MAGNETEC MAGNET-TECHNOLOGIE

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1 Presentation from Hans-Joachim Poess 2015 Motor & Drive Systems 2015 Manager EMC and Head of Development at Variable Frequency Drives are driving Motors and control the applications. The high performance of the VFD helps to save Energy and save costs. To have a reliable application it is needed to care About the high frequency Common Mode Noise which can damage the Motors, Bearings, Sensors and other components. To eliminate this HF Common Mode Noise the most efficient and maintenance free Solution is to Absorb it and change it to safe thermal energy. How to do this will be described in the Presentation. V MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 1

2 Where we do not need Inductive Absorbers: Histrorical Grinding system Curry Cinnamon, Kardamom, Marsala Without electroerosion of the bearings ;=) MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 2

3 Where we do we need Inductive Absorbers: All kind of electrical drive and converter systems MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 3

4 Cool Blue Plus What are Cool Blue inductive Absorbers Where they are used What is the advantage Which improvement Outview (new Typeline) 6 Other new Products MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 4

5 1 What are Cool Blue inductive Absorbers Nanocrystalline Ringcores made out of a ~ 20µm thick amorphous strip changed to nanocrystalline Structure by an annealing Process to a grain size of about 20 Nanometers. This gives about 1000 insulated areas only in the height direction of the tape. The Power losses of Nanoperm is about 1000 times lower than from typical Silicon Iron. The frequency range is from some Herz up to the 100 Mega Herz area. MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 5

6 Laboratory fabrication Amorphous Tape liquid metal under pressure, T = 1200 C melting furnace induction heating ceramic nozzle amorphous strip m thickness Cu casting wheel T = 20 C v = 100km/h MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 6

7 2 Where they are used To avoid electroerosion especially in Motorbearings MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 7

8 2 Where they are used To avoid electroerosion in industrial applications,especially in Motorbearings, Gearboxes, Sensors a.s.o. MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 8

9 3 What is the advantage Easy to mount and to retrofit Easy to select Effect is immediate seen (Sum Peak Current) Working parallel against conducted and radiated emissions Maintenance free Workingtime over decades (when correct designed) Low cost compared to other sollutions like Hybrid Bearings MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 9

10 4 Which improvement MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 10

11 4 Improved Inductivity MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 11

12 Z /Ω 1,40E+00 1,20E+00 1,00E+00 4 Measured values Which improvement Z (Cool Blue +)(f)/ Z (Cool Blue) 20 % 100 MHz estimated 8,00E 01 6,00E 01 Up to over 20 % 4,00E 01 2,00E 01 0,00E+00 Frequenz [khz] MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 12

13 5 Outview (new Typeline) Possible mechanical Dimensions MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 13

14 NANOPERM plate cores for wireless power transmission 6 Other new Products rectangular plate core Permeability µr~30k Dimension of one bar: 200x20x5 round plate core Permeability µr~5k Dimension OD~300mm ID~ 16mm H~ 9mm diamand core shape Permeability µr~30k Dimension of the bars: x10x5 MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 14

15 Cool Blue Cores are increasing the reliability of Motors and complete Machines in the case of maintenance and avalability. Cool Blue Cores are absorbing the dangerous electrical noise and change it to save thermical energy No expensive insulated (Hybrid) Motorbearings are needed in many cases Other Applications:EMC Filters, Common Mode Chokes, Transformers, Automotive EMC components against Radio disturbance, inductive Heating, With the new Cool Blue Plus + the performance is over 20 % higher MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 15

16 Special Electro Erosion 800kV Discharge MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 16

17 Adding NANOPERM Line Aborbers NaLA type M-381 option for effect demonstration : deactivate cores by a shortcut 2 x M-113 MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 17

18 Reducing I peak from ~ 40 A down to ~ 6 A by combination of COOL BLUE Cores and NANOPERM Line Absorbers NaLA and smoothening the High Frequency away with combined cores without cores MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 18

19 Solution: Combine the COOL BLUE Cores and NaLA cores to absorb the Common Mode Noise to save thermal Energy Common Mode 2 x M-112 COOL BLUE Cores U V W L1 L2 L3 shield Differential Mode 6 x M-381 (NaLA ) MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 19

20 Solution: Combine the COOL BLUE Cores and NaLA cores to absorb the Common Mode Noise to save thermal Energy 7,5 KW 50 m Common Mode 2 x M-367 COOL BLUE Cores U V W L1 L2 L3 shield N=2 Differential Mode 3 x M-053 (NaLA ) MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 20

