Experience with PM motors

Motores | Automação | Energia | Tintas

Experience with PM motors

Carlos E. G. Martins – [email protected] Research and Technological Innovation Department - WEG Motores Rua Venâncio da Silva Porto, 399 - Malote 41 89252-230 - Jaraguá do Sul - SC, Brasil

4th International Motor Summit 2012 – Zurich, 5 December

4th International Motor Summit 2012 – Zurich, 5 December 2

Summary

Introduction

Applications for Permanent Magnet Motors

Characteristics of Different Topologies

Industrial PM Motors

PM Motors for Cooling Tower

PM Motors for Electric Vehicle

PM Motors for Compressor

PM Motor for Textile Industry

PM Motor for Extrusion Machine

Conclusions


account for up to 70% of EU electricity consumption

[1] P. Waide, C. U. Brunner, “Energy-Efficiency Policy Opportunities for Electric Motor-Driven Systems”, International Energy Agency (IEA), 2011.

Electric motor-driven systems

[1]

[1]

the single largest electrical end-use.

account for up to 46% of all global electricity consumption

Introduction


[2] A. T. de Almeida, F. J. T. E. Ferreira, D. Both, “Technical and Economical Considerations in the Application of Variable-Speed Drives With Electric Motor Systems”, IEEE Transactions on Industry Applications, Vol. 41, No. 1, Jan/Feb 2005.

[2] Variable-speed

drives

offer significant energy saving potential

PM motors increase energy savings, mainly

below rated speed

Induction motors

the most used drives in industry

robustness, reliability, simple operation

Introduction


PM motors have a significant higher efficiency in low speeds than the Induction motors.

One frame size smaller than induction motors: up to 43% reduction in volume and 35% in weight.

Do not need forced ventilaton, nor over sizing for constant torque operation.

Introduction


Pumps, elevators, compressors, blowers, extruders, generators, electric vehicles, servodrives, household appliances.

Applications for Permanent Magnet Motors


External rotor: high-torque, low-speed applications (i.e. washing machine, elevators), ventilation.

Characteristics of Different Topologies

Surface magnets: low-speed applications (i.e. ventilation, exhaustion, residential pumps, elevators).

Interior magnets: low and high-speed applications (i.e. blowers, compressors, pumps, elevators, electric vehicles).

Line-start: low-speed, low-inertia applications, direct-on-line connection (i.e. small fans, pumps)


Rare-earth PMs

Output: 1.1 – 315 kW

Frames: 80 – 315S/M

Rated speeds: 1500 and 3000 rpm

Super Premium Efficiency

One frame size smaller than induction motor

Same inverter as for induction motor (sensorless control)

Applications: compressors, blowers, pumps

Wmagnet Drive System (IPM Motor) Industrial PM Motors


Direct-online starting

Output: 0.37 – 7.5 kW

4 and 6 poles

Frames: 80 – 132M/L

Specially designed aluminum cage and rare-earth PMs

Super Premium Efficiency

Same power/frame as for induction motor

Applications: low-inertia loads

WQuattro (Line-Start PM Motor) Industrial PM Motors


Output: 0.8 Nm – 40 Nm

Speed: 2000 – 6000 rpm

Rare-earth surface magnets

Sinewave drive

High dynamic performance, speed and position precision

Applications: robotics, winding machines, textile machines, positioning systems, packing machines, lathes.

Servomotors Industrial PM Motors


Rare-earth PMs

Direct-drive: eliminates gear-boxes less maintenance and less mechanical losses

High-torque, low-speed motor

Drive with sensorless control

Power: 15 kW – 150 kW

Torques: 500 – 10000 NM

Speeds: 100 – 300 rpm

Frames: 355 – 450

Short axial dimension frames

Example of a 45kW, 200rpm, 2150Nm cooling tower motor.

PM Motors for Cooling Tower


Rare-earth PMs

Rated Power: 21 kW

Base speed: 3600 rpm

Maximum speed: 10000 rpm

Water cooled

PM Motors for Electric Vehicle

Water-cooled PM motor


200 hp screw compressor

New PM motor: 150 kW, 3600 rpm, IEC frame 250 S/M.

Previous induction motor: 150 kW, 2 poles, IEC frame 280 S/M.

Significant increase in compressor efficiency.

PM motor is one frame size smaller: reduced weight and volume.

PM Motors for Compressor


Application: yarn starching machine

Previous motor: ring induction motor, 15 kW, IEC frame 160M.

New PM motor: 15 kW, IEC frame 132S.

Significant increase in efficiency.

Enhanced process due to constant torque x speed.

Reduced maintenance costs and shutdown hours of the machine.

PM Motors for Textile Industry


Previous motor: DC motor.

Reduced maintenance costs.

Smaller size of motor.

21% annual energy savings.

PM Motors for Extrusion Machine

DC motor

WMagnet PM motor


PM motors have higher efficiency than induction motors: significant reduction in energy consumption.

Variable speed applications: PM motors are even more advantageous, because they do not need forced ventilation nor over sizing for constant torque operation.

Rare-earth PM motors are usually one frame size smaller than the induction motor counterparts.

This leads to a reduced volume and weight, and lower noise and vibration levels.

Since PM motors have no Joule losses in the rotor, bearing temperature is lower, and life time is increased.

Conclusions


Thank you!

Carlos E. G. Martins – [email protected] Research and Technological Innovation Department - WEG Motores Rua Venâncio da Silva Porto, 399 - Malote 41 89252-230 - Jaraguá do Sul - SC, Brasil

Experience with PM motors

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