1. automotive and vehicles
2. motor shows

Future of
Motor Technologies
Dezember 24, 2012
Kutny Markus
Agenda
Energy
Laws and Standards
Motor Technology
Bauer Motors
Correct Motor Selection
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 2
Energy
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 3
Energy
Why saving energy?
constantly increasing
electricity costs
increasing working costs of
the machines
Increase in manufacturing
costs
increase of product costs
environmental protection
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 4
Energy
Possible savings
Current demand in Germany
Electrical drives
Mrd. kWh
200
Mrd. kWh
200
150
600
150
530
100
400
50
200
0
Strombedarf elektrische
Antriebe
0
Strombedarf effiziente
Antriebe
saving of energy by use of effecient technology:
refrigerator
lights
electrical drives
8 Mrd. kWh
22 Mrd. kWh
50 Mrd. kWh
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 5
Energy
Advantages of saving Energy
Environment
When we save only 1% of the energy, we save 3,5 million
Barrels of Oil in USA
Running costs
Gearmotors are designed for long life, so we save energy
over the complete lifetime of the gearmotor
Electricity Network
With reduced energy demand for the same power you need
a smaller electricity network
Running costs
by the use of permanent magnet synchronous motors the
reactive power will be smaller
smaller reactive power compensation equipment
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 6
Energy
Where we can save Energy?
correct
calculation
Gears
Motors
Inverter
transmissions elements
power losses
in cables
conveyer elements
etc.
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 7
Energy
Efficiency
90% 97%
50% 95%
80% 100%
96% 99%
95% 100%
80% 92%
70% 98%
70% 98%
60% 98%
30% 98%
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 8
Energy
Saving potential: E-Motor
E-Motor
smaller motors have a bigger saving potential
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 9
heat
Motor Technologies
Losses / Efficiency
Maschine
feeding Energy
(electrically)
discharged Energy
(mechanical)
Prozess
discharged Energy
Efficiency =
feeding Energy
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 10
Energy
Increasing efficiency
to improve the efficiency of the energy conversion
The whole efficiency is dependent on the worst element of the whole efficiency
chain
η ges = η1 ⋅η 2 ⋅η3 ...η x
Prozess or system improvement respectively
when possible switch off
optimal dimensioning of the motor
avoid part load
use of correct components
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 11
Laws
and
Standards
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 12
Energy
Energy- Laws
Present
• since 01.06.2011, IE-2
Laws
new
• from 01.01.2015
•Motors up to 1000V
•
only IE-3 or,
•0,75 kW to 375 kW
•
IE2 with Inverter
•Poles: 2, 4 and 6
•
for 7,5 - 375kW
•S1 and S3-80%
• from 01.01.2017
•
only IE-3 or
•
IE2 with Inverter
•
for 0,75 – 375kW
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 13
Energy
Energy- Standards
Preliminary Standards 2013
• ASM from 0,12 kW to 800kW in IE-2
• Voltage from 50V – 1000V
• 2-, 4-, 6-, and 8-pole Motors
• Temp. range -20°C - +60°C
• Motor IE-3 with Inverter -> IE-2
• etc.
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 14
Energy
Enery- Standards
EuP drives Motor technologies
• EU-guideline 640/2009 defines minimum
efficiency for motors in the EU
• IE 4 efficiencies are in the CDV and will
become standard soon. IE5 and IE6 are
being discussed
• New and old technologies (sold as new
technologies) are flooding the market:
Actual trends
•
•
•
•
•
PM- motor
Copper rotor
EC Motor
Synchronous reluctance motor
etc.
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 15
Energy
Energy Saving
Wirkungsgradverbesserun
Efficiency
improvement
g
100
blower- and friction losings
90
unmagnetize losings
80
Losings (%)
70
• Design opportunity:
eddy current losings
60
50
• more magnetic material
• better materials
Rotor electrical losings
40
• Strategy:
• fewer losses in the stator
• fewer losses in the rotor
30
20
Stator electrical losings
10
0
0,75
1,5
3
´5,5
11 18,5
30
45
75
110 160 250
Motor power
(kW)
Quelle: de Almeida, Ferreira and Fong, Standards for
efficiency of electric motors - Permanent magnet
synchronous motor technology, 2011.