21 1. Common Mode Noise suppression for Inverter drives with NANOPERM Cores Table: selection and amount of Cool Blue Cores depending on rated power and cable length All data are for information and not guaranteed values. Inverter power range up to Hans Joachim Poess Kilowatt 0,7 7, > horse power > p/n oval n/a M 049 M 049 M 283 M 302 M 111 M 248 Cable length [m] p/n round M 923 M 367 M 367 M 113 M 116 M 117 n /a N=2 N=1 50/164 ft /328 ft /492 ft /984 ft Low power range (up to 10 kw) need some times 2 turns on the Nanoperm cores Amount of cores [pcs.] MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 21

22 2. Differential Mode Noise suppression for Inverter drives with NANOPERM Line Absorbers NaLA Table : selection and amount of NaLA Cores depending on rated power and cable length All data are for information and not guaranteed values. Hans Joachim Poess Inverter power range up to Kilowatt 0,7 7, > horse power > p/n M 606 M 053 M 102 M 381 M 613 M 614 M 616 core size D a D i h [mm] 16x11x5 25x20x10 30x20x10 40x32x15 80x63x30 100x80x30 160x130x30 Cable length [m] 50/164 ft /328 ft /492 ft /984 ft Amount of cores [pcs.] If the NaLA cores getting too warm, use the double amount each line MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 22

23 MR Typelines (µr > 8000) Cool Blue Cores for Power Applications Mechanical shape like the R-series from Power Ferrites Higher Inductivity Higher Impedance Higher Saturation Induction Higher using Temperature More Robust 1:1 Substitution to Power Ferrites but better Performance. No change of Capacitors needed MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 23

24 MR Typelines (µr > 8000) Cool Blue Cores for Power Applications Types (Extract) dout x dinner x height [mm] L 100k Hz [µh] I sat [A] MR x32x MR x38x MR x40x MR x66x MR x103x MR x153x Even bigger available Ln-Inductivity at 100 khz; Isat Saturation current DC, all values are for information only. Details are in the dataheets. Our Ring cores are based on Nanocrystalline soft magnetic tape material NANOPERM. Compared to ferrite cores, the following advantages on the same core size are achieved: higher Inductivity higher Saturation current optimised Power losses mechanicaly extremely robust higher continuous component temp (120 C) higher Frequency bandwidth from Hz up to 100 MHz Cores are available for the nominal current range from Amps and higher, designed acc. to EN for U N = 500V. Operating temperature range: C. The casing material is UL listed and fulfils UL-94 V0. MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 24

25 How to measure Common Mode Noise and how to absorb it with Cool Blue Cores (Inductive Absorbers) MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 25

26 Inverter with a standard motor and a DC-load-motor MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 26

27 Measuring Voltages and Common Mode Currents MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 27

28 What is the source of the Problem: Common Mode Currents in high frequencies MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 28

29 High frequencies in the MHz range MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 29

30 Why Mhz and not khz? Because of the impedance of the Motor, especially the bearings: MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 30

31 Where does this currents come from? IGBT is the source of the Noise and the current loops back MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 31

32 Where are the vagabonding currents running? Runs over grounding pathes like brushes MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 32

33 How can we avoid these vagabonding currents? Absorb the currents And change it Into Thermal energy By using Inductive Absorbers Cool Blue MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 33

34 What is the effect of the Inductive Absorbers? Without inductive Absorbers With inductive Absorbers MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 34

35 How to check? Shortcut open the loop MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 35

36 How is the Common Mode Current changing with the amount of Cool Blue Cores? MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 36

37 What happens on more turns? It helps! The Cool Blue Cores should not go into saturation The parasitic capacity should be low enough MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 37

38 Theoretical Background: Simulation Voltage MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 38

39 Theoretical Background: Simulation no Saturation Voltage Current Current MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 39

40 Theoretical Background: Simulation with Saturation Voltage Current Current MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 40

41 To avoid saturation: New material parameters of Nanoperm Low my Saturation current up to Factor 80 MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 41

42 0, , µ 8000 Nanoperm low my 63x50x30 different permeabilities 0, L [H] 0, , µ 4000 µ 2000 µ frequency [khz] Diagram L(f) low my MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 42

43 7,00 Nanoperm low my 63x50x30 different permeabilities Inductivity ( current) turn no =1 6,00 5,00 4,00 inductivity (µh) 3,00 2,00 1,00 µ8000 µ4000 µ2000 µ1000 0, Low my diagramm L(I) current (A) MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 43

44 Calculation Imax Nanoperm of µr B=µ0*µr*H H= I*N/lfe magnetic field (A/m) B=µ0*µr*Imax*N/lfe magnetic induction (Vs/Am) B= 1 Vs/Am material constant Nanoperm (1,2T) 20 % savetymargin µ0= 4*pi*10^ 7 Vs/m² constant Imax= (B*lfe)/(µ0*µr*N) µr relative Permeability; N=turn no. Lfe middle pathlength) MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 44

