Motor Revolution: Synchronous reluctance motor technology

Transcription

1 Electrical Enineering Institutions Lecture Program 2014 Csaba Szabo ABB Australia 10/07/2014 Motor evolution: Synchronous reluctance motor technology

2 SynM package Why we do this? Today's technology makes it feasible Very high motor or system efficiency To be used where application already demands variable speed esults: competitive VSD package with very high efficiency, unobtainable with traditional induction motors 8/26/2014 Slide 2

3 SynM - Technology review

4 Synchronous reluctance technology History - key technology steps s (e) (c) (f) Iron Segment Magnetic Barrier (Normally Air) (d) (a) Simple salient pole (SP) rotor (b) Axially laminated anisotropy (ALA) rotor (c) Transversally laminated anisotropy (TLA) rotor (No) line start capability (d) J. K. Kostko 1923 (original patent) (e) ABB Synchronous reluctance servomotors (f) ABB Synchronous reluctance motor and drive package 8/26/2014 Slide 4

5 Synchronous reluctance technology Design concept Single sheet of punched electrical steel The sheets stack to a complete rotor body. Can either be stacked on a pre-assembly piece or direct on the shaft. Mounting the rotor body on a shaft. The rotor will be balanced after shaft assembly. The rotor body inset in a stator. A standard stator 4 pole design is used but with adapted winding. August 26, 2014 Slide 5

6 Synchronous reluctance technology otor construction 8/26/2014 Slide 6

7 Synchronous reluctance technology Function compared to induction motor 8/26/2014 Slide 7 T T T S S S T T T S S S S S T T T T T T T T S S S S S S Induction motor Synchronous reluctance motor Elimination of resistive rotor losses

8 New innovative motor and drive packages The technology for variable speed applications Standard motor + special rotor Standard drive + new software evolutionary drive package! Standard motor + special rotor Standard cast iron frame Special wound stator using standard materials Same auxiliaries and options available as for induction motor (500+) Special cageless rotor removes rotor iron losses reduction of total losses up to 40% less heat and higher efficiency 8/26/2014 Slide 8

9 New innovative motor and drive packages The technology for variable speed applications Standard motor + special rotor Standard drive + new software evolutionary drive package Synchronous reluctance motor needs a drive (ACS850) Can replace most of the variable speed driven induction motors in quadratic torque (pumps, fans) and constant torque applications eliable high efficient workhorse for general industrial applications 8/26/2014 Slide 10

10 SynM Package features Two approaches

11 Key to success Elimination of rotor losses 100% I 2 otor 60% Other I 2 Stator Other IE4 SynM motor I 2 Stator 80-90% Other IE2 induction motor Losses I 2 Stator High Output SynM motor 8/26/2014 Slide 12

12 New innovative motor and drive packages The technology for variable speed applications Two approaches: High output or IE4 Super premium efficiency 8/26/2014 Slide 13

13 New innovative motor and drive packages The technology for variable speed applications The High Output SynM package eduction of losses means cooler motor Smaller motor for same application Up to two frame sizes smaller Enables more compact machinery Weight reduction More power from same size Improve process performance Jump to next output level without mechanical changes to existing machinery 8/26/2014 Slide 14

14 Same power - smaller motor What does smaller size mean in practice? Same output from a smaller size or higher output from the same size 8/26/2014 Slide 15

15 Same power - smaller motor What does smaller size mean in practice? educed system space lower weight, easier installation 8/26/2014 Slide 16

16 Two new innovative motor and drive packages The technology for variable speed applications The IE4 Super Premium Efficiency SynM package Energy losses reduced by up to 40% compared to IE2 efficiency class Energy savings Output versus shaft height corresponds to IEC & AS/NZS standards Interchangeable with IE2 induction motor IE2 induction can be used as spare Easy to give it a go! 8/26/2014 Slide 17

17 New revolutionary motor and drive package Significant benefits Compactness and efficiency of permanent magnet motor Service friendliness of induction motor Magnet free design No magnetic forces No special tools No special training If you can service induction motor you can service SynM 8/26/2014 Slide 18

18 New revolutionary motor and drive package Higher reliability Higher reliability through lower bearing temperature Less heat in rotor Less heat transferred though shaft to bearings Grease will last longer and maintain better lubrication Less maintenance and down time 8/26/2014 Slide 19

19 New revolutionary motor and drive package High package efficiency Designed exclusively for variable speed operation Insulation technology suitable for voltage peaks and added harmonics stress. Package efficiency verified by ABB Test report stating real use efficiency available for each package (state of the art measuring equipment) 8/26/2014 Slide 20

20 New revolutionary motor and drive package Get the best of two worlds Packages available for quadratic and constant torque applications Competitive product offering compared to traditional or other new technologies High output: IE4: kW kw Advanced open loop control software No separate tacho or encoder needed Global ABB support 8/26/2014 Slide 21

21 New revolutionary motor and drive package Current anges rpm, 2100 rpm, 1500 rpm 8/26/2014 Slide Hz = 3000rpm, 70Hz = 2100rpm, 50Hz = 1500rpm

22 New revolutionary motor and drive package Load-ability 8/26/2014 Slide 23

23 SynM Advantages

24 How much does a motor cost? 65 % of total electricity at industrial sites is consumed by electric motors Motor purchasing price corresponds to 8 to 12 weeks of its electricity consumption The capital cost will represent only 1% of the total life cycle operational costs of the motor eliable motors with a high efficiency level ensure the lowest life cycle costs One 75kW Motor cost...25 years to run 24/7? $90,000 Life time cost of power $2,250, save...6% $135,000 8/26/2014 Slide 25

25 High output SynM motor and drive package Advantages in a nutshell Same power, smaller motor IE3 compact design without compromising efficiency Same size motor, higher power Full range Induction motor on the outside, innovative inside Verified package efficiency 8/26/2014 Slide 26

26 High output SynM motor and ACS850 drive package Motor highlights Powerful, yet highly compact motors up to two frame sizes smaller than conventional motor. Variant codes and mechanical constructions based on the proven M3BP cast iron Process performance motors. No magnets, no cage. Competitive product offering compared to traditional or other new technologies. Higher reliability through lower bearing temperature. Higher efficiency than conventional VSD fed induction motors. 8/26/2014 Slide 27

27 High output SynM motor and ACS850 drive package ACS850, Drive highlights Modular structure you pay only for the options you need. uns any motor Induction, permanent magnet and SynM motors. Memory module you can fine-tune drive settings and store them on the memory module. Slim design the drive is designed to take up minimum cabinet space. Set up as easy as with induction motors - simply enter the parameters from the motor. No feedback devices like encoders or position sensors are needed. 8/26/2014 Slide 28

28 System efficiencies Verified system efficiencies Current standards are focusing on separate motor or drive efficiency determinations. New standards (MEPS) will consider system efficiencies due to motor drive mutual optimisation. 8/26/2014 Slide 29

29 What s in the pipe line? New development: SynM 2 Low cost Ferrite magnets in the flux-air-gaps Added constant flux Further reduction of losses by approx. 20% Ultra premium IE5 level of efficiency Targeted range: 1 to 15 kw Speed range: 1000 to 4000 rpm 8/26/2014 Slide 30

30 New revolutionary motor and drive package The customer voice c1lnpyzgvfjd_o4wta_d 8/26/2014 Slide 31

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