Dan Jones Incremotion Associates Burnet D. Brown … Websites Public DOE Documents Various Technical...

Dan Jones Incremotion Associates

Burnet D. Brown GreenTech Motors Corp.

Motor Basics Various Motor Technologies AC Induction is King History of Motor Energy Efficiency Market & Applications DOE Establishes Efficiency Standards How do we Compute Efficiency Status Report – Where are we now? Leading Suppliers- Higher Efficiency A new paradigm- EFF X Power Factor Where are we going ? Conclusion Motor and Drive System 2016

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Various Websites Public DOE Documents Various Technical Presentations

o John Malinowski, Baldor o Ron Boteler, Nidec-Emerson ( Retired) o Conrad U. Brunner, SEEEM o Marci Lowe, Duke University o Ruggero Golini, Duke University o Gary Gareffi, Duke University o Sadrul Ula, Cal-State Riverside o George Holling, Rocky Mountain Technology o John Petro, Consultant o Jim Hendershot, Motorsolver LLC Various Conversations with individuals at multiple technical conferences &

exhibitions

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CONSTANT SPEED

VARIABLE SPEED

VARIABLE POSITION

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SINGLE PHASE AC INDUCTION MOTORS

3 PHASE AC INDUCTION MOTORS

BRUSHLESS PM MOTORS

SYNCHRONOUS RELUCTANCE MOTORS

SWITCHED RELUCTANCE MOTORS

HYBRID MOTORS

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Radial – Surface Magnets (Inner)

Radial – Surface Magnets (Outer)

Radial- Buried Magnets

Axial Flux

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January 14, 2016

I2R Losses

55%

Magnetic Core

Losses 20%

Friction & Windage Losses

9%

Stray Load

Losses 16%

$1000 Electricity

Input

5 HP 89.5%

Efficiency

$895 Electricity

Output

$105 Efficiency

Loss

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Total Losses 10.5%

Power Efficiency- Constant & Variable Speed

Power Density- Variable Speed + Higher Torque

Torque Density- Position (Servo)

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Constant speed (plug and run)

Variable Speed (VSD)

Torque/Position (servo)

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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.

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Can’t we just plug the AC Induction motor directly into a wall socket ?

Isn’t it a line start motor ?

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How did we get to where we are today?

Where are we going ?

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After World War II, the U.S. was at the pinnacle of it’s power.

We had energy to burn.

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Then came 1972-73, our first energy crisis.

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A small number of U.S. electric motor manufacturers in the late 1970’s and into the 1980’s began to build higher efficient units but sales were slow due to higher sales prices.

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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.

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Long-Term Trends in Consumer Prices (CPI) for Water, Electric and Gas Utilities (1983=100)

Adapted from © Beecher, Institute of Public Utilities, MSU [2011]

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Source: Beecher IPU-MSU. Exhibit 1. Long-term trends in the Consumer Price Index (CPI) for utilities (1913-2010). The index is set to 100 for 1982-1984 except for telephone and wireless services, where the index is set to 100 for 1997.

Water and Sewer (1953 - 2009)

CPI (1913, 1983=100)

Electricity (1913 - 2009)

Natural gas (1935 - 2009)

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Burnet-18

Why Electric Motors for Energy savings?

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(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)

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4.7 Trillion kWh

1.6 Trillion kWh 632 Billion kWh

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Compressors 32% Mechanical Movement 30% Pumps 19% Fans 19%

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Figure 3.2 ECG 1 (NEMA Design A & B) Electric Motors Shipments by Horsepower Rating for 2012 (DOE 2014, Technical Support Document - Energy Efficiency Program for Consumer Products and Commercial Industrial Equipment - Electric Motors, U.S. Department of Energy, Washington, DC, May 8, 2014, p. 3-23)

5 HP = 13.2%

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Figure 3.2 ECG 1 (NEMA Design A & B) Electric Motors Shipments by Horsepower Rating for 2012 (DOE 2014, Technical Support Document - Energy Efficiency Program for Consumer Products and Commercial Industrial Equipment - Electric Motors, U.S. Department of Energy, Washington, DC, May 8, 2014, p. 3-23)

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

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Dept. of Energy (DOE) was given the task of establishing regulations for the various AC Induction direct by the EPAct Law.

