Small step, big impact: Energy efficiency and dynamic performance

Transcription

1 Small step, big impact: Energy efficiency and dynamic performance The innovative synchronous-reluctance drive system with SIMOTICS motors and SINAMICS converters A new dimension of efficiency siemens.com/reluctance-drive-system

2 Synchronous-reluctance the new drive generation Efficiency Power Synchronousreluctance Induction Synchronous-reluctance technology ensures a noticeably lower energy consumption, especially in the partial load range. The requirements placed on the efficiency of drive systems and the individual components are higher than ever before and still rising. For conventional induction motor technology, the technical possibilities are essentially exhausted in this respect and it is hardly possible to increase efficiencies even further. Synchronous-reluctance motor technology represents an attractive alternative, especially for simpler applications, where it would not be cost-effective to use permanent-magnet synchronous motors. They allow very high efficiencies to be achieved at the rated operating point and in the partial load range and at the same time with high power density and dynamic performance. High energy efficiency and power density Synchronous-reluctance motors have a surprisingly high efficiency and also offer higher power reserves than comparable induction motors. A converter ensures the necessary stability in operation. However, just the same as for induction systems, perfect coordination and integration of all the system components is necessary so that the system can leverage its full potential. An integrated system pays off SIMOTICS reluctance motors are precisely harmonized and coordinated with SINAMICS converters to create a Siemens integrated synchronous-reluctance drive system. It offers all the advantages of well-proven standard platforms and links these with leading edge, energy-efficient synchronousreluctance motor technology. The complete drive system can be simply and quickly integrated into the automation landscape using the TIA Portal. Optimally adapted software and services help to fully utilize all the decisive potential for optimization in all the lifecycle phases. Small step, big impact The transition from an induction motor with converter to a synchronous-reluctance drive system represents a small step, however the impact is enormous: The high efficiency ensures minimum operating costs and high productivity, short payback time and a fast return on investment. 2

3 Team player number one: the SIMOTICS reluctance motor Energy efficiency SIMOTICS reluctance motors have a higher efficiency at the rated operating point than comparable induction motors with efficiency class IE4. However, the efficiency is not just higher at the rated operating point. Especially in the partial load range, they have significantly lower losses than comparable induction motors. Dynamic performance When compared to high efficiency induction motors, synchronous-reluctance motors have a moment of inertia that is up to one half less. This allows higher acceleration rates in cyclic operation, faster clocking and finally a higher degree of productivity. The response to load changes is significantly faster as the motor is more quickly magnetized when the load changes. Thermal behavior Synchronous-reluctance motors have high thermal reserves as a result of the minimum rotor losses in operation at the standard power rating. As a consequence, in continuous operation over a speed control range of 1:10 the torque does not have to be reduced as is the case for self-ventilated induction motors. However, just the same as for forceventilated induction motors, the rated torque is available even at low speeds. Further, synchronous-reluctance motors have a permanent overload capability of 20 % in a 1:10 speed control range with a slightly lower efficiency when compared to that at the rated operating point. Usability SIMOTICS reluctance motors and induction motors have the same external design. Just the same as standard motors, synchronous-reluctance motors are available as SIMOTICS GP with aluminum enclosure as well as SIMOTICS SD with cast iron enclosure. Identical frame sizes, shaft heights, shafts and flanges secure full compatibility so that the motors can be interchanged and all the mechanical options available for Siemens induction motors can be used. Functionality Temperature sensors monitor the motor temperature. Synchronous-reluctance motors are very rugged in operation thanks to the high thermal reserves and therefore the lower temperature rise of the mechanical system and the winding. The motor rating plate has a motor code to facilitate simple commissioning. 3

4 The innovative synchronous-reluctance drive system with SIMOTICS SD/GP (diagram, SIMOTICS GP aluminum version) and SINAMICS G120. 4

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6 Team player number two: the SINAMICS converter Energy efficiency For example, for fluid-flow machines, variable-speed operation using SINAMICS converters saves significantly more energy than conventional techniques such as throttles. The vector control of SINAMICS S120 and G120 converters facilitates precise closed-loop control of torque and motor magnetic flux. The flux is reduced in the partial load range to save energy. Optionally, additional electronic functions can be selected to switch off the converter in no-load operation and a cascade circuit switches-in additional devices if the power requirements for a single drive become too high. Dynamic performance The vector control with very high dynamic performance, also available with standard SINAMICS G120 converters, precisely controls the required torque. Usability The power scaling of the SINAMICS G120 converters is designed so that SIMOTICS induction motors and synchronous-reluctance motors with the same shaft output can be operated with the same converter. It is extremely simple to commission a SIMOTICS reluctance motor connected to a SINAMICS G120 converter, as the most important parameters are already predefined. To call these up, you only have to enter the code number from the motor rating plate into the converter. When switching on for the first time, the stator resistance is automatically measured and the closed-loop control appropriately set. The closed-loop control can be even better optimized for the driven load in additional commissioning steps. Functionality The pole position is identified when switching on, which avoids sudden jerky motion; there is no forward or backward motor alignment motion. The motors are thermally monitored using the temperature sensor integrated as standard and the closed-loop control is adapted as a function of the temperature. A flying restart function allows the converter to be switched to a spinning motor, for instance after a power failure. Also, motors spinning in the opposite direction can be synchronized when switching on. The following options are possible in conjunction with SINAMICS S120 converters: Operation down to zero speed when using a speed encoder Regenerative operation (energy recovery) Multi-axis operation Basic safety functionality is available as standard. Using the SINAMICS S120, a wide range of applications in general machinery construction can be addressed, for example winders, extruders and servo pumps. 6

