Thor Power Corporation

Transcription

1 Thor Power Corporation Technology & Applications Summary Thor Power Corporation is a Delaware C corporation registered under US law and with offices at 311 West Liberty Street, Allentown PA 18102, U.S. Maite Pina mpina@thor-power.com

2 THE COMPANY S TECHNOLOGY Thor Power Corporation has developed a unique Power System called Trezium. The Trezium System consists of a patent-pending power unit and a patented power converter. The power converter and the power unit, which can be configured as motor, generator or alternator are perfectly matched for maximum efficiency, power and control. The power converter s power circuit and the control circuit are mounted on one PCB for maximum reliability, durability, and safety, as well as for lower production costs. The power converter is an ac dc ac converter. It can be powered from universal AC power supply (100 to 264VAC, 50/60Hz) that is converted to around 400VDC and then converted to three phase AC to drive the motor. The converter can also be used as DC to AC converter only for use in DC facilities. Universality, it can be used worldwide. The Trezium System plugs into any outlet in the world with a simple plug change, operating at 50/60 Hz or, in aerospace, applications at 400Hz. At least 10% to 15% higher efficiency than brush type motors of comparable power Circa half the size of machines with comparable power Circa half the weight of machines with comparable power Wide input voltage range 110Vac to 264Vac Power Factor better than.995 for loads 50% to 100% at all voltages Power Factor better than.997 for all loads at 120Vac The power unit is an AC sine wave, permanent magnet synchronous motor that is brushless, slotless and sensorless. It provides the benefits of variable speed, forward/reverse, high power to weight ratio, and unparalleled efficiency. It is classified as a brushless AC motor and shares the positive characteristics of a brushless DC ( BLDC ) motors without having some of the disadvantages such as ratchet, which happens with BLDC motors when they run at variable speed at lower speed The power unit and power converter, together the Trezium System, have proven efficiency levels of 90% and 95%, respectively, and a combined efficiency of 84% at load factors from 50% to 100%. This performance level is substantially greater than the less than 60% efficiency level typical of motors at the 5kW and under power level. A summary of the benefits of the Trezium System are below: The power converter employs Field Orientation Control technology, also known as Vector Control, which gives superior torque speed control performance. It is of sensorless type which offers the benefits of being able to operate in hotter, duster, more humid environments when compared to the conventional Hall Effect methods of control. The Power Unit ( Grismir ) Grismir is an alternating current, synchronous, sinewave, permanent magnet device that is also brushless, slotless and sensorless. The power unit can be used as a motor, generator or alternator from the end of the production line. Since it utilizes alternating rather than direct current, it can be classified as a BLAC motor. However, it can also be classified as a permanent magnet AC 2

3 motor ( PMAC ) or a permanent magnet synchronous motor ( PMSM ). In other words, the motor defies classification using current motor nomenclature, because it combines several advantages into a single unit. Being brushless, Grismir requires no point of electrical or mechanical contact between the source voltage and the rotating component of the device, which means that it is maintenance free. In addition to reduced maintenance and its related costs, brushless motors offer higher efficiency and reliability, reduced noise, longer lifetime and overall reduction of electromagnetic interference. The Grismir power unit achieves all of this and more, as the unit can be used, as is, as a motor, electric generator, or an alternator Figure 1: Power Unit, Grismir Grismir is also slotless, which means that it has no series of teeth with slots between the teeth where the stator (the stationary part of the motor) windings are inserted. Slotless motors are significantly superior to slotted motors. They have an electrically more efficient design, weigh about half that of the slotted motor, smooth rotation and eliminate cogging, a better power response, and more internal space for magnets and wire. So, not only do these features improve Grismir as a motor, but also enhance performance as an electric generator or alternator. As an example, the Grismir unit as a replacement alternator produces 400A weighing approximately 30lbs, in the same volume package as the current 100A alternator weighing approx 27lbs. The Power Converter ( Trezium ) The Company s power converter represents the state-of-the-art in power electronics and a substantial improvement over existing motor controllers. It incorporates a fifth-generation IGBT Intelligent Power Module, and uses novel silicon bonding/packaging thermal management techniques for miniaturization. The front end of the drive electronics consists of a Power Factor Corrector (PFC) running at 57kHz. Running in a Boost configuration, this PFC circuit converts the input AC line voltage to 375Vdc while maintaining a very high 3

