Energy Efficient Appliances

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Why Energy Efficient Appliances ? The Need ….

Extracts from Bureau of Energy Efficiency’s presentationsExtracts from Bureau of Energy Efficiency’s presentations:– Energy is essential for the economic growth of the country– India is facing severe shortages on the energy supply-demand – Additional 100,000 MW required by 2012, costing approx Rs.

8000 Billion– Energy efficiency / conservation can reduce peak and average

demand– One unit saved, avoids 2.5 to 3 times of fresh capacity addition– Investment in energy efficiency is highly cost effective

contd…

The Need ….– BEE introduces Standards & Labeling program– Focus Products:

» Refrigerators, Air ConsRefrigerators, Air Cons » Lamps and Ballasts» Motors, Distribution Transformers » Agricultural pump sets

– Energy performance parameters to be monitored– Enforce minimum efficiency standards by prohibiting

manufacture, sale, and import of products not meeting the minimum standards

– BEE to recommend to Central Government on Labeling, introduce comparative labeling as the first step followed by minimum energy efficiency standards.contd…

The Need ….

What are we doing to comply with the Energy Conservation Act?

Key Objectives• Introduction to IR i-Motion & Deltech

» Brief about IR i-Motion & IRAM Module?» Design & Development - by Deltech

• Energy Efficient Appliances» Why Variable speed Refrigerator?» Why Variable Speed Air conditioner?» Comparison 3 & 1 phase Motor control

• Cost Vs Benefit Analysis» Benefits Variable speed drive» Cost Feasibility Analysis Refrigerator» Cost Feasibility Analysis Airconditioner» General concerns & Redressal

• Methodology» Technology Development Methodology» Technology Development Model» Action Items

Introduction to i-Motion & Deltech

Section-I

»Brief about IR i-Motion & IRAM Module?

Integrated Design Platform

Analog, HVIC Power Silicon IRAM ModuleDigital Control Technology

Software

IR has the capability to provide all necessary silicon for motion control with the highest performance and the lowest cost

IR i-MOTION – Integrated Design Platform for Motion Control

Complete Power Stage Solution for Low Power Motor drive application in a compact, cost effective module

IR IRAM Module - Intelligent Power Module

Bill Of Materials - Inside IRAM Module

IR21365

6x IGBT + 6 Anti-Parallel Diodes

6x Gate Resistors

3x Bootstrap Diodes + Resistor

1x 3-Phase IC Driver

Temperature/Current Protection

How Does the Product Work?Add bootstrap capacitorsSet RC values for desired

TTRIPAdd controller

(µC or DSP)Optional:

Add phase shunts forcurrent loop

Plug n drive the Motor

Benefits• Low EMI• Smaller PC Board requirements• Reduced system design time• Reduced assembly costs/time• Does not require additional isolation• Higher reliability (as compared to discrete solution)• Manage one SKU* versus 25

• Fewer parts to qualify• Fewer parts to manage inventory• Fewer parts for price negotiation and part ordering

*Stock Keeping Unit

$$ Reduced System’s Cost $$

Design & Development by by DeltechDeltech

Dalmia Electrodyn TechnologiesDalmia Electrodyn Technologies DeltechDeltech

Mission StatementMission Statement

Deltech will be a Premier Provider of Cost Efficient, Leading Edge Embedded Control Solutions in the Mixed Signal Domain, for Mass Market Products

DeltechDeltech Embedded ControlsSTRENGTHS

• Team of experienced professionals lead by– Dr.R.Ramarathnam, Managing Director

» B.Tech from IIT, Madras and M.Tech & Ph. D. – IIT, Bombay (Expertise on Motors, Power Electronics and Embedded Controls)

• Expertise in system integration & interfacing and handling mission – critical projects

• Excellent support in application engineering• Established track record of product development• Seamless Integration of Analog/Digital domains• Very Good R&D facilities

Deltech Deltech Embedded Controls

• Specialist R&D House in Embedded Controls– Patented Innovations for licensing – ODC and Contracted R&D

• Areas of Specialization– Appliances– Automotive – White Goods – Factory Automation

Vision

Solutions ….

International Rectifier & Deltechbrings solutions for

Power Saving & Energy Efficiency in Appliances

Energy Efficient Appliances

Section-II

»Why Variable Speed Refrigerator?

Refrigerator

RefrigeratorsRefrigerators account for up to 20% of energy usage in a home. Conventional refrigerators equipped with single phase RSIR/CSCR/CSIR motors work only at full speed. EC motors work at variable speed to reach the target temperature more smoothly. This allows for up to 30% energy savings.

