EMERGING TECHNOLOGIES IN MOTORS AND DRIVES DALE FRIESEN, P.Eng. Business Initiatives Manager Industrial & Commercial Solutions Manitoba Hydro Twitter hashtag: #ps10
ELECTRIC MOTOR ENERGY USAGE 65% of electricity generated by BC Hydro 85% of industrial usage converted to shaft power 51-500 hp 16% > 500 hp 26% 6-50 hp 30% 1-5 hp 9% Fractional hp 19%
STATE OF MOTORS & DRIVES Dominated by Poly-Phase Induction Motors Workhorse of industrial enterprise Standardized design, simple, rugged and reliable Several generations of efficiency enhancements Economies of scale, large production quantities Strong Presence by Variable Frequency Drives Widely accepted with growing application in industry Several generations of technological enhancements Minimal improvements in equipment efficiency Improvement in equipment efficiency/productivity
INDUCTION MOTOR EFFICIENCY 100 95 Full Load Effic ciency (%) 90 85 80 2010 1997 1994 75 70-25 50 75 100 125 150 175 200 Rating (hp)
PREMIUM EFFICIENCY MOTORS 100% Annual Motor Sales & Market Transformation Market Share (Sales s/stock) 90% 80% 70% 60% 50% 40% 30% 20% 10% PEM sales PEM installed stock 0% 1990 1995 2000 2005 2010 2015 2020 2025 2030
MOTOR & DRIVE EFFICIENCIES Chart courtesy of CEATI
OPPORTUNITIES FOR IMPROVEMENT Electrical Efficiency Gains for Standard Designs Modest improvements for fixed speed applications Low-resistance copper rotor bars and low-loss materials Variable speed drives provide some additional benefits Additional Opportunities in Application Design Advantages of higher power to weight densities Elimination of power train inefficiencies More efficient equipment and application design Emerging Motor and Drive Technologies Greater speed and torque capabilities, efficient packaging Variable-speed control enhances productivity and efficiency Switched Reluctance Motors, Permanent Magnet Motors
EXAMPLE - WASHING MACHINE Improved Functionality Greater variability in cycles Reverses direction easily Variable speed operation Compact power train Greater Efficiency Energy-efficient motor Lower drive-train losses Additional Benefits Less detergent usage Lower water consumption Longer clothing life
SWITCHED RELUCTANCE Rugged Rotor Design No windings/brushes No induction bars Laminated iron core Simple Stator Design Independent windings Low-loss configuration Operating Characteristics High turn-down ratios High speed capability Bi-directional operation Torque/speed control Photos courtesy of US Motors and SR Drives
US MOTORS - SR MOTORS 94 92 L90SR 90 kw induction motor ncy % Efficien effy.% 90 88 86 84 L90SR motor Improved part-load, 90kW induction motor part-speed efficiency 82 80 0 270 540 810 1080 1350 1620 1890 2160 2430 2700 2970 3240 3510 3780 4050 RPM Speed (RPM) Chart courtesy of US Motors and SR Drives
SWITCHED RELUCTANCE MOTOR slurry pumps APPLICATIONS Torqu ue High Torqu ue Low Speed Induction Motor Segment conveyor systems High Speed or wide constant power compressors screw turbine 300 900 1800 3600 Speed Illustration courtesy of US Motors and SR Drives
PERMANENT MAGNET MOTORS Low-Loss Rotor Design Permanent magnet rotor Simple, rugged construction Power Supply Features Electronic commutation Precise speed control Torque/speed matching High power factor Operating Characteristics High operating efficiency Losses are load dependent Lower operating temperature Elimination of maintenance Photos courtesy of Baldor Motors
BALDOR INDUCTION & PM MOTOR Frame Type Cast Iron Laminated Steel Product line NEMA Smooth RPM AC FL Frame Rotor Type Induction Surface PM Interior PM Enclosure TEFC TEFC TEBC TEBC TEBC HP @ 1750 RPM 20 100 100 100 100 Frame Size 256T 405T L2898 FL2586 FL2586 Weight 325 lbs 1160 lbs 1045 lbs 532 lbs 532 lbs lbs/hp 16.25 11.60 10.45 5.32 5.32 F.L. Amps 25.5 115 121 110 104 F.L. Power Factor 78.9% 86.4% 81.4% 90.3% 93.4% kw Losses 1.116 4.381 3.587 4.12 2.396 F.L. Efficiency 93.0% 94.5% 95.4% 94.8% 96.9% Rotor Inertia 2.42 lb-ft 2 26.1 lb-ft 2 11.1 lb-ft 2 4.9 lb-ft 2 4.9 lb-ft 2 Temp Rise 80 C 80 C 91.2 C 120 C 77.6 C Information courtesy of Baldor Motors
APPLICATION OF ADVANCED MOTORS Materials Handling Lower speeds w/o gearbox High starting torque Frequent start cycles High inertia applications Include photos of applications Pumps/Air Compressors Wide range of speed control High speed operation Refrigeration and HVAC High-speed compressors Cooling tower fans
HIGH-SPEED TURBO BLOWERS Price Bellows P.D. Multi-Stage Turbo Induction Motor Geared Single Stage Turbo Induction Motor Magnetic Bearing Direct Drive Single Stage Turbo PM Motor Foil Bearing Direct Drive Stainless Steel Impeller Single Stage Turbo Photos courtesy of KTurbo Inc.