4 power factor. This circuit can operate from 100Vac to a maximum of 264Vac (nominal 120Vac to 240Vac). With suitable modifications to the input protection devices, DC can also be supplied to the drive. In this case the PFC circuit is acting only as a boost converter. The DC input should be in the range of 100Vdc to 375Vdc. The 375Vdc bus supplies power to a three-phase, six switch IGBT inverter. The power section of the inverter is an Intelligent Power Module utilizing 5th generation IGBTs with a 600V/50A rating. The power module also contains integrated drivers, short circuit protection and over temperature protection. Drive to the inverter power module is from an ASIC that provides the basis for the Sensorless FOC (Field Oriented Control) of the motor. This IC provides open-loop startup of the motor to approximately 3,000rpm. From 3,000rpm to design speed, a controlled speed ramp is provided. Above the minimum speed, the FOC algorithm adjusts the drive to the motor in order to optimize the power output. Speed is regulated with a closed loop speed control algorithm that keeps the speed nearly constant from no-load to full-load. The sinusoidal drive voltages are generated using a Space Vector PWM operating at 12kHz. At 30,000rpm the drive generates a three-phase 500Hz output at approximately 200Vac line to line. A limited amount of the mechanical energy from the motor can be regenerated into the DC bus upon deceleration. This ASIC also monitors fault conditions such as over/under voltage of the DC bus, loss of a motor phase, improper startup, over-current, over-speed, and other control parameters. Supervisory control in the drive is handled by a separate dedicated microcontroller. This micro-controller monitors the input voltage, the DC bus voltage, as well as fault registers within the control ASIC. Higher level control algorithms such as output power levels, temperature controlled functionality, cool down timers, etc. can be custom programmed into this microcontroller. Heatsink temperature is monitored and shuts down the drive if the maximum temperature is exceeded Figure 2: The Trezium System In using space vector control, the controllability of the motor torque closely matches the load requirement and is less affected by the back EMF (ElectroMotive Force) noise. (Back EMF is a voltage that occurs in electric motors where there is relative motion between the armature of the motor and the external magnetic field.) The motor has less vibration, less torque ripple and better efficiency. Eliminating the Hall Effect sensors reduces component, assembly costs and provides better operating profiles in humid and dusty environments. As per Figure 2, all of the electronics are placed on a single printed circuit board (reducing the size of the controller). The electronics are separated and divided into two parts. On the left side, there is input power control circuitry connected by a DC link to control circuitry; on the right side is the power output circuitry. The Company s power converter can be used with other motors to improve the performance of those motors. The power converter has a power rating of up to 5 kw and works with all major international voltages, eliminating the need for having different control electronics and motors for the global market. 4

5 Finally, the power converter is completely enclosed and no fan is required. Since the system has no fan it is quieter in environments like operating theaters, and it can also be completely sealed for use in explosive environments and desert conditions. While The Company intends to market the system (power converter & power unit) in combination, the Company s power converter can be used with other motors to improve the performance of those motors. The advent of independent energy production (solar/wind/hydro) will cause significant adverse impacts to the existing electricity distribution networks due to harmonic generation. Independent energy production creates negative impacts to existing electricity networks due to: 1. Displacement Power Factor the real usable power is reduced; 2. Total Harmonics Distortion (THD) reduces the usable grid power and pollutes the grid with electrical distortion. The Thor Power Trezium energy management unit has the kernel in its hardware & with further software development to prevent this major problem. The Trezium Power Management System can resolves both issues Limit THD to very low level (e.g. under 3%) and achieve close to unity of displacement power factor. Modification to Trezium Circuit design Thor power focuses on continuous cost reduction of its product while maintaining the efficiency and quality of the product to its optimum level. Efforts are being made to reduce the size of the Trezium controller by using digital IC which incorporates several features like Power Factor correction (PFC), Motion Control Engine (MCE) for high efficiency sensorless control of permanent magnet motors and Control of various motor parameters into a single chip. This helps to achieve to achieve simple, low cost and high performance solutions for advanced appliance motor control Due to the rising demand of continuously variable speed of motor over the entire operation range efforts are also made to control the output of Trezium completely variable ( i.e 0 to rpm) THE COMPANY S PRODUCTS Thor Power Corporation is continuously developing new applications to be at the forefront of power system efficiency and green applications. Moreover, the green initiative can and should be addressed from both sides of the power equation: 1. more efficient use; and, 2. greater clean production. Thor Power s products are in the unusual position of being able to achieve both objectives. Finally, compared to most participants in the power market Thor Power, by offering both a patent pending power unit as well as a patented power management system, is in the additional unique position of being able to offer its customers a bespoke power solution rapidly tailored to the customer s specific requirements. MOTORS & GENERATORS Our Motor and generator is available in individuals units in its standard form or modified to specifications. Our standard products include: 5