Why?

Conventional Frostless Variable Speed RefrigeratorVsComparison

Conventional Vs Variable speed Refrigerator

•Higher energy usage because of timed de-frost cycle which must be designed for worst case conditions

•Enclosure heat loss is higher because temperature must be lowered beyond set point.

•Compressor is larger than needed because it needs to reduce temperature below the set point.

•On-off thermostat causes wide hysteresis (6 to 10°F) and poor energy efficiency.

•De-frost energy is minimized by comparing evaporator temperature with enclosure temperature and initiating de-frost cycle only when needed.

•Negligible heat loss due to operation at fixed temperature without hysteresis.

•Analog to digital thermostat continuously controls compressor speed in response to heat loss and optimizes energy usage.•Compressor capacity is optimized for enclosure heat loss only.

Improving Efficiency in Refrigerator

• Most of the energy used by a refrigerator is used to pump heat out of the cabinet. A small amount is used to keep the cabinet from sweating, to defrost the refrigerator, and to illuminate the interior.

• Improved energy efficiency can be achieved through:– Addition of vacuum insulation panels (too expensive)– Increased door and wall thickness (not acceptable by the market)– Addition of polyurethane foam to the doors to double insulation

thickness problems for pollution (material)– Replacement of automatic defrost control with an adaptive defrost

that operates only when needed– Replacement of AC motors with more efficient DC motors

• The most cost-effective solution is via variable speed electronic motor control

Present Refrigerator Technologies• Single-phase RSIR/CSCR motors power most of the present refrigerator compressors• An On/Off thermostat carries out the temperature control• No or Less Electronics• High-end frost-free models presently have timers and ElectronicsMerits & Demerits of Present MethodsMerits: • Simple ON/OFF control & proven technology Demerits:• Energy intensive and inefficient• As the demand for power and torque increases the motor becomes bulkier and expensive• Single-phase motors have low power to weight ratio• Since the motor is selected for peak duties the capacity of the motor is not optimal• High inrush makes it incompatible to low Power Backups viz. Generator/Inverter• Threatened obsoletes just like 2 stroke motor-bike technology

Present Technologies

»Why Variable Speed Air conditioner?

Why Variable speed Air conditioner?

Energy Efficiency

Room air conditioners are now being assigned an efficiency rating, known as energy efficiency ratio (EER). The EER is defined as the cooling output (in Btu per hour) divided by its energy input (Watts) at specified indoor and outdoor temperatures. The minimum EER allowed is between 8 and 10, depending on the capacity and type of unit. A higher rating means more efficiency. The best available EER is about 13.These specifications are regulated by the Department of Energy in US & by Bureau of Energy Efficiency in India.

Variable speed Air conditionerInverter Driven Air Conditioners Technology used in AC inverter air conditioners, control the electrical current frequency to the compressor according to the cooling and heat load of a room for optimum performance. Inverter technology promotes maximum compressor efficiency by adapting the rotation speed to accurately match requirements and offer finely-tuned operation. AC inverter air conditioners can reduce electricity consumption by up to 30% when compared to non-inverter units.

» Existing & Future Aircon Technology

Existing & Future Aircon Technology

• Single phase motors are used up to 1.5/2 ton capacity air-conditioner compressors. Beyond 2 ton, three phase motors are used.

• Both are bulky, without drive mechanism & less user friendly. Thus it’s with» No Electronic Controls, » Poor efficiency, » Large size, » No Mass appeal

Existing Aircon

• Three phase motors will be used in all Aircon compressors with Electronic controls.• Lower capacity AC segment also, Single phase motors will be phased out giving way to more efficient, less bulky, with drive three phase Compressor & fan motors. Hence, Future Aircon will be-

» Trendy, » User Friendly» More efficient, » Affordable

Future Aircon

Availability of the Technology

Reliability of the Technology

Technology available for over a decade or more & Now IR cost effective Inverter Modules are available for bulk purchase.

Earlier Commercial viability could not be established due to high Technology & Inverter component costs.

Now IR i-motion family has enabled low cost & high performance solutions for high volume applications

Technology is proven & Reliable

Laboratory tests have proved that it makes machine to perform better & improves the life of moving components.

