BY DAN JONES PRESIDENT OF INCREMOTION ASSOCIATES

Transcription

1 BY DAN JONES PRESIDENT OF INCREMOTION ASSOCIATES

2 I. HISTORY After WWII to 1992 Why Now? Why Electric Motors II. EISA VS. NEW 2016 RULE III. COMPETING MOTOR TECHNOLOGIES IV. MOTOR INTERNAL LOSSES V. STANDARDS VS. MARKET FORCES VI. EUROPEAN VS. US STANDARDS VII. NEW IE4 MOTORS VIII. NEW IE5 MOTORS IX. RMI AN ALTERNATE TECHNOLOGY X. FINAL COMMENTS

3 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. 3

4 After World War II, the U.S, was at the pinnacle of its power. We had energy to burn. 4

5 THEN CAME , OUR FIRST ENERGY CRISIS. 5

6 A small number of U.S. electric motor manufacturers in the late 1970 s and into the 1980 s began to build motors with higher efficiency, but sales were slow due to higher sales prices. 6

7 In 1992, the U.S. Congress passed The Energy Policy Act (EPact). For the first time, there were minimum motor power efficiencies for certain types of electric motors. 7

8 Rising cost of energy (oil and gas) Concern with pollution Increasing population Longer power plant build times NIMBY Aging grid Slow alternate energy development Economic growth 8

9 Larger AC Induction Motors (1 HP to 500 HP) consume the largest portion of electric energy. Applications include Material Handling, Compressors, Fans, Refrigeration, Material Processing and a host of other applications. 9

10 (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 - 10

11 632 Billion kwh 1.6 Trillion kwh 4.7 Trillion kwh Incremotion - 11

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15 SINGLE PHASE AC INDUCTION MOTORS 3 PHASE AC INDUCTION MOTORS BRUSHLESS PM MOTORS SYNCHRONOUS RELUCTANCE MOTORS SWITCHED RELUCTANCE MOTORS HYBRID MOTORS 15

16 Radial Surface Magnets (Inner) Radial Surface Magnets (Outer) Radial- Buried Magnets Axial Flux 16

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18 Induction Motors start directly from the power lines (single speed). All other high efficiency motor types require an electronic inverter to start. 18

19 The trend for induction motors is to operate with a VFD. Improves induction motor performance at lighter loads (25%, 50%). 19

20 TECHNICAL STANDARDS CAN PUSH OR RETARD NEW MARKET DEVELOPMENTS.

21 STANDARDS PUSHED THE US AND EUROPEAN MARKETS FOR NEW HIGHER MOTOR EFFICIENCIES IN THE 1990 s AND 2000 s. BY ABOUT 2010/2011 THE MOTOR MANUFACTURERS SURPASSED THE STANDARD LEVELS AND DEVELOPED HIGHER IE4 AND IE5 HIGHER EFFICIENCY MOTORS.

22 SET AT PREMIUM EFFICIENCY LEVELS DOE IS FOCUSING ON DRIVES PLUS PUMP AND BLOWER APPLICATIONS. THERE IS STRONG MOTOR SUPPLIER RELUCTANCE TO MOVE TO HIGHER EFFICIENCY. ONE REASON IS THAT THERE IS NO APPROVED TEST STANDARDS (AS YET).

23 WHILE JUST A PROPOSED EUROPEAN STANDARD, A REDUCTION IN 20% OF THE MOTORS INTERNAL LOSS WATT S THAT RAISES THE MOTOR EFFICIENCY TO THE NEXT LEVEL.

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28 Super Premium (IE4) Electric Motors 28

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37 IE 4 INDUSTRIAL MOTORS 30 HP TO 200HP ACCU SERIES.

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43 Ultra Premium (IE5) Electric Motors 43

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45 Hitachi IE5 Axial Flux Motor 45

46 Axial Flux Uses amorphous stator Very thin Laminations (.001 inches) Significantly reduces core losses PM Rotor Structure Uses Ferrite Magnets 46

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55 There is a simpler way to achieve IE3 and IE4 performance using Induction motors with a different winding scheme and some small capacitors. 55

56 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 56

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58 Patent No B1 Invention improves both power factor & motor efficiency Invention modifies the stator winding and leaves the rotor untouched 58

59 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 59

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61 1. Dual Windings for each of the 3 phase AC motors from 1 HP to 500 HP 2. All magneto-motive forces (MMFs) are positive. 3. A newly discovered fourth MMF 4. Unique Main Winding offset of 80 to 100 from the auxiliary winding 5. Each phase has a capacitor with carefully computed value. 6. A Main winding to auxiliary winding ratio of about 75% - 25% respectively. 61

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65 2 HP went from IE-1 to IE HP improved from IE-2 to IE-3 300HP moved from IE-1 toie-3 5 HP in process from IE-3 65

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67 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 target future regulations. The motor suppliers are differentiating themselves by moving to higher efficiency motors. 67

68 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 switch 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. 68

69 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. 69

70 COME AND SEE ME AT THE RMI & ImA BOOTH