6 The Grismir G4.5kW is an AC Permanent Magnet with the following characteristics: Output Options: 0 to 150 volts, a function of speed & load resistance; 1) 3phase Vac; or, 2) Rectified Vdc. Power Rating, Vdc and Vac: up to 3300 watts, Ø speed & load. The figure showed in the next page shows the design and dimensions of the Grismir G4.5kW. This figure demonstrates that Grismir is probably the smaller motor of its class. Figure 3: Design and dimensions of the Grismir up to G4.5kW. In addition to its size, Grismir offer many other characteristics as showed in the table below. Table 1: Product description; Grismir M3.3hp In addition the system offers: Motor Frequency Hz (max) Motor Speed & Action Variable; 2000 to ,000 rpm; Bi-directional Poles 2 Rated input power 2300W Rated output power 1900W Max Power 9.9kW (calculated) Rated Torque 0.605Nm Max Torque 400% (calculated) Rated Current 7.5A Rated Voltage 200V No load Current 1.6A Rotor Neo Magnets Stator Slotless Weight 3.4lbs. Expected Life 2000 hrs MTBF, hostile environment 4-pole will provide half the speed at the same frequency Slotted stator Three-phase supply Can be adapted to 12,48,96 VDC both stator and electronics 6

7 TREZIUM SYSTEM Thor Power was awarded two patents in May Automatic output power limiting electrical device. Electrically powered devices are provided that derive power from an incoming power source to produce output power to drive the device. This technology includes circuitry that determines at least one characteristic of the incoming power source, and circuitry that adjusts the output power to drive the device based on the characteristic or characteristics of the incoming power source. In the already existing technology, the circuitry is not included within the electrically powered device and is instead provided in a separate power converter that receives the AC power source and provides DC output power to the device. Hence this invention beneficially provide electrically powered devices that operate at reduced or lower output power, which correspondingly reduces the current drawn from the incoming power source, so that the device may be operated safely irrespective of the characteristics of the incoming power source. The incoming power source provides AC power and the characteristic of the incoming power source is the voltage, frequency, or a combination thereof, of the incomingacpower. Its applicable to various types of electrically powered devices, such as those that include one or more brushless DC motors that are driven with DC output power. The electrically powered devices may be, for example power tools, hand operated or otherwise, such as grinders, drills,saws,etc. In another aspect of the invention, an electrically powered device is provided that derives power from an incoming AC power source to produce DC output power to drive the device. The device includes at least one brushless DC motor and at least one controller adapted for: determining the voltage, frequency, or a combination thereof, of the incoming AC power source, and adjusting the DC output power to drive the brushless DC motor based on the voltage, frequency, or a combination thereof, of the incoming AC power source. 2. Control electronics for brushless motors This Technology provides improved electric efficiency compared to conventional alternating current motor systems. The applications of this technology are almost limitless, as alternating current motors are used extensively, world-wide, today in many products and applications, including air conditioners, refrigerators, power tools, washers, and dryers, and industrial power tools, such as angle grinders, to name a few. The preferred embodiments use new electronic motor control circuitry, which may be combined with highly efficient rare-earth magnetic, brushless direct current (BLDC) motors, to electronically regulate the motor. controller may accept all major international voltages, eliminating the need for having different control electronics and motors for many different countries and may be applied to motor systems up to 5 kilowatts, but have particular application to the 1 to 2 kilowatt power range. The important aspects are connecting a host including software program instructions to a microcontroller integrated circuit. When the software 7

