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IEEE Miami Section Energy Systems Research Laboratory
Florida International University
March 22, 2013
Recent Advances in Electric Machine Design
and Operation
By Jim Hendershot, IEEE Fellow
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In planning a SPEECH OR LECTURE I was once advised to employ the design principles frequently used by fashion designers for “MINI-SKIRTS” Therefore in preparation for this lecture I have tried to adhere to those important principles which are: 1- MAKE IT SHORT ENOUGH TO MAINTAIN ` AUDIENCE CONCENTRATION ! 2 – MAKE IT LONG ENOUGH TO COVER ALL THE ESSENTIALS !
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Origins of electric machines
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I assume by now that many of you think you know a lot about the origins of electric machines and most of you were taught that they have been around for only about 150 years give or take. Well I have a surprise for you !! Electric motors have been around for thousands of years or even longer. If you don’t believe me I have photographs and models of these early motors coming up. They are inside each of our bodies, as well as in the food and beverages we intake each day Biologists call them Bacterial flagella motors
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First known electric propulsion motor
Microscopic Bacteria
Propulsion Motors Plastic model of first motor
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Bacterial flagella propulsion motor
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45nm diameter with 20 parts & spins several hundred Hz cw & ccw Spins filaments like fish tails for rapid propulsion in liquids
Prof. Howard Berg
Harvard University
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One of Tesla’s first motor prototypes
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Another of Tesla’s examples
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What resulted from Faraday & Tesla’s (plus others) efforts over the last 120 or so years ?
Single phase powered AC induction motors Three phase AC induction motors DC motors, shunt, series ,compound wound and permanent-magnet
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Motors consume about 67% of USA grid power. (Ref: DOE)
Single Phase Induction Motors Line start AC Induction Three Phase Motors VFD (variable speed drives) DC motors, Steppers, brushless DC, switched reluctance & even VFD systems (variable speed drives)
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AC induction motor speed controlled by frequency (according to pole number)
DC motor speed is controlled by DC supply voltage
A.C. Motor Torque/Speed Curve
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Two most popular motors types from the 20th Century
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Two pole wound field Commutated motor (AC or DC powered)
Examples & details of Modern DC motors
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MAXON Slotless DC GEMOARTOR
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Cross section of modern AC induction motor
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Modern Reliance high performance AC Induction Motor.
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Large Dual Fed AC Machine by Siemens
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Single Phase Die Cast Aluminum Rotor
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Wound rotor AC Induction machines
Formerly used for lifting crane drives Currently used for wind turbine generators.
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Die Cast Copper Rotors
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AC Induction Torque vs. Speed Curve Driven with a Field Controlled Inverter
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By Andrew Frazer, Murdoch University Using Infolytica Magnet
Line start grid powered AC single or three phase rotors
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New motor technologies driven by inverters & microprocessors Stepping Motors PM Brushless DC PM-AC Synchronous (SPM & IPM) (axial & radial) Switched Reluctance Synchronous Brushless Reluctance Synchronous Brushless Linear machines of all above types
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Hybrid & PM Stepping motors
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BRUSHLESS & PM-AC SPM & IPM ROTORS
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High performance stator encapsulated in thermal conductive epoxy. Note liquid cooling jacket around stator. AC PM Synchronous motors and inverters used for high speed machining in machine tool spindles. ATE System GmbH
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High copper fill used in FORD Hybrid Vehicles
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STATOR EXAMPLES OF HI-SLOT FILLS AND SHORT END TURNS
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Automated hair-pin stator windings 60 slots & 10 poles REMY CORP.
2010 Toyota Prius Motor & Generator Parts
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IPM rotor stampings used in TOYOTA hybrid vehicles
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NOVA-TORQUE Axial-Cone-Flux (Inside Cone)
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NOVA-TORQUE Axial-Cone-Flux (Outside Cone)
QM POWER Hybrid PM-SR Motor
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Torus Axial Flux PM Synchronous Motors
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EXRO direct drive multiple PM generators for wind turbines
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Brushless motors with no magnets Switched Reluctance Simple construction Robust & low cost Can be noisy Difficult to control
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Switched Reluctance Starter/Generator For Gas Turbine Heavy Fuel Engine
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Switched Reluctance motors with no magnets
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2 Phase SR motor replaces AD-DC brush type motor
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ABB Reluctance Synchronous motors & Inverters
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In order for RSM machines to be technically competitive the ratio of inductance (Ld/Lq) must be greater than 5 and closer to 9.
RSM (Reluctance Synchronous)
ABB ABB
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Remy Corp.
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From Battery powered portable tools
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Battery operated brushless power tool motors
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Some important applications using high performance AC induction motors and
drives
Powered by:
Field Controlled Inverters
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AC, PM & SR LINEAR MOTORS
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Largest Atom Smasher in the World Hi-Speed Mag-Lev Train
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SONY Humanoid Robot
New white goods appliance in every US home by
middle of 21st Century
(Remember you heard this first from
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Tesla sports car and 3 – phase AC Traction Motor
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Two seat 1600 lb sports car by Ian Wright in an Ariel Atom chassis Acceleration, 0 – 60 in 2.9 sec, ¼ mile in 11.5 sec, 236 HP, 3 Phase
AC induction motor and drive by AC Propulsion, batteries A123 Systems
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Wheel Traction Motors
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Rotor & Stator by REMY
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2010 PRIUS ELECTRIC DRIVE
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Siemens four pole AC tractions mounted on a transmission
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CATERPILLER PM GENERATOR AC TRACTION MOTOR & INVERTER
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US NAVY & American Superconductor
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More Generators for large wind turbines
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WWOW!! 13 M dia. & almost 500 KG of rare earth magnets!!
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SLM Synchronous twin PM rails attached to underside of car & (32) 3-phase stators attached to track.
AC Induction or PM synchronous coaster launchers
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Flywheel Batteries using Halbach PM electric generator
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Flywheel Batteries using low loss RSM electric generator
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Hi powered electro-magnets with no PMs or iron.
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45 Tesla Magnet construction
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Bitter plates of thin copper sheets, insulated and spiral stacked to form a very flat wire coil to facilitate liquid cooling.
(3) Concentric coil stacks
Reference books on electric motor theory and design: (AVAILABLE ON AMZON)
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ISB 0-19-859369-6 ISBN 0-19-859389-9 ISBN 978-0-9840687-0-8
ISBN 0-9745470-2-6 ISBN 978-0-470-69516-6 ISBN 978-1-1182-1529-6
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Thank you very much for attending, Jim Hendershot 3-21-2013
I sincerely hope some of my remarks have awakened your creativity and stimulated some new thoughts and perhaps even some new inventions regarding electric machines and magnetics in general.
This is only the beginning of the electric motor and drive revolution !! We need to motivate and educate at least 250,000 Electric Engineers