SIMOTICS reluctance motor and SINAMICS converter Status: 2018-04-05 Botlek Studiegroep Internal Siemens AG 2017 siemens.com/simotics
CO 2 - reductie Page 2
Doorgaans wordt ca. 30 % van het totale energieverbruik van Nederland verbruikt door de Industrie, waarvan dan ca. 70% weer valt toe te schrijven aan de vermogensopname van elektromotoren. Dat is dus een behoorlijke noemer om energie te besparen. The challenge: Standards & legislation Drive systems use 70% of industrial power. Currently, there are standards and regulations that define the efficiency classes of DOL motors Solution: Future definition of efficiency classes for converters and systems in the various standards and later in the appropriate regulations The challenge: Suppliers of electrically driven production machines According to regulation EC 622/2012 (1W-2.5kW) circulating pumps must specify an energy efficiency index (EEI). The EEI is defined in the appropriate standards for additional pump types and power ratings. Solution: Analysis of the energy usage transitions from just the pure product approach to electrically driven machines
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Higher costs through higher efficiency lower energy costs? Page 5
EN 50598 allows the energy usage of electrically-driven machines to be analyzed New in EN 50598 Analysis of the energy usage Manufacturers of electrically-driven machines can analyze the energy usage using standardized load profiles Transparency The standard general conditions mean that drive systems (motor and converter) can be compared for every application Efficiency classes Converters will be classified according to IE efficiency classes and drive systems according to IES Publication The standard was published on Dec. 19th 2014 Obligation After publication, EN 50598 will be listed in the EU Official Journal As a consequence, converter manufacturers have a legal obligation (presumption of conformity with the standard) EU regulation, scheduled for 2018 Parameters In this standard, the losses at certain operating points are decisive
Energy saving Minimum efficiency requirements for line and converter operation in the EU IEC 60034-30-1: 2nd edition 06/2011 01/2015 01/2017 Line motors >= 7.5 kw Min. efficiency IE2 acc. to EU Directive 7.5.. 375 kw Min. efficiency IE3 acc. to EU Directive 7.5.. 375 kw Line motors < 7.5 kw Min. efficiency IE2 acc. to EU Directive 0.75.. 7.5 kw Min. efficiency IE3 acc. to EU Directive 0.75.. 7.5 kw Line motors operated with converters (capable of converter operation) Min. efficiency IE2 acc. to EU Directive, 0.75.. 375, kw VSD motors (converter motors) No minimum efficiency requirements According to the EU Directive, EISA, Page Page 7 5 May 25, 2017
EN 50598-2 stipulates Ecodesign requirements for drive systems and their associated components EN 50598 embedded in the mandates of the EU Drive components, electrical rotating machines - standards Drive system EN 50598 IEC 60034-2 Standard methods to determine the losses and efficiency from tests Part - 1 Part - 2 Fixed-speed Special motors motors Published Published 2007-09 2010-03-16 Part - 3 (TS) Motors for VSD Published 2013-11-01 M/470 Ecodesign requirements for drive systems and their associated components in an electrically-driven machine in the low-voltage area Energy efficiency Ecodesign M/476 IEC 60034-30 Efficiency classes (IE classes) Part - 1 Part - 2 Line supply 0.12 to 1000 kw - Up to 8-pole... Motors fed from drive controllers Part 1 Basic requirements relating to the necessary "semianalytical" models for The driven machine The integrated drive system Part 2 Requirements placed on drive systems: < 1000 V Rated powers up to 1 MW Classification limit values Part 3 Requirements relating to generating the ecological footprint of products. Published 2014-03-01
Standardized power loss data of the motor system allows the energy usage of the driven system to be analyzed Definitions from the standard EPA: Extended Product- Approach: Electrically driven machine PDS: Power Drive System: with CDM Motor MS: Motor- System: PDS or motor with starter CDM: Complete Drive Module: Frequency converter Source: EN 50598-2
EN 50598-2 is binding for the SINAMICS V20, G110, G120, G130, G150 and G180 series Area of validity of the EN 50598-2 standard EN 50598-2 must be applied for AC-AC converters/cdm without energy recovery functionality Motors with integrated converter/cdm (one product) Supply voltage: 100 V 1000 V Power range: 0.12 kw 1000 kw Independent of the motor technology EN 50598-2 is mandatory for the following CDM: SINAMICS V20 SINAMICS G110 family SINAMICS G120 family SINAMICS G130 SINAMICS G150 SINAMICS G180 EN 50598-2 can be optionally applied to: AC AC converters/cdm capable of energy recovery AC DC converters/cdm DC AC converters/cdm Devices with other power and voltage classes Any combinations of PDS (CDM and motor) In the first step, Siemens applies the EN 50598-2 for the following PDS: SIMOTICS FD & SINAMICS G120P SIMOTICS GP/SD VSD10 Line & SINAMICS G120 SIMOTICS GP/SD VSD4000 Line & SINAMICS G120