7 A perfect team... for use in various applications Pumps, fans, compressors Conveyor systems General machinery construction IES2 IES1 IES0 Maximum energy efficiency The system efficiency of an integrated synchronous-reluctance drive system from Siemens lies significantly above the minimum requirements of the highest system efficiency class IES2 that is defined. Minimum operating costs When compared to induction motor systems, energy usage can be significantly reduced due to the far higher efficiency, especially in the partial load range. High degree of productivity The lower intrinsic moment of inertia of synchronous-reluctance motors allows very short cycle times, therefore increasing the productivity of a plant or machine. 7

8 Horizontal integration Integrated drive portfolio All converters, motors, couplings and gearboxes are from a single source. Perfectly integrated, perfect interoperability. For all power and performance classes. As standard or completely customized solution Vertical integration Integrated in the automation technology: from the field through the controller level up to the MES thanks to Totally Integrated Automation (TIA). For every application. Lifecycle High efficiency, from full load down to partial load. Short payback time. Low operating costs over the complete lifecycle. 8

9 Increase energy efficiency and reduce losses by up to 50 % IES2 IES1 Significantly better than IES2 The European eco design standard EN defines eco design requirements for drive systems in electrically-driven machines. The energy efficiency requirements are extended from individual drive components up to the complete system, as well as to electrically-driven machines. By teaming up a SIMOTICS reluctance motor with a SINAMICS converter, Siemens is offering a powerful drive system with high energy efficiency. With up to 50 % lower losses than the reference system of the standard, it easily satisfies the requirements of system efficiency class IES2. IES0 With the TIA Portal reduce your engineering time by up to 30 % Convincingly efficient Both SIMOTICS reluctance motors as well as SINAMICS converters are integrated in the Totally Integrated Automation portal (TIA portal) and therefore in the complete automation landscape from the field up to the management level. This greatly simplifies engineering, commissioning and diagnostics and opens up completely new dimensions regarding efficiency. Engineering times are slashed by up to 30 %, for instance. SINAMICS Startdrive is integrated in the TIA Portal. Through SINAMICS Startdrive, the outstanding user-friendliness of the TIA Portal is now available for drive technology. Consequently, a high degree of functionality with simple operability is achieved. Achieve a return on investment in less than 1 year Fast payback The high energy saving potential of SIMOTICS reluctance motors ensures low operating costs and a high efficiency. This means that payback times are significantly reduced: When compared to standard induction motors in IE2, the somewhat higher initial investment has a payback time of less than twelve months. And when compared to a drive system with IE3 motor, for a pump load cycle according to the standardized profile Blue Angel in a two-shift operation and energy costs of 8 ct/kwh, this is shortened to five months. 9

10 Fast commissioning, fast savings Fast commissioning The motor code makes commissioning especially fast and straightforward. The motor rating plate has a code number. When the code is entered at the IOP of the SINAMICS G120 converter, then the most important parameters are already predefined. This avoids mistakes and saves time. Highlights at a glance High energy efficiency from the partial load range up to the rated operating point High dynamic performance through optimized control and low intrinsic moment of inertia Precise speed for encoderless control through synchronous operation High overload capability for rugged, reliable operation Minimum operating costs, fast payback and high productivity of your plant or system 10

11 Technical data Selection data, synchronous-reluctance drive system for 50 Hz and 400 V line voltage SIMOTICS reluctance motor SINAMICS inverter Blocksize Booksize Rated power (kw) Frame size Torque (Nm) Rated current (A) Speed (rpm) Motor code Motor Article No. Frame size Power Module Article No.: 1) e.g. Booksize Single Motor Module 2) M 3, FP1 04-0DB A 6SL3210-1PE11-8 L M FP1 04-0DB A 6SL3210-1PE12-3 L1 6SL3120-1TE13-0AA M 25, FP1 04-1BB B 6SL3210-1PE21-1 L S FP1 04-1CB B 6SL3210-1PE21-4 L M FP1 04-1CB B 6SL3210-1PE21-8 L0 6SL3120-1TE21-8AA M FP1 04-1DB C 6SL3210-1PE22-7 L0 6SL3120-1TE23-0AA L FP1 04-1DB C 6SL3210-1PE23-3 L M FP1 04-1EB D 6SL3210-1PE23-8 L0 6SL3120-1TE24-5AA L FP1 04-1EB D 6SL3210-1PE24-5 L0 6SL3120-1TE26-0AA L FP1 04-2AB D 6SL3210-1PE26-0 L0 6SL3120-1TE28-5AA3 Motor series EMV filter SIMOTICS GP aluminum frame 0 Non-filtered U SIMOTICS SD cast iron frame 5 Class A filter A 1) Either with CU230P-2 Control Unit (SINAMICS G120, from firmware V4.7 SP3) or CU310-2 (SINAMICS S120, from firmware V4.8) 2) In conjunction with CU320-2 Control Unit (SINAMICS S120, from firmware V4.8) 11

12 Experience more: siemens.com/reluctance-drive-system Discover the advantages of SIMOTICS reluctance motors teamed up with SINAMICS converters in an integrated drive system. Published by Siemens AG 2016 Process Industries and Drives Large Drives P.O. Box Nuernberg, Germany Article No.: PDLD-B Dispo WÜ/1887 WS Printed in Germany Siemens AG 2016 Subject to changes and errors. The information given in this document only contains general descriptions and/or performance features which may not always specifically reflect those described, or which may undergo modification in the course of further development of the products. The requested performance features are binding only when they are expressly agreed upon in the concluded contract. SIMOTICS and SINAMICS are registered trademarks of Siemens AG. Any unauthorized use is prohibited. All other designations in this document may represent trademarks whose use by third parties for their own purposes may violate the proprietary rights of the owner.