8 program instructions are executed, the host dynamically controls parameters of vector control algorithms embedded in the microcontroller integrated circuit. Other aspects are: Adapt a controller IC to the challenging high power, high speed, and high performance motor application. While the controller IC may have many control functions built-in, design customization in software sets the application specific control parameters and, through both power electronics hardware and the control algorithm development, is able to achieve a maximum 30,000 rpm motor speed at 2 kw load and upto 4 kw overload capability. Soft start is implemented to allow the motor smooth start-up. Implement a vector control method so that the motor has much smooth torque profile. Implement a PFC circuit design that is highly compact (smaller choke and power semiconductor devices and high efficiency). This is achieved through: a) very low Rds (on) MOSFETs (but still commercially viable); b) state-of-art Silicon Carbine Diode (SIC Diode) for zero reverse recovery current; c) higher switching frequency (over 60 khz), even under 110V supply, over 50 A current; and d) high switching frequency enabling much reduced choke size. taken of the IGBT characteristics, and the inverter achieves very compact design and high efficiency. Other aspects include comprehensive control software for motor specific applications: e.g. motor start-up; under various load condition; overload capability and protection and thermal protection--all these are achieved with a very low cost PIC processor Automobile Industry : The Thor Power electric system products find a number of homes in the automotive industry. Permanent Magnet Alternator : The Grismir windings, used in the stator, can be combined into a 400AMP alternator weighing approximately 30 lbs.- and, half the space of an existing unit. This compares with a unit in use today that provides 100AMP s and weighs 27lbs. The Grismir alternator, in fact, can be doubled up in that existing space for the 100AMP unit to create 800AMP s and weigh 60lbs. This compares with the alternator used in EMS vehicles today that weigh approximately 127lbs. and provide 700AMPs of power An inverter uses an IGBT IPM module with specific thermal substrate and package design. Through motor control algorithm, full advantage is 8

9 Electric Motor Bikes: A Grismir motor and Trezium could be matched to the drive wheels of an Electric Bike or a hybrid and charge the batteries while the vehicle is running. The base design can be further developed to fit into the wheel hub of a vehicle to work as a drive motor, as the technology is scalable to over 40kW. TPC provides two pole three phase PM synchronous AC motors to get the maximum efficiency at the normal operating range and is capable to ramp up speed upto 30,000 RPM with 2 kw of output power. Trezium with its state of art Electronic design and technology is capable to produce completely variable speed (i.e 0-30,000 rpm). Existing technology not only results in highly efficient performance but also helps to reduce battery packs size used in the current electric Vehicles. Trezium System is also designed to work with DC input voltage, hence Dc voltage from the battery packs can be boost up using power electronics and can be directly fed as controller Input. Electric Cars: All-electric vehicles that function entirely without an internal combustion engine need safe, cost-effective and high-capacity energy-storage systems. Efficient software algorithms, powerful microcontrollers (MCUs) and highly efficient electric motors can make maximum use of available energy. A central element of hybrid and electric vehicles is the electric motor in the powertrain, which is deployed in combination with a conventional internal combustion engine in hybrid cars or as an independent source of power for electric vehicles. Selecting the motor requires careful analysis of the dimensions, weight, reliability, robustness, required torque and total efficiency. Thor Power s Grismir and Trezium Technology provides the perfect balance of motor, power electronics, the MCU, and the control software adapts and implements algorithms which overcomes effects such as irregular running and excessive noise, which together have a negative impact on the degree of efficiency. Trezium controller makes use of various control algorithms like field-orientated control (FOC) combined with proportional integral derivative (PID) regulation systems for controlling rotor speed, torque and flux 9

