones Incremotion Associates
2 Technology Driving Forces Motor Design engineers are being asked to improve: 1. Power Efficiency 2. Power Density 3. Torque Density Wednesday, January 28, 2014 Dan Jones - 2
3 Degrees of Motion 1. Constant Speed 2. Variable Speed 3. Variable Position Wednesday, January 28, 2014 Dan Jones - 3
4 Technology Motion Alignment Power Efficiency Constant & Variable Speed Power Density Variable Speed Torque Density Position (Servo) Wednesday, January 28, 2014 Dan Jones - 4
5 Electric Motor Types AC Motor Induction Motor PM Brushless Motor Radial Gap Axial Gap (flux) Transverse flux Reluctance Motor Switched Reluctance Motor Synchronous Reluctance Motor Hybrid Motor Combines 2 motor types Wednesday, January 28, 2014 Dan Jones - 5
6 Today s Driving Forces Previously covered torque density at SMMA this past November Hold Power Density presentation for a future presentation. Focus on Power Efficiency Wednesday, January 28, 2014 Dan Jones - 6
7 Power Efficiency Many more speed based applications Most popular electric motor is the squirrel cage 1Ø and 3Ø induction AC motor Wednesday, January 28, 2014 Dan Jones - 7
8 Competing Electric Motor Types PM brushless Motors Ferrite Magnets Neodymium Magnets Synchronous Reluctance Motors Hybrid Types Wednesday, January 28, 2014 Dan Jones - 8
9 AC Induction Motor Cross-Section Wednesday, January 28, 2014 Dan Jones - 9
10 Target Motor Type AC Induction Motor squeezed between Competing Motor Technologies Government Agencies Wednesday, January 28, 2014 Dan Jones - 10
11 U.S. Shipments by Horsepower Wednesday, January 28, 2014 Dan Jones - 11
12 New DOE AC Motor Coverage Motor Type Power (HP) No. of Poles Enclosure NEMA Design A & B 1 to 500 2, 4, 6, 8 Open/Closed NEMA Design C 1 to 200 4, 6, 8 Open/Closed Fire Pump 1 to 500 2, 4, 6, 8 Open/Closed Brake Motors 1 to 30 4, 6, 8 Open/Closed Gear Motors* 1 to 500 2, 4, 6, 8 Open/Closed *Remove Gearbox & test as motor only Note: All Efficiency Comparisons use 4 Pole, Design B, Enclosed Units Wednesday, January 28, 2014 Dan Jones - 12
13 AC Motor Horsepower Breakdown Wednesday, January 28, 2014 Dan Jones - 13
14 Application & Performance of Existing Equipment Wednesday, January 28, 2014 Dan Jones - 14
15 Electric Motor Use 46% of all electricity consumed is by electric motors What % is consumed by covered integral HP- AC induction motors??? Wednesday, January 28, 2014 Dan Jones - 15
16 Annual Electricity Use By Electric motors (2009) Motor Size Billion Kw-hr % of Total Small (< than 1 HP) Medium ( 1 Hp to 503 HP) Large (503 HP to 134,100 HP) Total Wednesday, January 28, 2014 Dan Jones - 16
17 Electricity Consumed Worldwide By Electric Motor-Driven Systems (IEA) trillion Kw-hr worth $565 billion US trillion Kw-hr worth $900 billion US Electric motor-driven systems (EMDS) Wednesday, January 28, 2014 Dan Jones - 17
18 Environmental Conditions Population Growth Increasing Use of Electricity Rising Cost of Electricity Change in long term weather conditions Ten + year cycle time for building power plants Wednesday, January 28, 2014 Dan Jones - 18
19 Saving Electrical Energy If one cannot build enough power plants (whether fossil fuel or alternative energy based), then programs dedicated to energy savings would be required. Wednesday, January 28, 2014 Dan Jones - 19
20 Scientific American January 2014 Renewable Energy Sources Could Take the World by Storm by Vaclav Smil, University of Manitoba Modern renewables only supply 3.4% (2012) Renewable Energy is not taking off any faster than coal, oil or gas has done. Renewable Energy has large fluctuations (intermittent energy). The most important way to speed up the gradual change to renewables is to lower overall energy use through efficiency gains. Wednesday, January 28, 2014 Dan Jones - 20
21 Saving Electric Energy Prodding by the various government agencies was not working in the late 1980 s. US Congress stepped in and passed the EPAct law (1992) that dictated higher motor efficiencies. The focus was on 3 phase induction motors (1 HP to 250 HP, later extended to 500 HP). The Department of Energy (DOE) was given the task of implementing the law through regulations. Wednesday, January 28, 2014 Dan Jones - 21
22 NEMA Design B Motor Candidate Standard Levels Wednesday, January 28, 2014 Dan Jones - 22