It took them a little over 5 years before the regulations went into effect in October 1997.

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The original EPAct Law gave the DOE the

responsibility to periodically evaluate the need for higher energy or power efficiencies for electric motors every 5 years.

By mid 2010 there was a number of discussions, papers and conference presentations about evaluation the electronic drives or variable speed drives for higher efficiencies.

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1. Initially focused on 1HP to 200HP 3 phase 60hz AC Induction Motors Starting in 1997.

2. Extended coverage to 500HP AC Induction Motors in 2007.

3. Will cover more G.P. Motor types the year (June)

4. New Small Motor Rule (1/4 to 3HP) implemented. Covers Single Phase CPCR & CSIR Motor Types Plus 3 Phase.

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• 1-500HP Squirrel Cage Single Speed Motors • Continuous Operation • 3 Phase 60HZ Line Power • 2,4,6&8 Pole Configuration • 600 volts or less • NEMA 3 Digit Frame Sizes & Enclosed 56

Frame and IEC Equivalent. • NEMA Design A,B,C & IECN & H Performance

Requirement

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Added Special & Definite Purpose Motors to General Purpose

Gear Motors Vertical Motors TENV Configurations Encapsulated Motors Partial Motors

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Small AC Motors ( Small Motor Rule) DC Motors Multi Speed Motors Medium Voltage Motors (Above 600 Volts) Water Cooled Motors Design D Motors Submersible Motors Intermittent Duty Motors Synchronous AC Motors PM AC Servo Motors

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Lower Rotor & Stator Lengths Better Magnetic Steel Laminations Thinner Stator Laminations More Copper Full Copper Rotor Synchronous Motor Types Change Rotor Slot Shapes Change The Stator Windings (Dual Windings)

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The DOE decided to hold the IHP Efficiency levels at Premium Efficiency levels for the U.S.= IE3 in Europe.

Various individual motor suppliers from Brazil, U.S. & Europe have developed IE4 motor products.

Some have reached IE5. Others are working on higher efficiency

levels.

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Two special very small motors

IHP-IE4 (Super Premium) & IE5 (? Premium) Motor Efficiency.

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Preliminary Testing at Oakridge National Lab. 12 watt evaporator fan motor. Shaded Pole -20% Power Efficiency 1 Phase PSC – 29% Power Efficiency Brushless DC – 60% Power Efficiency Q-SYNC PM-AC 73% Power Efficiency Special Controller that directly plugs into the

grid. Currently in Beta testing in Supermarkets.

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SMMA 2014 48

New family member Motor output – 120 Watts (1/6 HP) Lower cost version of AXU and BX Direct 50:1 Speed Ratio Speed Regulation+/-0.2% 3.54 inch Square Motor Frame Motor Efficiency – 82.8% Has a Dedicated Drive DOE 3 phase motor efficiency 1/4HP-68.3%

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SMMA 2014 50

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DOE has kept the Premium Efficiency level (IE3) in the latest motor rule.

Europe is still working on adopting the Premium Efficiency level (2017) (IE3).

While the Induction Motor is still King, it is being challenged by the PM Motor and the two Reluctance motors.

Higher Motor efficiencies above (IE4) will not be squirrel cage AC Motors .

The Hidden Power Drain for motors is the Power Factor.

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The EU Preliminary standard for establishing higher IE levels is to reduce the motor losses by 20%. The motor manufacturer is already using this standard.

The most important parameter is performance/cost.

The most important energy parameter is Efficiency X Power Factor.

The top motor efficiency achieved is 98.3% at 2400rpm rated speed. Rated Power Level is 1800watts or 2.41HP.

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The top Brushless PM Motor is the Axial Flux Motor. The major focus for the DOE & NEMA is the VFD

efficiency improvements which will be increasingly used to drive electric motors.

Parallel efforts by DOE for improving efficiency in Fans, Pumps and Compressors.

The DOE focus for efficiency will be extended into the motion system

The money saved in the U.S. for using less energy to pay for electricity will be hundreds of millions of dollars.

Can we reach 99%? Can we measure 99% performance?

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