10 depending on the application. By means of inverse Park/Clarke transformation, the system is transformed into a rotor-based vector system and the voltages to be set are transmitted to the motor via the power electronics by means of pulse-width modulation. the motor controller consists of an MCU, a power-output stage, the motor in conjunction with a rotor position sensor (resolver) and the RDC, which is usually implemented as a discrete circuit. This generates the resolver signal and determines the rotor position and rate as quickly and precisely as possible based on the sinusoidal/cosinusoidal information returned. This information is forwarded to the microcontroller so that it can be taken into account in the motor control algorithm Thor Power s first licensee, in 2006, is a manufacturer of electronic power systems for off-road electric vehicles such as golf carts, swamp buggies, forklift trucks, and wheel chairs. They referred to the Trezium electronics package as the Valhalla of electronics for EV s because Trezium (Fig. 4.2) can be used for both charging and controlling all in one device and, can be connected to any mains outlet in the world. materials to replace conventional materials with considerable supply chain, price and availability issues. This development will provide improvement to national security not just through military applications, but also in the commercial markets. Electron Energy Corporation (EEC) is a fully integrated innovator, designer and manufacturer of rare earth magnets and rare earth magnet assemblies and Thor Power Corporation (Thor Power ) designs, develops and markets electric systems to improve the efficient use of electricity, including permanent magnet power units and electronic power converters that consume over 50% less energy than existing systems Power Systems and Renewable Technology 3 kw High Performance Permanent Magnet Alternator SBIR awarded Thor Power & Electron Energy Phase I contract for the development & application of new material to substitute or diminish dependence with respect to rare earth elements in the production of permanent magnets. The objective will be to develop an advanced permanent magnet alternator with state of the art materials, controls and electronics for alternator applications, using alternative permanent magnetic Flexible Generators Among the multiple applications within the renewable energy sector, Thor Power has started the design of two wind turbines, and developed a flexible generator. 10

11 The flexible generator, FlexGen, is designed as a modular unit that can support output requirements of 2kW to 20 kw. The advantage of this system is at least two-fold: 1. Due to the BLAC, the generator can start generating electricity at lower wind speeds than standard generators (even in large systems such as GE or Siemens they are moving to permanent magnet units for just this reason); 2. Our system provides for redundancy so that should one generator fail, the additional units can at least provide continued, albeit lower, electricity output. THOR POWER FLEX-GEN (VARIABLE OUTPUT GENERATOR) 1.5kW - 20kW & UP SHAFT TO TURBINE TOP PLATE GEAR 2 to 4 - PLACES GEAR NEMA 34 MOTOR BLAC 3 PH, 3.5HP The Iya turbine systems developed by Thor Power are purposely designed for residential, commercial, municipal and light industrial energy independence. Moreover, because the units will be not much different in size than a TV satellite dish, zoning approval is already extant; the vertical design will minimize wildlife kills when compared to horizontal turbines; the units can be constructed to be free of electromagnetic pulse damage; and, they will be light enough for utility poles for cell phone switching centers, street lamps & traffic lights. Power Tools COOLING FAN 1.5' - 2.5' Ø size offering OUTLET TO ELECTRICAL HOOKUP Among the multiple applications within the Power tool sector, Thor Power has initially developed the GRISMIR 3000, a professional grinder which will compete against seven and nine-inch angle grinders already present in the market and used in continuous heavy duty industrial environments such as ship yards, forges and foundries, and generally, job shop metal working businesses. Moreover, due to its variable speed control the GRISMIR 3000 can replace the need for three to five additional tools. 11