23 NEMA Design B 5 HP Wednesday, January 28, 2014 Dan Jones - 23
24 NEMA Design B 30 HP Wednesday, January 28, 2014 Dan Jones - 24
25 Wednesday, January 28, 2014 Dan Jones - 25
26 Manufacturers Implementation DOE Estimates (Large Suppliers) Document # EERE-2010-BT STD 0027 Average selling price for a 5 HP Design A & B Induction motor will increase from $595 (Premium EL2) to $1050 (Max Tech EL4). Average selling price for a 30 HP-Design A & B Induction motor will increase from $1845 to $3198 (Max Tech EL4). Conversion Cost Estimates: $80 million in retooling $68 million in re-engineering, testing, prototyping, specifying Wednesday, January 28, 2014 Dan Jones - 26
27 AC Motor Performance DOE efficiency is specified at a single operating point. Both motor efficiency and power factor will drop as the application load is smaller. Enter the Variable Speed Drive (VSD) Wednesday, January 28, 2014 Dan Jones - 27
28 Saving Electrical Energy New DOE Standards will go into effect in March 2015 for fractional and December 2015 for integral AC motors. This new set of DOE Standards has pushed the AC induction motor standards about as far as possible. But what about the other motor types? Wednesday, January 28, 2014 Dan Jones - 28
29 Motor Loss Comparison Wednesday, January 28, 2014 Dan Jones - 29
30 Losses in Electric Motors Wednesday, January 28, 2014 Dan Jones - 30
31 Competing Motor Technologies Wednesday, January 28, 2014 Dan Jones - 31
32 Moving to Full Production ABB NovaTorque Wednesday, January 28, 2014 Dan Jones - 32
33 Wednesday, January 28, 2014 Dan Jones - 33
34 Wednesday, January 28, 2014 Dan Jones - 34
35 Wednesday, January 28, 2014 Dan Jones - 35
36 Wednesday, January 28, 2014 Dan Jones - 36
37 ABB Synchronous Reluctance Motor Wednesday, January 28, 2014 Dan Jones - 37
38 ABB Syn Rel vs. DOE Maximum Efficiency 1. ABB 15 Kw (20 HP) % (91.5%) DOE 20 HP (4) % 2. ABB 37 Kw (50 HP) % (92.5%) DOE 50 HP (4) -- 95% *In parentheses Motor + Drive Efficiency Wednesday, January 28, 2014 Dan Jones - 38
39 Wednesday, January 28, 2014 Dan Jones - 39
40 NovaTorque Configuration Wednesday, January 28, 2014 Dan Jones - 40
41 Wednesday, January 28, 2014 Dan Jones - 41
42 NovaTorque Efficiency Comparison Focused on HVAC Applications ( Fans, Blowers, Pumps, Compressors) 1. NovaTorque 3 HP 93% DOE (4) 3 HP 87.5% 2. NovaTorque 5 HP 92% DOE (4) 91% Wednesday, January 28, 2014 Dan Jones - 42
43 Moving Toward Production Electric Torque Machines (ETM) QM Power Wednesday, January 28, 2014 Dan Jones - 43
44 Electric Torque Machines (ETM) Wednesday, January 28, 2014 Dan Jones - 44
45 Electric Torque Machines (ETM) Wednesday, January 28, 2014 Dan Jones - 45
46 Electric Torque Machines (ETM) Wednesday, January 28, 2014 Dan Jones - 46
47 Electric Torque Machines (ETM) Wednesday, January 28, 2014 Dan Jones - 47
48 E-Scooter Tech Specs Wednesday, January 28, 2014 Dan Jones - 48
49 Electrical Torque Machines Efficiency Comparison ETM 1.8 Kw (2.5 HP) % DOE 3.0 HP (4) % Wednesday, January 28, 2014 Dan Jones - 49
50 QM Power Has developed two major motor technologies Q-Sync & Parallel Path Magnet Technology (PPMT) Has received many ARPA-E & National Science Foundation (NSF) Grants Investors money flows in early 2013 Can use Ferrite Magnets in the PPMT design Wednesday, January 28, 2014 Dan Jones - 50
51 QM Power Parallel Path Magnetic Technology Wednesday, January 28, 2014 Dan Jones - 51
52 QM Power PPMT Motor Wednesday, January 28, 2014 Dan Jones - 52
53 QM Power Wide Power Range Wednesday, January 28, 2014 Dan Jones - 53
54 QM Power vs. DOE Efficiency Comparison 1. PPMT 5 HP -- 93% DOE (4) 5 HP -- 91% 2. PPMT 30 HP % DOE (4) 30 HP % 3. PPMT 75 HP -- 97% DOE (4) 75 HP % Wednesday, January 28, 2014 Dan Jones - 54
55 R&D, Engineering Services & Academia (1) LaunchPoint Technologies (2) Royal Institute of Technology (3) CSIRO Marand Wednesday, January 28, 2014 Dan Jones - 55
56 LaunchPoint Technologies Wednesday, January 28, 2014 Dan Jones - 56
57 LaunchPoint Technologies Wednesday, January 28, 2014 Dan Jones - 57
58 LaunchPoint Technologies Wednesday, January 28, 2014 Dan Jones - 58
59 Halbach Arrays Wednesday, January 28, 2014 Dan Jones - 59
60 LaunchPoint Technologies DOE versus UAV Motor UAV Motor 7 HP -- 95% DOE (4) 7.5 HP % Wednesday, January 28, 2014 Dan Jones - 60
