Investigating ways to
increase the efficient use of
Electrical Energy in the
Manufacturing Industry
MALTA
Energy Efficient Electric Motor
Systems
Key Experts:
Prof. Ing. C. SpiteriStaines
Co-Supervisors: Dr. Cedric Caruana
Researcher:
Industrial Partners :
Playmobil
Toly Products
Andrews Feeds
Mr. Peter Spiteri
Department of Industrial Electrical Power
Conversion
Faculty of Engineering – University of Malta
Introduction
• It is estimated that motor driven systems
account for around 65% of the electricity
consumed by the European industry.
• 1.5% improvement in the motors’ efficiency
implies a reduction of around1% energy
consumption in the European industry.
• The more efficient use of energy in the
manufacturing industry has become a key factor
for the industrial organisations to maintain a
competitive edge.
Department of Industrial Electrical Power Conversion, University of Malta
Aims of Project
• The objective is to facilitate the adoption of energy saving measures
on electric motors by the Maltese industry.
• Carry out an extensive Data gathering exercise on Energy Usage
and Patterns of Electrical Motor Systems in various local industries
• Develop a user-friendly software tool to help organisations take
intelligent decisions on the options available for reducing electric
motors’ energy consumption.
• Other benefits derived from project:
– Knowledge on :
• electrical motors used in selected manufacturing industries
• energy savings mechanisms for manufacturing industry
– Additional benefits: possibility for reduced heat dissipation and
lower maintenance costs.
Department of Industrial Electrical Power Conversion, University of Malta
Increasing Efficiency in Motor
Systems
Department of Industrial Electrical Power Conversion, University of Malta
Results
• Experimental Tests were carried out :
• In a laboratory set-up and
• On-site in selected industries
• Studies were carried out to quantify the energy savings that can be
achieved by a Motor Energy Controller (MEC) or a High Efficient
Motor (HEM).
On-site Case Studies:
Lab rig tests:
• Profile of an Elevator
load
• Two different Injection
Mould Machine profiles
• Andrews Feeds (Malta) Ltd
• Motor Energy Controller
• High Efficient Motor
• Toly Products (Malta) Ltd
• Motor Energy Controller
• FS Eng. & Plastics Ltd (Malta)
• Motor Energy Controller
6
Department of Industrial Electrical Power Conversion, University of Malta
Laboratory Test Rig schematic
Department of Industrial Electrical Power Conversion, University of Malta
Laboratory Test Rig
Department of Industrial Electrical Power Conversion, University of Malta
Lab test rig results
• Motor (5.5kW) at no load
No Load
PowerBoss from OFF to ON
Input power (kW) vs time(s)
600
35% Energy
Savings
500
Active power (W)
471W
400
300
305W
Motor Energy
Controller
switched ON
200
100
0
0
1
2
3
4
5
Time (sec)
6
7
8
9
10
Department of Industrial Electrical Power Conversion, University of Malta
Lab test rig results
• Comparison of efficiency with the MEC ‘on’ and ‘off’ for
different operating points
Efficiency (%) vs Output power (kW)
100
MEC OFF
MEC ON
95
90
Efficiency (%)
85
80
75
High Load
Low Savings
70
65
60
Low Load
High Savings
55
50
0
1
2
3
Output power (kW)
4
5
6
Department of Industrial Electrical Power Conversion, University of Malta
Elevator Profile (Lab Results)
5.3% overall energy savings
Input power (W) vs Time (s)
3500
1%
3000
Input power (W)
2500
2000
1500
9.7%
1000
MEC OFF
MEC ON
500
0
50
100
150
200
250
300
350
400
450
500
Time (s)
Department of Industrial Electrical Power Conversion, University of Malta
Injection Mould Machine (Lab Results)
Profile 1
Input power (kW) vs time(s)
7000
MEC OFF (IMM profile)
MEC OFF (ave. load)
MEC ON (IMM profile)
MEC ON (ave. load)
6000
Active power (W)
5000
4000
4.6%
Energy Savings
3000
2000
1000
0
0
10
20
30
40
50
Time (sec)
60
70
80
90
100
12
Department of Industrial Electrical Power Conversion, University of Malta
Injection Mould Machine (Lab Results)
Profile 2
BOY profile (PowerBOSS OFF)
Input power (kW) vs time(s)
6000
5000
Active power (W)
MEC OFF
4000
3000
Average power = 1.20kW
2000
1000
0
0
20
40
60
80
100
Time
(sec)
BOY Profile
(PowerBoss
ON)
120
140
160
180
200
Input power (kW) vs time(s)
6000
Active power (W)
5000
4000
3.3%
energy
savings
MEC ON
3000