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 16
Energy
Energy saving with motors
What is the effect of an energy saving Motor?
We regard a motor with an output power of 7,5kW. It is running 5 hours per day.
approx. 1800 hours/year, 360 days
Motor IE-2
Efficiency motor
Annual usage
= 88,0%
= 15.341 kWh
Motor IE-3
Efficiency motor
Annual usage
= 90,1%
= 14.983 kWh
Motor IE-4
Efficiency motor
Annual usage
= 92,1%
= 14.658 kWh
Saving with other motors IE-2 to IE-4 approx. 683 kWh; approx. 68,3 Euro per year
Energy dissipation improvement: ca. 37%
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 17
Overview of
MotorTechnologies
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 18
Motortechnologies
Asynchronous motor (ASM)
• Technology:
• Cooper in the stator
• cast aluminium winding in the rotor
• higher efficiency with longer iron sheet packages
or with better iron quality
• IE2 possible
• Advantages:
• robust
• line start possible
• Disadvantages:
• sometimes bigger motor than the IE-1 type
• Inverter:
• Danfoss can controll each ASM
ASM
with aluminium rotor
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 19
Motortechnologies
Asynchronous motor (ASM with copper rotor)
• Technology:
• construction as the ASM but with copper rotor
for better efficiency
• IE-3 possible
• Advantages:
•
•
•
•
smaller lossses in the rotor
„compatible“ to the IE-1 motos (same housing)
line start possible
bigger starting torque (+ current)
• Disadvantages:
• higher price because of copper
• complex production tooling in the factory
• usually bigger housing
• Inverter:
ASM
with copper rotor
• Danfoss can control each ASM with copper rotor
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 20
Motortechnologies
Permanent magnet synchronous motor
(PMS-Motor)
• Technology:
• magnets in the rotor: PMSM (salient)
• magnet on the rotor: PMSM (non salient)
• IE-4 possible
• Advantages:
Permanent
Magnet
magnets in the rotor (salient)
•
•
•
•
•
no losses in the rotor
PMSM: extended weakening field
constant torque from 0 rpm – max. rpm
bigger efficiency under partial load
smaller design size (compact)
• Disadvantages:
• bigger price (simillar to ASM IE-3)
• need an inverter
• Inverter:
magnets on the surface (non salient)
• Danfoss running possible (VVC+ PM and Flux)
• IPM motors until Ld/Lq rate to ca. 1:2
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 21
Motortechnologies
brushless motor (EC-Motor)
Stator
Permanent
Magnet
Rotor
• Technology:
• Block comutated PM Motoren
• IE3 and IE4 possible
• Advantages:
• the rotor is outside and the stator inside
• Disadvantages:
• bigger comutating losses
• noise level and torque steps
• need special controller/ inverter
• Inverter:
outside rotor with magnets
EC = Block Comutating
PM = Sinus-Comutating
• it is possible but not very efficient with danfoss
inverter
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 22
Motortechnologies
Line- Start PM-Motor (LSPM)
• Technology:
Permanent
Magnet
Aluminium
winding
• design like ASM
• the rotor is added with magnets (PM)
• IE3 and IE4 possible (line start)
• Advantages:
• direct start on line possible (DOL)
• Disadvantages:
•
•
•
•
•
•
•
DOL (Direct On Line) Motor
by start it is possible, that the motor runs backward
fall out of synchronity by huge torque steps
no overweight start, no high dynamic like PMSM
torque peaks at start about (7 – 17 of M-rated)
sensitive when the voltage is low (Mains)
efficiency in part load is below PM
expensive because of two technologies in one motor
(ASM and PMSM)
• Inverter:
• With Danfoss it´s possible (u/f, VVC+, VVC+ PM)
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 23
Motortechnologies
Synchronous- Reluctance- Motor (SR)
• Technology:
• stator like IM
• rotor produces the reluctanz torque
• IE3 and IE4 possible
• Advantages:
Reluctance principle
• no rare earths
• higher efficiency
air
• Disadvantages:
• need a special controller / inverter
• very loud
• bad cos φ
(bigger inverter is needed)
SR Motor
• Inverter:
• first tests with Danfoss are possible
not every SR-motor has a high
efficiency!