Performance of the TechnologyDemo unit is ready & concept may thus be demonstrated

Performance however proven, may be evaluated

Also, No need of stabilizers i.e. product becomes all terrain & rugged

Automatic control of blower fan

Product improves EER/SEER ratings

Present Technologies Single-phase RSIR/CSCR motors power most of the present air conditioner compressors up to 2 ton capacity An On/Off thermostat carries out the temperature control No or Less Electronics

Merits & Demerits of Present Methods

Merits:  Simple controls & proven technology

Demerits: Energy intensive and inefficient low capacity segment Single-phase motors have low power to weight ratio Since the motor is selected for peak duties the capacity of the motor is not optimal up to 2 ton capacity High inrush generally makes it incompatible to Power Backups viz. Generator/Inverter Threatened obsoletes just like 2 stroke motor-bike technology

Present Technologies

» Comparison 3 phase Vs 1 Phase Motor Control

Parameter Single Phase Motor + Control Three Phase Motor + Control

Size Bigger motor for a unit output For the same power the size of the three-phase motor reduces to 2/3rd size of single-phase motor. Can be further optimized for the loading requirements.

Starting Needs Auxiliary winding, Capacitor for starting. The quality of the auxiliary winding & Capacitance defines the starting characteristics

Inherently self-starting with good starting torque. No Capacitor required

Windings Presence of a optimized auxiliary winding to generate Cross field

Balanced three phase active windings uniformly distributed in all equal slots

Operational merit

Pulsating torque Uniform Torque is operational merit, since it sets up a revolving field in the air gap

Comparison 3 & 1 Phase Motor Control Configuration

Parameter Single Phase Motor + Control Three Phase Motor + Control

Iron Content

Iron Content is Higher Minimum Iron content and optimal to a design

Copper Content

Copper Content is Higher For the same power the copper content is typically 25% less than single phase motors

Speed Control

Not popular, Non-standard designs and expensive control. Reversing through complex mechanisms and step speed change by only pole changing

Very popular and Highly standardized and economic. Easy speed reversal through phase sequence reversing. Variable speed is achieved by simple Voltage/Frequency control

Motor Speeds

Limited to the mains frequency Can be increased beyond 50Hz to deliver more cooling capacity when required

Comparison Contd…

Section-III

Cost Vs Benefit Analysis

» Benefits Variable speed drive

Refrigerator

Benefits Variable speed drive Refrigerator• Soft start without demanding peak mains Input

• Elimination of on/off duty increasing reliability of Mechanical Components

• Energy savings

• Minimal Noise Vibration

• Feature Enrichment

• Software Control

• Ease of Compatibility with standby power source viz. Household Gen-set or Inverter

» Cost Feasibility Analysis

Volumes Drive Costs

Typical VSD control for a 100-Watt Refrigerator Compressor

BOM costs for Electronic Basic Variable speed drive

In Quantities of 20,000 - Rs. 1200/- * and

In Quantities of 100,000 - Rs. 760/- *

Note (*) -- Target System can be developed Cost Negative/ Cost Neutral- Costs may vary vis-à-vis volumes/ costs prevailing at the time of actual ordering Above costs are indicative only.- It may be possible to drive costs further down in case 1m units are targeted as indicated

Tentative Electronic Drive Costs

Cost Per Drive unit

Volumes Produced20000 No’s 100,000 No’s

Rs 1200/-

Rs 550/-target

Rs 760/-

1,000,000 No’s

Drive is Cost Negative / Cost Neutral ?Implementing Variable speed drive enables-

• Possible reduction in motor costs – 25%

• Elimination of components used in present control – XX%

• Addition of Electronic Motor Control – YY%

• Further the compressor speeds can reach – 135Hz

• In absolute terms a smaller compressor will deliver higher cooling capacities

• Savings in compressor costNote:

Can be Driven cost negative for premium segments (with sufficient electronics) & Cost neutral in Mid range Appliance (with less electronics) & Marginal or Negligible increment in direct Cool segment

Costs Involved

Components (added for implementing drive)

a) Three phase control electronicsb) Thermistor for Appliance temperature control

Optional Components (for added features @ extra cost)

a) User Interface b) Visual controlsc) Thermistor for Motor Temperature sensingd) …

Savings from Elimination of Electrical components

Drive Eliminates Following Components of Conventional system

• Defrost Timer• Capacitor if Motor is CSCR / PSC• Over Current relay• Heater Control Switch• Thermal Overload Protection, which can be replaced by

Thermistor• Bulky Thermostat (Which will be replaced by Thermistor)• Savings in Converting to three Phase Motor• Other Electronics, if any

Further The manufacturer to estimate savings through reduction in following other/ Mechanical Components

1.      Savings in Cubicle/Thermal Volume?

2.      Savings in heat reservoirs/ Linings?

3.      Savings in PUF?

etc…

Savings from Elimination of other components

Cost Vs Benefit Analysis Air-conditioner

Section-III

» Benefits Variable speed drive

Benefits of implementing Variable speed drive• Soft start without demanding peak mains Input

• Elimination of on/off duty increasing reliability of Mechanical Components

• Energy savings

• Minimal Noise & Vibration

• Feature Enrichment

• Software Control

• Ease of Compatibility with standby power source viz. Gen-set or Inverter

» Cost Feasibility Analysis

Volumes Drive Costs

Typical VSD control for a 1.5-ton Air-conditioner Compressor is highly competitive.

