A Global View of. High Efficiency Electric Motors. By Dan Jones Incremotion Associates, Inc. Thousand Oaks, CA

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1 A Global View of High Efficiency Electric Motors By Dan Jones Incremotion Associates, Inc. Thousand Oaks, CA 1

2 Motor Operation AC induction motors are our dominant motor technology in terms of consuming electricity. They typically run continuously for long periods of time and possess a measurable efficiency. 2

3 (IEA 2011, Paul Waide and Conrad U. Brunner, Energy-Efficiency Policy Opportunities for Electric Motor-Driven Systems, International Energy Agency, Paris, France, 2011, p. 33) Incremotion - 3

4 632 Billion kwh 1.6 Trillion kwh 4.7 Trillion kwh Incremotion - 4

5 Induction Motors start directly from the power lines (single speed). All other high efficiency motor types require an electronic inverter to start. 5

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7 The trend for induction motors is to operate with a VFD. Improves induction motor performance at lighter loads (25%, 50%). 7

8 SINGLE PHASE AC INDUCTION MOTORS 3 PHASE AC INDUCTION MOTORS BRUSHLESS PM MOTORS SYNCHRONOUS RELUCTANCE MOTORS SWITCHED RELUCTANCE MOTORS HYBRID MOTORS 8

9 Radial Surface Magnets (Inner) Radial Surface Magnets (Outer) Radial- Buried Magnets Axial Flux 9

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11 While just a proposed standard, a reduction in 20% of the motors internal loss watt s that raises the motor efficiency to the next level. 11

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13 Super Premium (IE4) Electric Motors 13

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26 Ultra Premium (IE5) Electric Motors 26

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28 Hitachi IE5 Axial Flux Motor 28

29 Axial Flux Uses amorphous stator Very thin Laminations (.001 inches) Significantly reduces core losses PM Rotor Structure Uses Ferrite Magnets 29

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36 How much does a higher efficiency motor worth? It is not acquisition cost that is most important it is LIFE CYCLE COST. 36

37 There is a simpler way to achieve IE3 and IE4 performance using Induction motors with a different winding scheme and some small capacitors. 37

38 Improve both motor efficiency & power factor from 1HP to 500HP Use the same motor parts Add a few components Limit the cost for the improvements to less than 10% of the motor sales price 38

39 Use a dual winding, a main & an auxiliary Utilize a 75% main & 25% auxiliary winding based on stator slot area utilization. Add a capacitor in series in each auxiliary winding. Connect the auxiliary winding in parallel across the winding. Phase shift the auxiliary winding 90 degrees plus/minus 10 degrees from the main winding. US Patent number 8,095857B1 39

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41 Can be run as a Line Start motor, no VFD necessary for improved performance. Superior Power Balance. Raises motor efficiency at 25% and 50% load points. Increases motor's power factor to near unity at 100% load. Improves power factor levels at lower 25 % & 50% loads. 41

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43 LOAD 225 KW/300 HP KW/HP % STD RMI MOTOR EFFICIENCY MOTOR POWER FACTOR

44 2 HP went from IE-1 to IE HP improved from IE-2 to IE-3 300HP moved from IE-1 to IE-3 5 HP in process from IE-3 44

45 The US & Europe have established a baseline minimum set of regulations covering minimum efficiency levels fro ¾ HP to 500HP They cover ac induction motors Premium or IE-3 levels. VFDs are the current for target future regulations. The motor suppliers are differentiating themselves by moving to higher efficiency motors. 45

46 Other motor technologies (PM,SR,&SYR) are challenging the AC induction motors primacy in the global market. PM motor types have the highest efficiencies & power factor at a cost premium. Synchronous Reluctance motors can achieve a high motor efficiency a lower cost & a poor power factor, Switched reluctance motors must be matched to their unique drive topology If a user wants to move from one efficiency level to the next efficiency level then the RMI technology may be the best. 46

47 3phase AC motors can start without VFDs (Single Speeds) To save electricity uses a VFD provides a higher efficiency & power factor at lower load points (25% &50%). Buying an induction motor on price only is a short sighted policy. IHP motors typically run years & occasionally up to 50 Years. 47

48 COME AND SEE ME AT THE RMI BOOTH M26 48