Ecodesign De Europese normenserie EN 50598 definieert de Ecodesign voorwaarden voor aandrijfsystemen in een elektrisch aangedreven machine, inclusief energieefficiëntie en levenscyclusanalyse. De basis voor het vaststellen en optimaliseren van de efficiëntie van elektrisch aangedreven machines werden gemaakt met het gezamenlijke concept opgesteld door drivefabrikanten en machinebouwers. Page 11
All application characteristics can be emulated using 8 operating points Page 12
Customers can calculate PDS system values themselves Siemens supplies the values for Siemens PDS Power Drive Systems (PDS) losses at the defined operating points RM relative torque / % Motor losses 100 p L,RM (100;100) Power Drive System / motor system losses 50 PDS relative torque / % 100 IES0 - IES2 p L,PDS (100;100) + 50 100 = CDM losses CDM relative torque current / % 25 100 50 25 IE0 - IE2 50 90 100 p L,CDM (90;100) RM relative speed / % CDM relative motor stator frequency / % 50 25 50 100 PDS relative speed / % Customers can calculate or measure PDS system values themselves (when purchasing individual components) For the PDS, Siemens supplies precise and optimized power loss values SIEMENS provides the PDS values in the tools LINK TO STANDARDS Page 13
The efficiency class is defined at the rated operating point Page 14
Synchronous-reluctance motors behave differently than permanent magnet synchronous motor and induction motors and therefore they open up completely new advantages for customers! Attributes of synchronous-reluctance drive systems Energy efficiency Maximum Comparable PM synchronous IE3 IE4 Reluctance PM synchronous Performance High As an example servo pump Induction motor Reluctance Synchronous Servo List price Low Between 1LE1 IE3 and IE4 IE3 Reluctance IE4 Application-specific advantages Lower intrinsic moment of inertia (referred to 1LE1 IE3/4) A separately driven/external fan is not used Closed-loop control without encoder Page 15
Motor technologies for high-efficiency motors Positioning of the drive system in our portfolio Performance / efficiency Synchronous reluctance motors with converters + Rugged + Favorably priced For standard drive systems + Efficient + High dynamic performance + Low costs For standard drive systems IE4 induction motors with converters Permanent-magnet synchronous motors with converters + Efficient + Highest dynamic performance - Cost-intensive For special applications + Rugged converter + Simple closed-loop control - Cost-intensive and maintenance-intensive For special applications DC drives Page 16 Costs
Energy-saving Higher energy efficiency requires new technologies Efficiency New technologies IE4 "IE4" SYN IE2 IE1 IE3 Synchronous motors with magnetic materials / utilizing reluctance technology Standard induction motors Technology Page 17
Synchronous reluctance motor From "ugly duckling" to shooting star Jaroslaw K. Kostko 1927 patent for a synchronous motor operating according to the reluctance principle Alfredo Vagati 1990 Professor for electrical machinery and drives at the University of Cagliari, Italy. 1995 to 2003 Head of the Electrical Engineering Department in the Technical Institute, Turin, Italy His scientific research covered power electronics and electric drives. His most important activity is the design and closed-loop control of high-performance synchronous reluctance motors (patent back in 1998). Page 18
Synchronous reluctance motor Torque generation 1st step With the exception of the air gap, the stator flux is exclusively through the iron Low magnetic impedance Lowest "system energy" 2nd step Stator flux has changed, must take a longer route through the air gaps Low magnetic impedance Increased system energy This results in a torque, which acts to minimize the system energy 3rd step Rotor rotates into the position of step 1 As the stator field rotates, then the rotor must also continually rotate The rotor frequency corresponds to the stator frequency however, rotor and stator are phase-shifted with respect to one another q d Comparable with two magnets that are "stuck" to one another Comparable with two magnets that are quickly moving together Page 19
