Electrical Enineering Institutions Lecture Program 2014 – Csaba Szabo ABB Australia
Motor Revolution: Synchronous
reluctance motor technology
10/07/2014
SynRM package
Why we do this?
© ABB Group
8/26/2014
| Slide 2

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
1888
1960’s
1923
1989
1998
2005
2010
(e)
(c)
(d)
Iron Segment
Magnetic Barrier
(Normally Air)
(No) line start capability
© ABB Group
8/26/2014
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
(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
(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
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Synchronous reluctance technology
Function compared to induction motor
Synchronous reluctance
motor
Induction motor
R
R
R
R
R
S
T
T
R
R
S
T
S
S
T
S
S
R
T
S
T
R
T
T
S
T
R
T
T
R
S
S
T
S
R
R
© ABB Group
8/26/2014
| Slide 7
R
S
S
S
R
R
T
T
Elimination of
resistive rotor losses
New innovative motor and drive packages
The technology for variable speed applications
Standard motor
+
special rotor
© ABB Group
8/26/2014
| Slide 8
Standard drive
+
new software
Revolutionary
drive package!

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
New innovative motor and drive packages
The technology for variable speed applications
Standard motor
+
special rotor
© ABB Group
8/26/2014
| Slide 10
Standard drive
+
new software
Revolutionary
drive package

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
SynRM Package features
Two approaches
Key to success
Elimination of rotor losses
60%
Other
100%
I2 R
Rotor
I2 R
Stator
Other
IE4 SynRM motor
80 -90%
I2 R
Stator
Other
Losses
IE2 induction motor
© ABB Group
8/26/2014
| Slide 12
I2 R
Stator
High Output SynRM motor
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
© ABB Group
8/26/2014
| Slide 14

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
Same power - smaller motor
What does smaller size mean in practice?
Same output from a
smaller size or higher
output from the same
size
© ABB Group
8/26/2014
| Slide 15
Same power - smaller motor
What does smaller size mean in practice?
Reduced system
space – lower weight,
easier installation
© ABB Group
8/26/2014
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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



© ABB Group
8/26/2014
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Interchangeable with IE2 induction motor
IE2 induction can be used as spare
Easy to give it a go!
New revolutionary motor and drive package
Significant benefits
© ABB Group
8/26/2014
| Slide 18

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
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

© ABB Group
8/26/2014
| Slide 19
Less maintenance and down time
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

© ABB Group
8/26/2014
Test report stating real use
efficiency available for each
package (state of the art
measuring equipment)
| 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


© ABB Group
8/26/2014
| Slide 21
No separate tacho or encoder needed
Global ABB support
New revolutionary motor and drive package
Current Ranges - 3000 rpm, 2100 rpm, 1500 rpm
© ABB Group
8/26/2014
100Hz = 3000rpm, 70Hz = 2100rpm, 50Hz = 1500rpm
| Slide 22
New revolutionary motor and drive package
Load-ability
© ABB Group
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
© ABB Group
8/26/2014
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High output SynRM motor and drive package
Advantages in a nutshell
Same power,
smaller motor
Same size motor,
higher power
Induction motor on the
outside, innovative inside
© ABB Group
8/26/2014
| Slide 26
IE3 – compact design
without compromising
efficiency
Full range
Verified package
efficiency
High output SynRM motor and ACS850 drive package
Motor highlights
© ABB Group
8/26/2014
| Slide 27

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
ACS850, Drive highlights
© ABB Group
8/26/2014
| Slide 28

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.
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.
© ABB Group
8/26/2014
| Slide 29
What’s in the pipe line?
New development: SynRM2
© ABB Group
8/26/2014

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
| 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