Saving energy and costs in electrical drive systems

Getriebemotoren \ Industriegetriebe \ Antriebselektronik \ Antriebsautomatisierung \ Services

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Saving energy and costs in electrical drive systems 1

EML / Doppelbauer / March 2007

Dr.-Ing. Martin Doppelbauer

Manager Motor Development and DesignSEW Eurodrive GmbH & Co KGD-76642 Bruchsal


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Outline

• SEW Eurodrive – Who we are and what we do

• Basic facts on energy consumption; Worldwide standardization

• Some technical aspects of electrical energy efficiency in drives

• Case studies, real life examples


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SEW Eurodrive GmbH & Co KG

1.5 billion € Turnover 11 Production Plants 1.5 mill. Geared Motors p.y.11.000 Employees 60 Assembly Plants100% privately owned (all figures 2006)


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SEW industrial product range

Induction Motorsfrom 0.1 kW to 200 kW

Permanent Magnet Motorsfrom 0.5 Nm to 100 Nm

Standard Frequency Invertersfrom 0.37 kW to 132 kW

Servo Controllersfrom 2 A to 100 A

... and much much more

Helical-, Bevel-, Worm-, Spiroplan-Gearboxesfrom 50 Nm to 50,000 Nm

Industrial Gearboxesfrom 10 kNm to 10,000 kNm

Mechanical Motor Brakes from 0.5 Nm to 2,000 Nm

Automation Controls(Axis Controller, PLC, Industrial Networks, ...)

Automation Systems(Electric Monorail Systems, Automatic Guided Vehicles,Roller Conceyors, ...)

Helical-, Bevel-, Planetary- Servo-Gearboxesfrom 25 Nm to 3,000 Nm


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Consumption of Electricity in Germany in 2002

Total: 60,7 Mio t coal equivalents = 494,3 billion kWhSource: VDEW-Materialien, M-19/2003, http://www.ag-energiebilanzen.de


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Classes of Industrial Motors

# of Pieces Total Powerin Germany 2005 in Germany 2005

Small-Power Motors 162 Mio 13 Mio kWDC / Single-Phase; 5 W ... 500 W(Domestic and Automotive Market)

Three-Phase Induction Motors 4.4 Mio 14 Mio kWLow-Voltage; 500 W ... 500 kW(Industrial Market)

Large Motors 7600 4.7 Mio kWHigh-Voltage; > 500 kW(Industrial Market)

(Source: Statistisches Bundesamt / ZVEI)

>75% AutomotiveVery low total operating time

Typical Efficiencies > 95%

Typical Efficiencies 70%...90%Largest saving potential


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Worldwide standards on energy efficiency motorsUSA, Canada High-Efficiency mandatory (EPACT, CSA C380-98),

Premium-Efficiency is implemented (NEMA MG1)

Panamerika High-Efficiency currently being implemented (Bs As CT 152)

Brasilien High-Efficiency is implemented (NBR 7094)

Indien High-Efficiency is implemented (IS 12615:04)

Japan High-Efficiency is imlpemented (JIS C 4212)

China High-Efficiency is implemented (GB18613),Two Premium-Efficiency Classes are under discussion

Taiwan High-Efficiency is implemented (CNS C4482-2003)

Thailand High-Efficiency is implemented

Australien/NZ High-Efficiency is mandatory (AS/NZS 1359.5),Premium-Efficiency is implemented

IEC 60034-30 New project has been started (2/1422/CD)


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Sales share of 4-pole eff1, eff2 and eff3 motors

Source: ZVEI, 2007


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Energy efficiency of eff1 and eff2 motors

70,0

75,0

80,0

85,0

90,0

95,0

100,0

1 10 100

eff1

eff2

%

Motor power [kW]

15...20%cost increase

15...20%cost increase


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Energy saving potential of eff1 compared to eff2 motors

2 shifts per day240 working days per year100% average workload

10 cts per kWh energy cost

0

1

2

3

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9

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1 10 100Motor pow er [kW]

Ener

gy S

avin

gs [%

]

0

50

100

150

200

250

300

350

400

450

500

Ener

gy S

avin

gs [€

per

yea

r]

% €/year


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Super Premium – the next step ?

high

low

Ene

rgy

Effi

cien

cy

low highCosts

BelowStandard

*Standard

**High

***Premium

Cage induction motors

SuperPremium ?New

Technologies


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Preconditions for effective use of high-efficiency motors

• High number of daily operating hours• High average motor load• Few starts/stop (S1 continuous duty)• Combination with gearboxes which

also have a good efficiency (helical,bevel – no worm-gearboxes)

• Belt and chain conveyors• Worm conveyors• Roller conveyors• Magnetic stirrer• Cooling tower drives• Pumps / Fans / Compressors• ...

• Palletizer (cyclic operation)• Hoists (cyclic operation)• Roller tables (cyclic operation)• Garage door openers• Gate openeres• ...