Synchronous reluctance motor The SIMOTICS GP/SD series is the basis General Purpose motors SIMOTICS GP Power: 0.55 kw to 15 kw No. of poles: 4 Short, compact motors Aluminum frame for a low weight Modular mounting concept for encoders, brakes, external fans Severe Duty motors SIMOTICS SD Power: 0.55 kw to 45 kw No. of poles: 4 Rugged cast iron frame for harsh environments Can be extensively modified using a wide range of options Modular mounting concept for encoders, brakes, external fans Page 20
SIMOTICS GP/SD VSD/DOL strategy of the 1LE1 platform 1LE1 platform IE1 class IE2 class IE3 class IE4 class DOL + Converter-capable 1LE1 platform "Reference class" (IES 1 / 2) "Super efficiency class" (IES 2) VSD Line (only converter operation) VSD10 VSD4000 Page 21
Synchronous reluctance motor Rating plate for SH80 225 Motor voltage optimized for converter operation Converter-optimized motor without efficiency class according to IEC 60034-30-1 Only for converter operation Rated speed for converter operation Code number for simple commissioning with SINAMICS G120 Universal use on 50Hz and 60Hz line supplies Used for 50Hz, 60Hz and 87Hz voltage/frequency characteristics Page 23
Overview assignment of power units to motors G120 S120 Rated motor load PM240-2 (LO power + MLFB) PM240P-2 (LO power + MLFB) Booksize Motor Module 0.55 0.55kW / 6SL3210-1PE11-8 L1 3.0/ 6SL312-1TE13-0AA3 0.75 0.75kW / 6SL3210-1PE12-3 L1 1.10 2.20 3 4 4kW / 6SL3210-1PE21-1 L0 5.5 5.5kW / 6SL3210-1PE21-4 L0 18/ 6SL312-1TE21-8AA3 7.5 7.5kW / 6SL3210-1PE21-8 L0 18/ 6SL312-1TE21-8AA3 11 11kW / 6SL3210-1PE22-7 L0 30/ 6SL312-1TE23-0AA3 15 15kW / 6SL3210-1PE23-3 L0 45/ 6SL312-1TE24-5AA3 18.5 18.5kW / 6SL3210-1PE23-8 L0 22kW / 6SL3210-1RE24-5 L0 45/ 6SL312-1TE24-5AA3 22 22kW / 6SL3210-1PE24-5 L0 30kW / 6SL3210-1RE26-0 L0 60/ 6SL312-1TE26-0AA3 30 30kW / 6SL3210-1PE26-0 L0 37kW / 6SL3210-1RE27-5 L0 85/ 6SL312-1TE28-5AA3 Page 25
Efficiency System attributes Energy efficiency at rated operating point and in the partial load range System with reluctance motor kw 5.5 7.5 11.0 15.0 18.5 22.0 30.0 Reluctance * 91.9 92.6 93.5 93.9 94.2 94.5 94.9 IE4* 90.7 91.5 92.3 93.0 93.3 93.7 94.1 IE3* 88.0 89.0 90.1 90.9 91.5 92.0 92.6 IE2* 85.9 87.0 88.4 89.2 89.9 90.3 91.1 Efficiency at the rated operating point At the rated operating point, the efficiency of a drive system with reluctance motor is higher than a drive system with IE4 induction motor + 2 System with induction motor 1 Efficiency in the partial load range + In the partial load range, the efficiency of a drive system with reluctance motor is significantly higher than a drive system with IE4 induction motor 0.5 P rated P rated Power Page 26 *) Minimum efficiency according to IEC 60034-30-1. Converted over to converter operation according to DIN EN 50598-2 (Section 5.3.2.6: Harmonic-dependent supplementary losses)
System attributes Dynamic performance low intrinsic moment of inertia Relative intrinsic moment of inertia 1) Intrinsic moment of inertia + 180% 160% 140% 120% 100% 80% 60% 40% By optimizing induction motors with regard to efficiency (copper rotor, electrical sheet steel with lower loss coefficient) the intrinsic moment of inertia of IE3 and IE4 motors increases to twice the moment of inertia of synchronous reluctance motors. This becomes evident for dynamic applications with higher overall torque and motor current. Synchronous reluctance motors have approximately the same intrinsic moment of inertia as three-phase induction motors with energy efficiency class IE1 20% 0% Reluctance motor Induction motor IE4 Induction motor IE3 Induction motor IE2 Converter motor VSD10 1) Average values 5.5 kw to 30 kw Page 29
System attributes Thermal behavior high operational reliability as a result of the low motor temperature Utilization F acc. to F Thermal limit Thermal utilization at rated power Utilization F acc. to B Thermal reserves Synchronous reluctance motors have almost no rotor losses; as a consequence, they have high thermal reserves when compared to induction motors Torque reduction As a result of the thermal reserves, synchronous reluctance motors can be operated down to 1/10 of their rated speed with full torque torque derating is not required + + Induction motor Synchronous reluctance motor Overload capability, service factor 1.2 As a result of the thermal reserves, synchronous reluctance motors can be operated with a service factor SF = 1.2 this means 20% overload in a control range of 1:10 with slightly reduced efficiency + Page 30
System attributes Thermal behavior when compared to an induction motor Torque in Nm 200 Speed control range 1:10 150 Induction motor 22 kw 100 Load characteristic 97Nm, 150 1500 rpm 50 0 0 150 300 450 600 750 900 1.050 1.200 1.350 1.500 1.650 1.800 1.950 2.100 2.250 Speed rpm Page 31