61 KTH Research Wednesday, January 28, 2014 Dan Jones - 61
62 Royal Institute of Technology (KTH) Stockholm, Sweden Electrical Engineering Department dedicated to electric machines & power & control electronics Working on line start AC, Synchronous Reluctance and Various types of PMSM machines Utilizing Halbach magnet configurations Wednesday, January 28, 2014 Dan Jones - 62
63 KTH Electrical Engineering Wednesday, January 28, 2014 Dan Jones - 63
64 KTH Electrical Engineering Wednesday, January 28, 2014 Dan Jones - 64
65 KTH Wednesday, January 28, 2014 Dan Jones - 65
66 Marand Electric Motors Wednesday, January 28, 2014 Dan Jones - 66
67 Marand Wednesday, January 28, 2014 Dan Jones - 67
68 Marand Wednesday, January 28, 2014 Dan Jones - 68
69 Marand Wednesday, January 28, 2014 Dan Jones - 69
70 Marand Wednesday, January 28, 2014 Dan Jones - 70
71 Marand Precision Engineering Comparison DOE vs. Marand Efficiency MARAND 24 HP % DOE (4) 37 HP % Wednesday, January 28, 2014 Dan Jones - 71
72 Summary of Motor Efficiency Levels Wednesday, January 28, 2014 Dan Jones - 72
73 Issues & Items Not Covered DOE s Efficiency Ruling for 1Ø & 3Ø Fractional HP motors Power Factor New Power Electronic Devices Variable Speed Drives (VSDs) Induction Motor Efficiencies at other load points Induction vs. PM motors in Traction Applications Current electricity cost in cents/kw hour, Regional & National More thorough data on energy sources What s happening with energy sources in Europe & Asia New potential targets for DOE s further actions New motor developments (PM, VR, Hybrid) Lifecycle costs Intensive review Water Wednesday, January 28, 2014 Dan Jones - 73
74 Conclusions Electric motors in the US use 46% of all electricity consumed. AC Induction motors consume over 80% of that energy. Use of electricity grows annually at about 2% or 80 billion kilowatt hours. The electric grids in most regions are increasingly experiencing a number of brownouts or blackouts each year. New York, Connecticut & Vermont have the highest average retail electricity rates in the continental US. Global warming has a direct impact on the need for more electricity. It takes over 10 years to build a 20 megawatt power plant. Wednesday, January 28, 2014 Dan Jones - 74
75 Conclusions The best energy solution is to save energy. It is the least costly approach. The obvious target is the ac induction motor. The US Congress passed various laws to increase ac induction motor power efficiency. The US Congress gave DOE the responsibility to establish new efficiency ratings. The DOE has increased IHP induction motor power efficiency 3 times since The latest regulations will go into effect late in 2015 and will require the use of copper rotor windings and very high stator slot fill (84%). Wednesday, January 28, 2014 Dan Jones - 75
76 Conclusions The AC motor s horsepower sweet spot is 5 HP, which is 23% of total span of 1 HP to 500 HP. The latest DOE efficiency regulations is estimated to cost the big 7 ac induction motor manufacturers over $148 million by DOE estimates. AC motor sales prices will increase by 45 75% depending on ac induction motor horsepower ratings (EL3 to EL4). Automatic stator winding may have to be replaced by hand insertion operations. My rough estimate is that US Manufacturers will pay over $5 billion to retool and recertify their AC motor products over the next 3 yrs. Since each new electric power plant costs about $2 billion the overall financial impact is lessened by having US motor manufacturers foot the bill! Wednesday, January 28, 2014 Dan Jones - 76
77 Conclusions The permanent magnet motor in it s many forms possesses a higher intrinsic power efficiency than it s AC motor counterpart. There are examples of highly efficient PM motors using ferrite magnets. Reluctance motors can match & exceed the highest AC induction motor s efficiencies. Hybrid motors may be the best solution for highest efficiencies in the future (PM + Reluctance, PM + Induction). PM motor cost is a challenge for many PM & SR motors. A more comprehensive review of new motor development is required. The best combination of motor & drive presented today is MARAND s motor & KTH s drive (98.4 X 99.7 or 98.0% combined). Wednesday, January 28, 2014 Dan Jones - 77
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