12 The reason this application has been chosen is due to its modular, robust design, offering the most benefits for both operators and companies as customers. Currently, grinders produce dust which is hazardous to the operator, tool and environment. Often, the buildup of the hazardous dust creates a electrical "short" in the grinder and the operator receives a serious "shock" requiring medical attention. However, the GRISMIR 3000 s revolutionary design eliminates the potential for harmful effects to the operator. Additionally, the hazardous dust can't impede the operations of the tool thereby causing premature tool failure. In turn, the customer will reduce tool expenditures since the GRISMIR 3000 will have a longer life. Finally, this is a niche which is underserved by competitors. Table 2 shows a comparable market for Grismir Based on this comparison, The Company s product is superior, or equal, to competition in all areas, save initial purchase price. However, annual savings from using Grismir 3000 can be well over $8000 a year, compared with competitive units. In just one simple comparison product durability Grismir 3000 has tested over five times the life (2000 hours) of competitive products. Table 2: Angle Grinder Market Comparison Atlas Copco Thor Power CS Unitec Bosch DeWalt Hitachi Makita Makita Model Grinder Brazor II Grismir Varilex D2847W G18MR GA7020 GA9040S Wheel Diameter (in) 7 2 to 7 4 to 7 9 & Watts output RPM x to to Weight (lbs) Power/weight (w/lbs) Length (in) Street price ($) n/a n/a Source: and Amazon.com year 2009 ANNUAL TOTAL COST of OWNERSHIP COMPARISON, $ - Example Existing (Vac) Motor System Operating Item Grismir Machine Cost machines/man x $172 avg. price 22,220 x 2020 hours 22,220 (8,888) (insert your cost = Spare Parts - reliability x 10 (Your cost x %) = ) (insert your cost = Maintenance Labor - reliability x 10 (Your cost x %) = ) (insert your cost = Consumables 49% (Your cost x %) = ) (insert your cost = - 30% (Your cost x %) = ) $23,308 Total Cost of Ownership $15,411 nil Min. SAVINGS $7,397 Notes on previous table: 1. Machine use is based on 1818 operating hours in a total hours work year of 2020 hours. The Grismir 3000 has 5 times the life of a Vac unit. $172 is the average unit cost in the market (2010 prices). Impact of substituting Grismir 3000 for more than one tool in a shop due to its variable speed - is not 12

13 included; 2. Operator cost comes from the average wage (in 2010) for these types of workers based on Bureau of Labor Statistics data. Productivity arises from a more powerful, efficient, and ergonomic machine, but no worker s comp savings are included;3. As the circumstance for each company differs with respect to the cost of spare parts, maintenance labor, and consumables, we have used the results from measured use of the machines and materials to calculate the cost differences for these items. A specific cost for a specific company and application can be calculated by using the numbers in the Grismir 3000 column as a percent to adjust the users actual cost for their existing system. Grismir 3000 also provides: 84% Efficiency 40% greater cutting efficiency. 6 db(a) quieter (approximately a 50% noise reduction) 70% lower consumable use vibration lower than 2.5m/sec² (can use the tool for eight hours a day) 49% lower energy use. With some small changes in the controller to create variable speed will result in 5 tools in one. TECHNICAL RESULTS The following graphs show Trezium System parameters results taken under the following conditions: All measurements taken at room temperature. Line voltage is nominal value, actual line voltage varied with load. Line frequency was 60Hz. Electrical power measured with Yokogawa WT1600. Mechanical power measured with Magtrol WB43. Figure 4: Inverter Efficiency vs. Torque at 120Vac Input for Motor Speeds 5k- 30krpm And lastly, the Grismir 3000 provides the lowest total cost of ownership as described in the box below. 13

14 Figure 5: Inverter Efficiency vs. Output Power at 120Vac Input for Motor Speeds 5k-30krpm Figure 7 Inverter Power Factor vs. Output Power at 120Vac Input Figure 6 System Efficiency vs. Torque at 120Vac Input for Motor Speeds 5k- 30krpm Figure 8 Inverter Efficiency vs. Torque at 240Vac. Input for Motor Speeds 5k- 30krpm 14

15 Figure 9 Inverter Effic vs. Output at 240Vac. Input for Motor Speeds 5k-30krpm Figure 11 Inverter Power Factor vs. Output Power at 240Vac Input Figure 10 System Efficiency vs. Torque at 240Vac Input for Motor Speeds 5k- 30krpm Figure 12 Motor Efficiency vs. Torque at Motor Speeds 5k-30krpm 15

16 GRISMIR GENERATOR TECHNICAL SHEET Figure 13: Volts vs. Speed of the generator 16

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