System attributes Thermal behavior when compared to an induction motor Torque in Nm 200 Speed control range 1:10 150 100 50 Load characteristic 97Nm, 150 1500 rpm Reluctance motor 15 kw 0 0 150 300 450 600 750 900 1.050 1.200 1.350 1.500 1.650 1.800 1.950 2.100 2.250 Speed rpm Page 32
System attributes Thermal behavior when compared to an induction motor Torque in Nm 200 SF 1.2 Speed control range 1:10 150 100 50 Load characteristic +20% Load characteristic 97Nm, 150 1500 rpm Reluctance motor 15 kw 0 0 150 300 450 600 750 900 1.050 1.200 1.350 1.500 1.650 1.800 1.950 2.100 2.250 Speed rpm Page 33
SIMOTICS reluctance motor and SINAMICS converter Drive system with the highest efficiency based on innovative technology SIMOTICS reluctance motors and SINAMICS G120 Drive system with the highest energy efficiency Highest efficiency using synchronous motor technology State-of-the-art control algorithms for best efficiency, especially in partial load range Energy saving with a flying restart where the load is still rotating A cost-effective system + Optimized system costs through standard Power Modules harmonized and coordinated for reluctance motor technology High control dynamic performance in encoderless operation Extremely simple commissioning as the controller does not have to be parameterized + System efficiency class IES 2 Highest energy efficiency in the IES 2 Class Lowest lifecycle costs (lower energy costs) Can be universally used Suitable for all load torques Special synchronous motor control allows high starting and accelerating torques Guaranteed motor power when operated with a converter System-tested data are stamped on the rating plate + + + Page 34
SIMOTICS reluctance motor and SINAMICS converter High degree of cost effectiveness based on innovative motor technology Top highlights SIMOTICS reluctance motors and SINAMICS G120 Feature/function State-of-the-art control algorithms for the best efficiency, especially in the partial load range Special synchronousreluctance control allows high starting and accelerating torques High control dynamic performance in encoderless operation Standard Power Modules coordinated and harmonized for reluctance technology τ τ τ τ Benefits Low energy demand at each operating point Can be used in each and every application High degree of productivity Encoders have been eliminated therefore capital investment costs optimized Minimized system costs (converters do not have to be overdimensioned) Page 35
SIMOTICS reluctance motor and SINAMICS converter Energy efficiency and functionality for pumps, fans and compressors Energy efficiency At its rated operating point, the reluctance motor/frequency converter has a higher efficiency than an IE4 induction motor in converter operation In the partial load range, the efficiency is higher than for systems with comparable induction motors For fluid flow machines, the motor flux is adapted to the optimum operating point (flux reduction) Converter functionality Drive shutdown depending on the process (hibernation mode) Control, converter and line motors (cascade/staging circuit) Flying restart circuit for fan drives, connecting to a drive, even if it is rotating in the opposite direction Handling Synchronous reluctance motors are compatible to existing induction motors regarding flange and shaft dimensions + + + Page 36
SIMOTICS reluctance motor and SINAMICS converter Dynamic performance and thermal response in conveyor technology Dynamic response The low moment of inertia of synchronous reluctance motors in conjunction with the dynamic vector control of the converter allows higher clock cycle rates (for example, to address fluctuating load levels) than for systems with induction motors with efficiency class IE3 or IE4 + Thermal behavior Torque does not have to be reduced in the control range 1:10; as a consequence, overdimensioning is not required, as is the case for induction motors Continuous overload capability of 20% possible in a control range of 1:10 + Converter functionality + The pole position identification avoids jerky forward/backward motion when switching on The starting torque is 150 % of the motor torque Page 37
Many thanks for your attention! Ing. Gertjan Bakker Productmanager Sinamics Siemens Nederland N.V. RC-NL DF PRM MC Prinses Beatrixlaan 800 2595 BN Den Haag, Nederland Mobil: +31 62250 9436 mailto:gertjan.bakker@siemens.com www.siemens.nl www.twitter.com/siemens www.siemens.com/ingenuityforlife Handelsregister Den Haag nr 27015771 Page 38