PACKAGED AIR COMPRESSORS Direct-Drive Configuration Eliminates drive-train losses Eliminates motor bearings Variable-Speed Operation Match output to air demand Stop during low demand Higher Power-Weight Ratio Up to three times greater Allows for smaller package Photos courtesy of Ingersoll-Rand
HYDRAULIC POWER UNITS Efficient Components and System Design Flexibility Energy Recovery for Improved System Efficiency Availability on Demand without Continuous Energy Consumption No requirement for continuous pressure relief bypass Innovative switching valves only consume current when they have to trigger movements Photos courtesy of Bosch-Rexroth
LINEAR AND ROTARY ACTUATORS Integrated Segmented Lamination Brushless Motor Technology Electric versus Pneumatic/Hydraulic Photos courtesy of Exlar Corporation Before After
DIRECT-DRIVE COOLING TOWER FAN Conventional Tower Design Fan New Direct Drive Tower Fan Design AC Motor Disc Coupling Drive Shaft Disc Coupling Gear Box Benefits: Eliminates gearbox, drive shaft, disc couplings and two-speed induction motor Energy savings of > 10% Capability for variable-speed control Energy Savings of > 30%
COOLING TOWER FAN DEMO - BEFORE
COOLING TOWER FAN DEMO - AFTER
COOLING TOWER FAN DEMO RESULTS Results Criteria Power: full-speed Power: half-speed Energy Savings: Incremental Cost over induction + VFD Direct Drive PM Motor & Drive 10% savings over existing 25% savings over existing 25%-33% higher than PEM+VFD +100% (based on list price) Reliability & Maintenance Quieter, fewer rotating parts, no lubrication Speed Control Incremental Project Economics Automatic modulation based on cooling tower outlet temperature versus discrete manual control Estimated at 2-3 years
BC HYDRO DEMONSTRATION PROJECT FUNDING How it Works: Step 1: Get in contact with BC Hydro Step 2: Develop project with partners Step 3: Sign the agreement and start Step 4: Implementation and report findings Step 5: Verify energy savings and report lessons learned For additional information, please visit our website: http://www.bchydro.com/powersmart/technology_tips/innovation_technology.html Or just search for Innovation and Technology on www.bchydro.com
QUESTIONS ABOUT TECHNOLOGY Reliability and Cost Considerations Lack of a proven track-record in industry High initial costs and greater complexity Evaluating Energy Performance Test standards developed for induction motors Wide-range of speed/torque make comparison difficult Energy Efficiency Regulation Establishing a rating point for comparison Relationship between rating and performance
MOTOR & DRIVE SELECTION 79 80 81 82 83 83 84 84 85 85 86 87 88 89 90 91 Conveyors 69 70 71 72 73 74 74 75 75 76 76 77 77 77 78 78 78 79 79 79 79 80 80 80 81 81 81 81 82 82 82 82 83 83 83 83 84 84 84 84 85 85 85 85 86 86 86 87 87 87 88 88 88 89 89 90 90 91 Pumps & Fans
PROMISE OF TECHNOLOGY Additional Opportunities for Innovation Fewer constraints on speed range Greater range of torque availability Ability to start and stop more frequently Maximize Benefits Through Integration Integrated Approach versus Component Approach Maximize savings through integrated assemblies Greater contribution to the Systems Approach
INNOVATION IS NOT AN ACCIDENT! Innovation is accomplished by people 1. Leaders who give permission and encouragement. 2. Staff who work with determination and imagination. 3. Customers who provide input and feedback. Regardless of the source of ideas and technologies, innovation relies on timely evaluation and clear decision making.
QUESTIONS..? DALE FRIESEN, P.Eng. P.O. Box 815, 6 th Floor, 260 Portage Ave Winnipeg, Manitoba, R3C 2P4 Tel: 204.360 4928, Fax: 204.360 6108 drfriesen@hydro.mb.ca Twitter hashtag: #ps10