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 24
Motortechnologies
Synchronous- Reluctance- Motor with Ferrit
(SR)
• Technology:
• design like SR
• Groove filled with ferrit
• IE3 and IE4 possible
Ferrit
• Advantages:
• suitable for high speed applications
• high efficiency
• Disadvantages:
• need special controller / inverter
• bad cos φ ( bigger inverter is needed)
• very loud
• Inverter:
• first tests with Danfoss are possible
Rotor from a SR motor with ferrit
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 25
Motorentechnologies
difference ASM and PMS-Motor
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 26
Bauer Gear Motor
„Motor- Technologies“
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 27
Motorentechnologies
Bauer Gear Motor GmbH
Asynchronous motors (ASM)
Permanent-Magnet-SynchronousMotors (PMSM)
losses 100%
no losses in the rotor
copper has a bigger
electrical conductivity
• no thermal loss in rotor
•rotor resistor about 40%
lower
• total loss about 25%
reduced
•thermal loss in rotor about
40% less
• total efficiency about
>10% larger
• rotor loss 100%
terminated
•the total loss about
10…15% lower
•total efficiency about 1…2%
larger
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 28
Overview of motors
Asynchronous motor technology (ASM)
Features:
• aluminium rotor
• copper rotor
• weakfield start of the 50Hz motors from 60Hz
• Y-/ D- swichtable
• different voltages
• Explosion proof motors (Zone 1, 2, 21, 22)
• USA-Motors (UL, CSA)
• Nema (Class I, Division II)
Asynchronous motors:
IE-1, IE-2, IE-3
Power IE-1:
12W – 37kW
Power IE-2:
0,37kW – 22kW
Power IE-3:
0,75kW – 15kW
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 29
Overview of motors
Permanent magnet technology (PMSM)
Features:
• Permanent magnets in the rotor
• weakfield start of the 50Hz motors from 70Hz
• Y-/ D- switchable (more Power/ Torque)
• Voltage 400V; 50Hz
• Explosion proof motors (Zone 1, 2, 21, 22)
• USA-Motoren (UL)
• Inverter always required
•Flux-Vektor-controlling
PMS-Motors:
•VVC+ controlling (Danfoss FC302)
IE-3, IE-4
Power IE-3:
1,65kW – 15kW
Power IE-4:
0,55kW – 11kW
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 30
E-Motor
Losses
Pab = Pzu − ∑ Verluste
Pmech.
Pmechanisch
η=
Pelektrisch
rotor losses
iron sheet losses
none by
PMS-Motors
copper calbe losses
friktion losses
P1 = 3 ⋅U ⋅ I ⋅ cos ϕ
Pelectr.
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 31
E-Motor
Energy requirement
Energy requirement is dependent of the load of the motor
ASM has a worse efficiency in part load as PMS-motors
ASM should be calculated that they don´t run in partial load
operation
is also valid for inverter running motors!