45 Imax= (B*lfe)/(µ0*µr*N) Examples on one core dimension 63x50x30 mm Imax (µr=30000) = 4,8 A Imax (µr=1000) = 143A Imax (µr=500) = 286 A Dimensioning Imax calculation MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 45

46 Imax (dimensions and µ) H= I*N/lfe B=µ0*µr*Imax*N/lfe B=µ0*µr*H Imax= (B*lfe)/(µ0*µr*N) B 1Vs/Am µ0 4*pi*10^ 7 Vs/m² lfe (m) 0,18 0,225 0,28 0,36 0,45 0,58 1,49 coredim 63x50x30 80x63x30 100x80x30 130x100x30 160x130x30 200x175x30 500x450x30 µr Imax Imax Imax Imax Imax Imax Imax ,4 1790,5 2228,2 2864,8 3581,0 4615, , ,5 358,1 445,6 573,0 716,2 923,1 2371, ,2 179,0 222,8 286,5 358,1 461,5 1185, ,6 89,5 111,4 143,2 179,0 230,8 592, ,8 44,8 55,7 71,6 89,5 115,4 296, ,9 22,4 27,9 35,8 44,8 57,7 148, ,8 6,0 7,4 9,5 11,9 15,4 39, ,4 3,0 3,7 4,8 6,0 7,7 19, ,8 2,2 2,8 3,6 4,5 5,8 14,8 You can online calculate: MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 46

47 Different succesful applications Wind turbines Chillers Solar converter And other Industrial Inverter Applications From Water pumps (some hundred Watt) up to Stone grinding (Inverter steered up to 5 MW) Power Distribution via GIS (Gas Insulates Switches in th 800 kv range) MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 47

48 Basic working Principle of Cool Blue without filter cores I CM = up to 60A with Cool Blue cores ICM ~ 10A ok! EMC measurements were carried out in the nacelle (height 80m) How did it start? proof of principle experiment in 2006 MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 48

49 Cool Blue application examples contains: M 116 M 117 Realisation: now Professional airconditioning systems used in industrial environment, airports, office buildings etc. Function: EMC compliance, motor bearing protection Professional airconditioners, chillers up to 500kW MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 49

50 Cool Blue application examples typical configuration of Cool Blue cores in Photo Voltaic central inverter with P = 500kW Function: EMC filter Realisation: now S500kW Solar Central Inverter for Power Plants MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 50

51 Photovoltaic Inverters Application Example our EMC chokes may partly replace Ferrit chokes Photovoltaic : residential string Inverters: 3 12 kw MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 51

52 On the cables MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 52

53 Thermocouples for checking overtemperature Picture of cores with thermocouple MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 53

54 emobility: electrical Cars and Infrastructure On Board: DC/DC converters for battery chargers and power supply in a range from 3,0 6 kw DC/AC converters for motor drive in the range from kw electrical steering systems Off Board: Stationary Charging Stations 5 25kW private and public Option: Witricity EMC products for on board and off board systems MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 54

55 Cool Blue application examples Function: absorption of destructive high current transient pulses Cool Blue cores in a 800kV switchgear for a modern energy distribution system over long ranges high voltage gas insulated switchgear, GIS MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 55

56 This diagram shows the impedance of a Motor against Common mode noise 140 Ohm 100 Ohm The Problem of the motor bearings are the resonances in the area of 100 khz and in the area of some MHz. The low impedance drives high common mode currents up to 100 A through the motor and over the motor bearings. The living time of the bearings is dramatically reduced if the common mode current is working in this frequency range. To avoid this fast damaging, the impedance against common mode currents have to be increased. The working solution for this is a Cool Blue core which is made from Nano crystalline material (Nanoperm) which is put over the motor cables. This Cool Blue Cores have a high impedance For example: M-160 (160x130x30 mm³) µ~30000 L~ 20 µh at 100 khz (per turn) Z=2*pi*f*L Z~ 2*3,14* Hz* 0,00002 H ~12 Ohms For each core Typical numbers for the amount of the Cool Blue Cores are 4 8 Pc 8*12 Ohm ~ 100 Ohms for 100 khz For 3 MHz Z~ 2*3,14* Hz* 0, H ~18 Ohms 8*18 Ohms ~ 140 Ohms for 3 MHz This impedances are added to the common mode path and can reduce Significant the common mode current down to the 10 th part. This will increase the living time of the motor bearings up to factors. MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 56

57 Magnetec in Hungary and now Thank you for your time! MAGNETEC GmbH, Germany Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers Hans Joachim Poess 57