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Motor Revolution: Synchronous reluctance motor technology
Electrical Enineering Institutions Lecture Program 2014 – Csaba Szabo ABB Australia 10/07/2014
SynRM package
© ABB Group
8/26/2014 | Slide 2
Why we do this?
Today's technology makes it feasible
Very high motor or system efficiency
To be used where application already
demands variable speed
Results: competitive VSD package with very
high efficiency, unobtainable with traditional
induction motors
SynRM - Technology review
Synchronous reluctance technology History - key technology steps
© ABB Group
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2010 2005 1989 1960’s 1923 1998 1888
(d) Iron Segment
Magnetic Barrier
(Normally Air)
(No) line start capability
(a) Simple salient pole (SP) rotor
(b) Axially laminated anisotropy (ALA) rotor
(c) Transversally laminated anisotropy (TLA) rotor
(d) J. K. Kostko 1923 (original patent)
(e) ABB Synchronous reluctance servomotors
(f) ABB Synchronous reluctance motor and drive package
(e)
(c) (f)
Synchronous reluctance technology
Design concept
Single sheet of punched electrical steel
The sheets stack to a complete rotor body.
Can either be stacked on a pre-assembly
piece or direct on the shaft.
Mounting the rotor body on a shaft. The rotor
will be balanced after shaft assembly.
The rotor body inset in a stator. A standard
stator 4 pole design is used but with adapted
winding.
© ABB Group
August 26, 2014 | Slide 5
Synchronous reluctance technology Rotor construction
© ABB Group
8/26/2014 | Slide 6
Synchronous reluctance technology Function compared to induction motor
© ABB Group
8/26/2014 | Slide 7
R R R
R R R
T
T
T
S
S
S T
T
T
S
S
S
R R
R R
S
S
T
T
T T
T
T
T T
S
S S
S
S
S
R
R
R R
R
R
Induction motor Synchronous reluctance
motor
Elimination of
resistive rotor losses
New innovative motor and drive packages
Standard motor + special rotor
Standard cast iron frame
Special wound stator using standard materials
Same auxiliaries and options available as for
induction motor (500+)
Special cageless rotor
removes rotor iron losses
reduction of total losses up to 40%
less heat and higher efficiency
The technology for variable speed applications
8/26/2014
© ABB Group
Standard motor
+
special rotor
Standard drive
+
new software
Revolutionary
drive package!
| Slide 8
New innovative motor and drive packages
Synchronous reluctance motor needs a
drive (ACS850)
Can replace most of the variable speed
driven induction motors in quadratic torque
(pumps, fans) and constant torque
applications
Reliable high efficient “workhorse” for
general industrial applications
The technology for variable speed applications
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© ABB Group
| Slide 10
Standard motor
+
special rotor
Standard drive
+
new software
Revolutionary
drive package
SynRM Package features Two approaches
© ABB Group
8/26/2014 | Slide 12
Key to success
Losses
Elimination of rotor losses
I2R
Stator
I2R
Rotor
Other
I2R
Stator
Other
I2R
Stator
Other
IE2 induction motor
IE4 SynRM motor
High Output SynRM motor
100%
60%
80 -90%
New innovative motor and drive packages
Two approaches: High output or IE4 Super premium
efficiency
The technology for variable speed applications
8/26/2014
© ABB Group
| Slide 13
New innovative motor and drive packages
The High Output SynRM package
Reduction of losses means cooler motor
Smaller motor for same application
Up to two frame sizes smaller
Enables more compact machinery
Weight reduction
More power from same size
Improve process performance
Jump to next output level without mechanical
changes to existing machinery
The technology for variable speed applications
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© ABB Group
| Slide 14
Same power - smaller motor What does smaller size mean in practice?
© ABB Group
8/26/2014 | Slide 15
Same output from a
smaller size or higher
output from the same
size
Same power - smaller motor What does smaller size mean in practice?
© ABB Group
8/26/2014 | Slide 16
Reduced system
space – lower weight,
easier installation
Two new innovative motor and drive packages
The IE4 Super Premium Efficiency SynRM package
Energy losses reduced by up to 40% compared to IE2
efficiency class
Energy savings
Output versus shaft height corresponds to IEC & AS/NZS standards
Interchangeable with IE2 induction motor IE2 induction can be used as spare Easy to give it a go!