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 32
E-Motor
efficiency acc. to load
Efficiency of IE-2 motors
load
PMSM
25%
50%
75%
100%
125%
konstant
0,37
66
75,5
76,5
76,2
71,5
x
0,55
68,5
78
79
78,4
75
87,7
0,75
70
79,5
80,5
79,7
77
87,4
1,1
73
82,5
83,5
82,7
81,5
89
1,5
73,5
83,5
84
83,2
82
90,1
2,2
75
84,5
85,5
84,5
83,5
91
3
77
87
87,5
86,5
86
89,8
4
78
88
88,5
87,5
87
91,5
5,5
79,5
89,5
89,5
88,9
88,5
93
7,5
79,5
89,5
89,5
88,9
88,5
92,1
9,5
80,5
90
90
89,4
89
92,7
11
81
90,5
91
90,3
90
92,9
15
81,5
91
91,5
90,6
90,5
91,9
power [kW]
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 33
E-Motor
energy requirement by starting
ASM has a 3-15x bigger starting current on the mains
Motor direct on line start
with softstarter
• huge load of the cable for the motor
• small losses in the motor cable
• P=I²*R
• P=I²*R
huge power losses
• in cyclic operation larger heating
small power losses
• softer for the whole mechanics
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 34
E-Motor
Correct choice /
Dimensioning of
E-Motors
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 35
E-Motor
Dimensioning
Motor dimensioning
1. Thermal dimensioning
The motor temperature should not reach a
limited value
2. Overload
The motor should be able to give the required
torque which is needed for the application
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 36
E-Motor
Thermal graph
Thermal dimension
wrong
Motor too
hot
right
Motor too
cold
lower efficiency
lower efficiency
reduced life time
(partial load)
Motor temperature
ideal
ideal efficiency and
life time
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 37
E-Motor
heating in the motor
There are 2 main heat losses in a motor during the energy
conversion process
PV = PV 0 + PVL
PVL = k ∗ I
2
PV = transformation losses in the motor
PV0 = eddy current losses (foucault current losses)
PVL = thermal current losses in the coil
k=coil resistor; I = current
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 38
E-Motor
heating of the motor surface
PV ⋅ dt = A ⋅ (ϑ − ϑ A ) ⋅ dt + Cϑ ⋅ dϑ
dϑ
PV (t ) = A ⋅ ∆ϑ + C ⋅
dt
t
−


T
ϑ
ϑ = ∆ϑ∞ ⋅ 1 − e 


| Property of Bauer Gear Motor GmbH | Dezember 2012 | 39
E-Motor
operating modes
For the best efficiency result, the correct choice of the operating mode
is very important
Advantages for the correct mode:
• longer life time
• higher efficiency
• smaller motor for the same power
• ideal motor temperature
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 40
E-Motor
Duty Cycle
continuous duty S-1
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 41
E-Motor
Duty Cycle
S2 = short time duty (e.g. S2 - 5 min)
Last P
The operating time under rated load is short compared
with the subsequent rest period.
The standard operating times are 10, 30, 60 and 90
minutes. The equipment can operate
for this period under the rated load without exceeding
the allowable temperature.
Motortemperatur ϑ
Example: S2 – 60 min
t
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 42
E-Motor
Duty Cycle
S3 = Intermittent periodic duty
Last P
motor temperature ϑ
S3 duty consists of a sequence of identical cycles,
each composed of an operating time
with constant load and a rest time with the windings
de-energised. The cycle is such that
the starting current does not significantly affect the
temperature rise. The operating time
under rated load and the subsequent pause are
both short. The equipment can operate
under load only during the period indicated by the
duty cycle as a percentage of the total
cycle time (cycle duration).
The standardised duty cycles are 15, 25, 40 and
60%. The cycle duration is 10 minutes unless
otherwise specified.
t
ED =
tN
tN
× 100 % =
× 100 %
t cyc
t N + t0
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 43
E-Motor
Duty Cycle
S4 = Intermittent periodic duty with starting
S4 duty consists of a sequence of identical cycles, each of
which is composed of a distinct
starting time, a time of operation under constant load, and
a rest period with the windings
de-energised.
The operating time under rated load and the
subsequent pause are both short. The
equipment can operate under load only during the
period indicated by the duty cycle as a
percentage of the total cycle time (cycle duration).
The duty cycle can be determined as follows:
ED =
ta + t N
t +t
× 100 % = a N × 100 %
t cyc
ta + t N + t0
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 44
E-Motor
Duty Cycle
S5 = Intermittent periodic duty with electric braking
S5 duty consists of a sequence of identical cycles, each of
which is composed of a starting
time, a time of operation under constant load, a time of fast
electric braking, and a rest
period with the windings de-energised.
The operating time under rated load and the subsequent
pause are both short. The
equipment can operate under load only during the period
indicated by the duty cycle as a
percentage of the total cycle time (cycle duration).