Due to a lot of factors including availability costs may vary.

Note (*) --Costs may vary vis-à-vis volumes/ costs prevailing at the time of actual ordering Above costs structures are indicative only. - It may be possible to drive costs further down in case 1m units are targeted as indicated

Tentative Electronic Drive Costs

Cost Per Drive unit

Volumes Produced20000 No’s 100,000 No’s 1,000,000 No’s

Rs. X

Rs. X less y%

Rs. X less z%

Drive is Cost Negative / Cost Neutral ?Implementing Variable speed drive enables-

• Possible reduction in motor costs up to 2 ton capacity– 25-40%

• Elimination of components used in present control – XX%

• Addition of Electronic Motor Control – YY%

• Further the compressor speeds can reach – 135/150Hz

• In absolute terms a smaller compressor will deliver higher cooling capacities • Savings in compressor cost

Costs Involved

Components (added for implementing drive)

a) Three phase control electronicsb) Thermistor for Appliance temperature control

Optional Components (for added features @ extra cost)

a) User Interface b) Visual controlsc) Thermistor for Motor Temperature sensingd) Remote control

Savings from Elimination of Electrical components

Drive Eliminates Following Components of Conventional system

• Capacitor if Motor is CSCR / PSC up to 2 ton capacity• Thermal Overload Protection, which can be replaced by

Thermistor• Bulky Thermostat (Which will be replaced by Thermistor)• Savings in Converting to three Phase Motor in the lower

capacity segment• Capacitor for PF improvement above 2 ton capacity• Other Electronics, if any

Further The manufacturer to estimate savings through reduction in other Process or Mechanical Components

1.      Savings in Process ?

2.      Savings in Mechanical components ?

3.      Overall Savings after implementation ?

etc…

Savings from Elimination of other components

» General Concerns & Redressal

Concerns Redressal

a) Component Changeover

Motor – Negligible Change is required to make 3 phase motor

Electronics – Can be outsourced as a entire assembly, If the manufacturer possesses the capability of Motors & Electronics the effect is minimum

b) Parallel operation of 1 and 3 phase motor winding –

Motor - Intelligent tooling activities can lead to negligible loss of time in process change. Same single phase machine may be used to Produce 3 phase Motors.

Electronics – Simple adoption if the process is captive

Feasibility Study in adopting 3 phase design

c) Technology appraisal– Early dissemination of the technology across the board once the decision of technology change is considered. Benefits of change should be punched properly down the line

d) Training – Aided/Augmented by the guidance provided by technology developer and component supplier

e) Compressor

Development of Higher speed compressor.Higher speed brings the rationalization of compressor models

Note : The increased power density of the compressor should be the Drive & Motive

Feasibility Study in adopting 3 phase design contd…

Methodology

Section-IV

» Technology Development Methodology

DEVELOPMENT METHODOLOGY

• Demonstration of a conceptual model

• Customer engagement and Sign off Non Disclosure Agreement

• Specification Exchange

• Agree to a development specification

• Agree on a Development cost based on Time & material basis

• Agree to a business understanding before development process in form of MoU

• Development of Prototypes

• Prove out the prototypes

Methodology

• Conduct External/ Statutory reliability tests if any Sign Final Agreement

• Release Pilot batch Documents

• Pilot Batch Feedback correction

• Release mass manufacturing documents

• Customization/s for other products

• Technology Up gradation & Support

Development Methodology contd…

» Technology Development Model

Technology Development ModelCommercial Models

a) Prototype development costs will be borne by customer (Time & material model) OR

Alternatively retainer basis (Specific group dedicated to client requirements) model for time charges+ Material costs

b) Technology Upfront/Commitment fee with the signing of agreement (Depending on the Segment, Market size, Geography, Exclusivity/Non-Exclusivity)

c) Per unit Royalty [Based on commercial model point No.(b) above]

d) Customization Charges on each model. + Time & Material Cost

e) Technology up gradation Charges. + Time & material cost

Action Items/Questions

ACTION ITEMS

• Can we Identify more applications the Technology

• TAM and SAM for these products

• Feedback

Thank you