Electrical Enineering Institutions Lecture Program 2014 Csaba Szabo ABB Australia 10/07/2014

Motor Revolution: Synchronous

reluctance motor technology
SynRM package
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
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SynRM - Technology review
Synchronous reluctance technology
History - key technology steps

1888 1923 1960s 1989 1998 2005 2010

(e)

(c)
(f)

Iron Segment (d)

(a) Simple salient pole (SP) rotor

Magnetic Barrier (b) Axially laminated anisotropy (ALA) rotor

(Normally Air)
(c) Transversally laminated anisotropy (TLA) rotor

(d) J. K. Kostko 1923 (original patent)

(No) line start capability
(e) ABB Synchronous reluctance servomotors

(f) ABB Synchronous reluctance motor and drive package

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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.

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August 26, 2014 | Slide 5
Synchronous reluctance technology
Rotor construction

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Synchronous reluctance technology
Function compared to induction motor

Induction motor Synchronous reluctance

motor

R
R T R
R R
R T R
S S
S T
S
S
S T
R T

S T R T

T S T R

T R
T S
S S
T S S S
R R R T
R R T
Elimination of
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resistive rotor losses
New innovative motor and drive packages
The technology for variable speed applications

Standard motor Standard drive

+ Revolutionary
+
drive package!
special rotor new software

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

ABB Group
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New innovative motor and drive packages
The technology for variable speed applications

Standard motor Standard drive

Revolutionary
+ +
drive package
special rotor new software

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

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8/26/2014 | Slide 10
SynRM Package features
Two approaches
Key to success
Elimination of rotor losses
60%
Other

100% I2 R
Stator
I2 R
Rotor

Other IE4 SynRM motor

80 -90%
I2 R
Stator Other

Losses

IE2 induction motor I2 R

Stator
High Output SynRM motor
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8/26/2014 | Slide 12
New innovative motor and drive packages
The technology for variable speed applications

Two approaches: High output or IE4 Super premium

efficiency

ABB Group
8/26/2014 | Slide 13
New innovative motor and drive packages
The technology for variable speed applications

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

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Same power - smaller motor
What does smaller size mean in practice?

Same output from a

smaller size or higher
output from the same
size

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8/26/2014 | Slide 15
Same power - smaller motor
What does smaller size mean in practice?

Reduced system
space lower weight,
easier installation

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8/26/2014 | Slide 16
Two new innovative motor and drive packages
The technology for variable speed applications

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!

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8/26/2014 | Slide 17
New revolutionary motor and drive package
Significant benefits

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

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New revolutionary motor and drive package
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

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New revolutionary motor and drive package
High package efficiency

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)

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8/26/2014 | Slide 20
New revolutionary motor and drive package
Get the best of two worlds

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

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8/26/2014 | Slide 21
New revolutionary motor and drive package
Current Ranges - 3000 rpm, 2100 rpm, 1500 rpm

ABB Group
100Hz = 3000rpm, 70Hz = 2100rpm, 50Hz = 1500rpm
8/26/2014 | Slide 22
New revolutionary motor and drive package
Load-ability

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8/26/2014 | Slide 23
SynRM Advantages
How much does a motor cost?

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

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High output SynRM motor and drive package
Advantages in a nutshell

Same power, IE3 compact design

smaller motor without compromising
efficiency

Same size motor,

higher power Full range

Verified package
efficiency
Induction motor on the
outside, innovative inside

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High output SynRM motor and ACS850 drive package
Motor highlights

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.

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8/26/2014 | Slide 27
High output SynRM motor and ACS850 drive package
ACS850, Drive highlights

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.

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8/26/2014 | Slide 28
System efficiencies
Verified 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.

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8/26/2014 | Slide 29
Whats in the pipe line?
New development: SynRM2

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

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8/26/2014 | Slide 30
New revolutionary motor and drive package
The customer voice

http://www.youtube.com/watch?v=LKgVXk72spY
http://www.youtube.com/watch?v=69mtuom774E&index=4&list=PLg4s1do3XuVlw
c1LnpyZgvfjd_o4wtA_D

ABB Group
8/26/2014 | Slide 31