The standardised duty cycles are 15, 20, 40 and 60%. The
cycle duration is 10 minutes unless
otherwise specified
The duty cycle can be determined as follows:
ED =
t a + t N + t Br
t +t +t
× 100 % = a N Br × 100 %
tcyc
t a + t N + t Br + t0
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 45
E-Motor
Duty Cycle
S6 = Continuous-operation periodic duty
Last P
This type of duty corresponds to S3, with
the exception that the equipment remains
energised
during the rest periods. In other words, it
operates with no load during these periods.
The duty cycle and cycle duration are
specified the same way as for S3 duty.
Motor temperature ϑ
The duty cycle can be determined as follows:
t
ED =
tN
t
× 100 % = N × 100 %
t cyc
t N + t0
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 46
E-Motor
Duty Cycle
S7 =Continuous-operation periodic duty with electric braking
The machine starts up, operates under load, and then is
braked electrically, for example
by feeding it from a DC power source. Following this, it
starts up again immediately. The
machine can operate continuously in this manner if the
specified moments of inertia of the
motor JM and of the load JExt as well as the specified duty
cycle are not exceeded. If the cycle
duration is not specified, it is assumed to be 10 minutes.
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 47
E-Motor
Duty Cycle
S8 = Continuous-operation periodic duty with relative load/speed changes
The machine runs continuously under variable load with
frequent speed variations. The
machine can operate continuously in this manner if at each
speed the specified values are
not exceeded (moments of inertia JM and JExt cycle
duration (if other than 10 minutes), rated
output and duty cycle. With a moment of inertia of 1 kg
m2, the acceleration characteristics
are the same as with a mass of 1 kg at a distance of 1 m
from the axis of rotation).
The duty cycle can be determined as follows:
ED =
ta + t N 1
t +t
×100%; Br N 2 ×100%
tcyc
tcyc
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 48
E-Motor
Duty Cycle
S9 = Duty with non-periodic load and speed variations
In S9 duty the load and the speed vary non-periodically
within the permissible operating
range. This includes frequently applied overloads, which
must never exceed the reference
load.
For this duty type, a constant load appropriately selected
and based on duty type S1 shall
be taken as the reference value Mref for the overload.
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 49
Torque- / Power- graph
S1 and S3 / S6-60%
Torque of S1- und S6- Motor
60
Electric
motor:
50
40
4,0kW -100%
M [Nm]
S-1 duty
S1
30
S3/S6-60%
20
same motor
10
7,5kW -60%
65
55
40
28
24
20
16
12
8
4
0
0
S-6 duty
f [Hz]
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 50
Size differences between motors
Size difference
between S1 and S3/S6
for a periodic duty you can choose
a smaller motor (z.B. S3 o. S6)
The motor can produce more
power because the temperature
limit will not be reached in a
periodic duty
Example:
P
M
I
ED
S1
3kW, 20Nm, 6,8A, 100%
S3/S6
3kW, 20Nm, 6,8A, 60%
IE1
IE2
IE1
kW
S1
S1
S3/S6 6-60%
0,55
D08MA4
D08LA4
D07LA4
0,75
D08LA4
D08XA4
D08MA4
1,1
D08XA4
D09LA4
D08LA4
1,5
D09LA4
D09XA4
D09SA4
2,2
D09XA4
D09XA4C
D09LA4
3
D11SA4
D11MA4
D09XA4
4
D11MA4
D11LA4
D11SA4
5,5
D11LA4
D11LA4C
D11MA4
7,5
D13MA4
D13LA4
D11LA4
9,5
D13LA4
D16MA4
D13MA4
11
D16MA4
D16LA4
D13LA4
15
D16LA4
D16XA4
D16MA4
18,5
D16XA4
D18LA4
D16LA4
22
D18LA4
D18XA4
D16XA4
30
D18XA4
-
D18LA4
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 51
E-Motor
Energy Efficiency Improvement
Check list:
there are gearboxes with a high efficiency?
do you choose the correct motor?
do you use an inverter for different speeds?
do you use a softstarter for motors which are
starting very often?
are there useless drive components which cause
a bad efficiency (e.g. non direct mount, belt,
etc.)?
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 52
| Property of Bauer Gear Motor GmbH | Dezember 2012 | 53