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Speed characteristic of eff1 versus eff2 motors

Be aware when retrofitting eff2 motors with eff1 motors!

0

10

20

30

40

50

60

70

80

0 300 600 900 1200 1500

Torq

ue [N

m]

Speed [rpm]

eff2-motor

eff1-motor

. .

load


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Rotor inertia J and permissible start/stops per hour Z0

-60

-40

-20

0

20

40

60

80

100

1,1 1,5 2,2 3 4 5,5 7,5 11 15 18,5 22 30

[kW]

[%]

Rotor Inertia J increase

No-Load Switching Z0 decrease

Changing of high efficiency motors (eff1) in relation to standard efficiency motors (eff2)


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Partial load saving potential (voltage reduction)

Load dependant efficiency of a 1,5 kW eff1-motors when operated on different voltages.

DTE90L4

50

55

60

65

70

75

80

85

90

100 1000 10000P [W]

eta

[%]

eta-400eta-380eta-360eta-340eta-320eta-300eta-280eta-260eta-240eta-220DT90L4

Total saving potential: 0...10%


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Saving potential by using Permanent Magnet Technology

Load dependant efficiency of a 1,5 kW eff1-Motor at constant flux and 1500 rpm at different voltages and frequencies compared to permanent magnet motor.

Vergleich eff1-ASM und SM (beide am Vektorumrichter)

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100 1000 10000W

A

50

55

60

65

70

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80

85

90

95

100

%

I1 SMI1 ASMeta SMeta ASM



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Comparison of worm gear and helical/bevel gearWirkungsgrad von Getrieben (i = 30...60, fB = 1)

75

77

79

81

83

85

87

89

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93

95

0,1 1 10Abgabeleistung [kW]

Ges

amtw

irku

ngsg

rad

[%]

Stirn- und KegelradgetriebeSchneckengetriebe

(Source: Catalog data of SEW-Eurodrive GmbH&Co KG)



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Direct Drive versus Geared Motor

Direct Drive

Speed

Pow

er

OutputPower

I²R Losses

Iron and Friction Losses

η =77,8%

η =50%

η =30%

Motor plus Gearbox

Speed

Pow

er

OutputPower

I²R Losses

Iron and Friction Losses

η =75,4%

Gearbox Losses

η =73,1%

(Helical and bevel gears)

Lower frequency, higher number of poles

Higher gearbox ratio


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Case study: Throttle versus speed control of a pumpsystemThrottle control Speed control

(Source: „Energiesparen mit elektrischen Antrieben“, ZVEI, 1999)

Total saving potential: 44%


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Case study: „Compressed air study“

(Source: „Compressed Air Systems in the European Union“, Peter Radgen, Edgar Blaustein, Frauenhofer ISI, 2001)

High-efficiency motor: 0,5 %

Speed control: 3,8 %

Air leaks: 16 %

Total saving potential: 33%


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Case study: Conduit size optimization of a pump system

(Source: Norbert Gröning, KSB Aktiengesellschaft, Fachvortrag VEM Fachtagung, Wernigerode, Juni 2003)

Conduit size 50 mm: η = 0,37 Pw = 3,95 kWConduit size 80 mm: η = 0,83 Pw = 1,76 kW

... more savings are possible in partial load by using a speed control for the pump...

Total saving potential: 55 %


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Case study: Cold production with optimized speed control

(Source: Norbert Gröning, KSB Aktiengesellschaft, Fachvortrag VEM Fachtagung, Wernigerode, Juni 2003)

Pump with conventional speed control H = 30m = const. Pw = 156 kWPump with optimized speed control Pw = 97 kW



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Case study: Industrial ventilator

(Source: Prof. Dr. Hans Witt, Witt&Sohn AG, Fachvortrag VEM Fachtagung, Wernigerode, Juni 2003)

70

75

80

85

90

95

100

1 10 100 1000

4-polige MotorenVentilatoren

%

P1 [kW]

Channel diameter 0,9 m: air resistance Δpt = 3050 Pa ∼ PWelleChannel diameter 1,0 m: air resistance Δpt = 2000 Pa ∼ Pwelle→ Saving potential 34%

Condiut bending radius 0,25 m: drag factor ξ = 0,4Conduit bending radius 0,5 m: drag factor ξ = 0,25→ Saving potential 37,5%



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Saving potential for industrial electricity use

0

10

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50

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70

Eins

parp

oten

tial [

%]

High-/premiumEfficiency

Motors

VariableSpeedDrives

OptimizedSystems


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New SEW DR-motor series

• One Motor for the world in all efficiency classes(Standard, High, Premium) from 0,11 kW up to 200 kW

• Second generation copper rotor technology• Introduction at Hannover Fair 2007 / available from 1.1.2008


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Conclusion

The Knowledge is there

The Products are there

... Let‘s use them !

Saving energy and costs in electrical drive systems

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