Average Power = 1.16kW
2000
1000
0
0
20
40
60
80
100
Time (sec)
120
140
160
180
200
Department of Industrial Electrical Power Conversion, University of Malta
Case Study 1
Motor Energy Controller (MEC)
installed on elevator motor at Andrews Feeds Ltd
Active power (W) vs Time (s)
8000
MEC OFF
MEC ON
7000
6000
Active power (W)
5000
4000
3000
2000
1000
More than 20%
energy savings were
achieved at low load
0
-1000
2000
2200
2400
2600
2800
3000
Time (s)
3200
3400
3600
3800
Department of Industrial Electrical Power Conversion, University of Malta
Case Study 2
Motor Energy Controller (MEC)
installed IMM motor at Toly Products Ltd
• Motor Energy Controller (MEC) was installed on
an Injection Mould Machine at Toly Products (Malta)
Ltd
• Motor rating = 22kW
• Average power with the MEC OFF = 7.12kW
• Average power with the MEC ON = 6.89kW
• Energy savings = 3.2%
Department of Industrial Electrical Power Conversion, University of Malta
Motor Energy Controller (MEC)
installed on IMM at FS Engineering & Plastics Ltd
Case Study 3
Active power (kW) vs Time (s)
9
MEC OFF:
Average power =
3.18kW
Average p.f. = 0.4129
8
MEC ON:
Average power =
3.11kW
Average p.f. = 0.4549
Active power (kW)
7
MEC OFF
MEC ON
2.2%
2.2%
energy
Savings
savings
6
5
4
3
2
0
20
40
60
Time (s)
80
100
120
Department of Industrial Electrical Power Conversion, University of Malta
Case Study 4
High Efficient Motor (HEM)
replaced ‘older’ elevator motor at Andrews
Feeds Ltd.
Active power (W)
Active power (W) vs Time (s)
10000
Around
8000
25%
6000
overall energy
savings
Old Standard Motor
High Efficient Motor
4000
2000
0
More than 35%
energy savings at
low load
-2000
-4000
9.4
9.42
9.44
9.46
9.48
Time (s)
9.5
9.52
9.54
9.56
9.58
4
x 10
Department of Industrial Electrical Power Conversion, University of Malta
Motor Energy Saving Tool (MEST)
Screenshot of
software tool
developed to
guide technical
persons in
industry to take
right decisions
in order to
increase the
efficiency in
motor
applications
Department of Industrial Electrical Power Conversion, University of Malta
Increasing Energy Efficiency during
Testing of Equipment by novel
Grid‐connected Load Units
Key Experts:
Dr. Maurice Apap
Co-Supervisors: Prof. C. Spiteri
Staines & Prof. J. Cilia
Researchers:
Industrial Partners :
Abertax
Delta (Malta)
Mr. Francarl Galea
Department of Industrial Electrical Power
Conversion
Faculty of Engineering – University of Malta
Introduction
•
Manufacturing Cycle
• Testing of each product must take place before reaching the market and the
customer.
•
Testing of certain products leads to high energy consumption.
• power supply full load burn-in test usually last for a minimum of 24
hours. (can exceed 400,000kWhr yearly.)
• batteries testing is carried out by cycling.
Department of Industrial Electrical Power Conversion, University of Malta
Aims
• This project is targeted at increasing the efficiency during testing of
manufactured electrical equipment: namely, DC Power Supplies and
Battery Banks.
• Currently Electrical Energy consumed
during testing is ‘wasted’ (as heat) in
Active Loads.
• The aim of this project is to REDIRECT
the Electrical Energy used during testing
back to the Electrical Supply.
• 70% energy saving is predicted.
Department of Industrial Electrical Power Conversion, University of Malta
Case Study
• Testing of a 70V 800W Power Supply with the Regenerative Load
• The energy savings obtained in this test were 83% (excluding losses
in the Power Supply).
Department of Industrial Electrical Power Conversion, University of Malta
Case Study
• List of savings obtained when testing various models of Power
Supplies
Device
under test
Power consumed in
resistive load
Power consumed with
Regenerative Load
Percentage Decrease in Energy consumption
(excluding losses from the Device under Test)
200V
800W
123W
84.6%
70V
800W
135W
83.1%
35V
800W
212W
73.5%
30V
300W
65.4W
78.2%
30V
150W
43W
71.5%
30V
1500W
418W
72.1%
70V
2000W
350W
83.5%
200V
2000W
255W
87.5%
300V
2000W
272W
86.4%
400V
2000W
261W
87%
600V
2000W
275W
86.3%
Department of Industrial Electrical Power Conversion, University of Malta
Thank you for your attention
- next talk shall consider in detail one
case study concerned with regenerative
load testing
MALTA
Department of Industrial Electrical Power Conversion, University of Malta