The technology for variable speed applications
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© ABB Group
| Slide 17
New revolutionary motor and drive package
Compactness and efficiency of permanent
magnet motor
Service friendliness of induction motor
Magnet free design
No magnetic forces
No special tools
No special training
If you can service induction motor you
can service SynRM
© ABB Group
8/26/2014 | Slide 18
Significant benefits
New revolutionary motor and drive package
© ABB Group
8/26/2014 | Slide 19
Higher reliability
Higher reliability through lower bearing temperature
Less heat in rotor
Less heat transferred though shaft to bearings
Grease will last longer and maintain better
lubrication
Less maintenance and down time
New revolutionary motor and drive package
Designed exclusively for
variable speed operation
Insulation technology
suitable for voltage peaks
and added harmonics
stress.
Package efficiency verified by
ABB
Test report stating real use
efficiency available for each
package (state of the art
measuring equipment)
© ABB Group
8/26/2014 | Slide 20
High package efficiency
New revolutionary motor and drive package
Packages available for quadratic and constant
torque applications
Competitive product offering compared to traditional
or other new technologies
High output: 1.1 – 350kW
IE4: 11 – 355 kW
Advanced open loop control software
No separate tacho or encoder needed
Global ABB support
© ABB Group
8/26/2014 | Slide 21
Get the best of two worlds
New revolutionary motor and drive package Current Ranges - 3000 rpm, 2100 rpm, 1500 rpm
© ABB Group
8/26/2014 | Slide 22
100Hz = 3000rpm, 70Hz = 2100rpm, 50Hz = 1500rpm
New revolutionary motor and drive package Load-ability
© ABB Group
8/26/2014 | Slide 23
SynRM Advantages
How much does a motor cost?
8/26/2014
© ABB Group
| Slide 25
65 % of total electricity at industrial sites is
consumed by electric motors
Motor purchasing price corresponds to 8 to
12 weeks of its electricity consumption
The capital cost will represent only 1% of the
total life cycle operational costs of the motor
Reliable motors with a high efficiency level
ensure the lowest life cycle costs
One 75kW Motor cost ............25 years to run 24/7? $90,000 Life time cost of power $2,250,000............ save............6% $135,000
High output SynRM motor and drive package Advantages in a nutshell
© ABB Group
8/26/2014 | Slide 26
IE3 – compact design
without compromising
efficiency
Full range
Verified package
efficiency Induction motor on the
outside, innovative inside
Same size motor,
higher power
Same power,
smaller motor
Powerful, yet highly compact motors up to two
frame sizes smaller than conventional motor.
Variant codes and mechanical constructions
based on the proven M3BP cast iron Process
performance motors.
No magnets, no cage.
Competitive product offering compared to
traditional or other new technologies.
Higher reliability through lower bearing
temperature.
Higher efficiency than conventional VSD fed
induction motors.
High output SynRM motor and ACS850 drive package Motor highlights
© ABB Group
8/26/2014 | Slide 27
Modular structure – you pay only for the options you
need.
Runs any motor – Induction, permanent magnet and
SynRM motors.
Memory module – you can fine-tune drive settings
and store them on the memory module.
Slim design – the drive is designed to take up
minimum cabinet space.
Set up as easy as with induction motors - simply
enter the parameters from the motor. No feedback
devices like encoders or position sensors are needed.
High output SynRM motor and ACS850 drive package ACS850, Drive highlights
© ABB Group
8/26/2014 | Slide 28
System efficiencies
Current standards are focusing on separate
motor or drive efficiency determinations.
New standards (MEPS) will consider
system efficiencies due to motor – drive
mutual optimisation.
Verified system efficiencies
© ABB Group
8/26/2014 | Slide 29
What’s in the pipe line?
Low cost Ferrite magnets in the “flux-air-gaps”
Added constant flux
Further reduction of losses by approx. 20%
Ultra premium IE5 level of efficiency
Targeted range: 1 to 15 kW
Speed range: 1000 to 4000 rpm
New development: SynRM2
© ABB Group
8/26/2014 | Slide 30
New revolutionary motor and drive package
http://www.youtube.com/watch?v=LKgVXk72spY
http://www.youtube.com/watch?v=69mtuom774E&index=4&list=PLg4s1do3XuVlw
c1LnpyZgvfjd_o4wtA_D
The customer voice
© ABB Group
8/26/2014 | Slide 31
