wmagnet drive system

Motors | Automation | Energy | Coatings

Howest Technical Seminar – 7 th October 2010 – Belgium Sebastião L. Nau

WMAGNET DRIVE SYSTEM

The WMagnet Drive System is composed by a permanent magnet synchronous motor plus a frequency drive with dedicated software to maximize the performance of the application through the special characteristics that allow superior torque levels to be delivered by the motor.


WMAGNET DRIVE SYSTEM

Special Assembly

Slot

Magnet


Special Construction Reluctance and Alignment Torques


Stator Pole at 0 °

Zero Torque

Stable balance

ALIGNMENT TORQUE

Stator Pole at 90 °

Maximum Torque

Rotor Rotation


Zero Torque

Instable balance


Stator Pole at 0 °

Zero Torque

Instable balance

RELUCTANCE TORQUE


Zero Torque

Stable balance


Zero Torque

Instable balance


ALIGNMENT + RELUCTANCE TORQUE


SENSORLESS CONTROL

WMagnet motors are sensorless, which means that they do not require any equipment such encoders or resolvers to indentify the exact position of the rotor. This is done through an advanced algorithm developed by

WEG, which detects the variation of the inductance to obtain the precise positioning of the rotor thus allowing the correct phase switching.


WMAGNET MAIN BENEFITS

- Extra High Efficiency

- Lighter and Compact Package

- Wide speed range with Constant Torque

- Lower Noise and Vibration Levels

- Lower Bearing Temperature

- Extended Relubrication Intervals

- WISE Insulation System


EXTRA HIGH EFFICIENCY

WHY DO WMAGNET MOTORS HAVE A HIGHER

EFFICIENCY WHEN COMPARED TO THE

SQUIRREL CAGE INDUCTION MOTORS?



SQUIRREL CAGE INDUCTION MOTORS

In induction motors the magnetic flux lines produced by the stator pass through the rotor, inducing electrical currents in the aluminium bars. These currents generate a magnetic field in the rotor which interacts with the stator producing electromagnetic torques. The flux variation in the rotor and the current circulation in the bars generate losses and heat.



WMAGNET MOTORS

WMagnet motors have high energy magnets in the rotor. Due to their inherent magnetic properties, it is not necessary to induce currents and as a consequence there is not current circulation in the rotor. The flux variation is also practically null, so the Magnetic and Joule losses in the rotor are eliminated. Additionally no heat is produced in the rotor.


LIGHT AND COMPACT

WHY ARE WMAGNET MOTORS SMALLER IN

SIZE AND LIGHTER WHEN COMPARED TO

SQUIRREL CAGE INDUCTION MOTORS?


LIGHT AND COMPACT

Once the rotor losses are eliminated, it is possible to raise the stator current levels, increasing in this way the torque production and keeping the same overall temperature rise.

Comparing to the standard kW ratings of the induction motors, it is possible to deliver the same kW output in smaller frames, significantly reducing the weight and volume of the WMagnet solution.


WIDE SPEED RANGE WITH CONSTANT TORQUE

WHY DO WMAGNET MOTORS HAVE A WIDE

SPEED RANGE WITH CONSTANT TORQUE?



Induction motors are not efficient at low speeds. The cooling system efficiency is directly linked with the speed reduction. Even with the magnetic losses reduction, it is also necessary to reduce the motor current to avoid damage by high temperatures.

That is why a Derating Curve is required to induction motors at lower speeds.



WMagnet motors are more efficient than induction motors throughout the speed range, specially at lower speeds.

Therefore, the cooling system efficiency reduction is compensated by the magnetic losses reduction linked to the VSD operational frequency reduction thus allowing constant torque in the entire speed range.


LOWER NOISE AND VIBRATION LEVELS

WHY DO WMAGNET MOTORS HAVE LOWER

NOISE AND VIBRATION LEVELS WHEN

COMPARED TO THE SQUIRREL CAGE

INDUCTION MOTORS?


LOWER NOISE AND VIBRATION LEVELS

WMagnet motors are usually framed one or two sizes smaller than induction motors to the same kW rating.

This allows for lower noise and vibration levels.


LOWER BEARING TEMPERATURE

WHY DO WMAGNET MOTORS HAVE LOWER

BEARING TEMPERATURE WHEN COMPARED

TO THE SQUIRREL CAGE INDUCTION

MOTORS?


LOWER BEARING TEMPERATURE

In the induction motors the heat transference from the rotor to the stator occurs through convection and radiation, whilst to the bearings is through conduction. The airgap works as a thermal insulation making the rotor heat dissipation more difficult. Therefore, a significant portion of the rotor heat is transferred to the bearings thus

In the Wmagnet motors there is no shortening bearing relubrication heat generation in the rotor, so intervals and lifetime. decreasing the heat transference to the bearings.


WISE INSULATION SYSTEM

Aiming at extending the motor lifetime and reliability of motors fed by inverters, WEG developed the WISE system, which is the result of the enhancement of materials in all production stages related to the motor insulation system such as wires, insulating films, impregnation system and material, among other components included in the process.


TYPICAL APPLICATION

The WMagnet Solution is ideal to:

- Compressors

- Ventilation Systems

- Pump Systems

- Conveyor Belts

And they can also be used in:

- Elevators

- Any other speed variation system.


WMAGNET DRIVE SYSTEM SCOPE

• Frames IEC 132 to 250 and NEMA 213 to 404/5

• Outputs from 11kW to 150kW

• Base speed 3000/3600 rpm and 1500/1800 rpm

• Maximum speed 8000 rpm (with encoder)

• Dimensions same as standard induction motors (IEC72)

• Cooling IC411 (self ventilated)

• CFW09-PM Sensorless Inverter

• Other frames and speeds under request


WEG PERMANENT MAGNET SYNCHRONOUS MOTOR LINE

PREMIUM EFFICIENCY - EUROPE 400V 3000 rpm

Output

FRAME Current (A)

(kW)

Efficiency

(%)

Pow er

Factor

DRIVE (A)

45

55

75

90

15

18.5

22

30

37

110

132

160

160M

160L

180M

200L

200L

225S/M

250S/M

280S/M

280S/M

315S/M

315S/M

315S/M

26.9

33.1

39.6

54.8

65.8

79.7

94.9

130.0

157.0

190.0

227.0

272.0

92.5

93.1

93.7

94.0

94.6

94.7

95.0

95.6

95.8

95.8

96.0

96.2

0.880

0.880

0.870

0.850

0.870

0.870

0.890

0.880

0.870

0.880

0.880

0.890

70

86

105

142

30

38

45

60

180

211

240

312

PERMANENT MAGNET MOTORS - 400V - 3000 rpm

FRAME Current (A)

Efficiency

(%)

Pow er

Factor

DRIVE (A)

132S

132M

160M

180M

180L

200M

225S/M

225S/M

225S/M

250S/M

250S/M

250S/M

24.3

29.9

36.4

48.7

57.4

73.3

88.6

116.4

139.7

168.8

216.4

251.3

95.8

95.8

95.8

96.2

96.4

96.6

96.6

96.9

97.1

97.3

97.4

97.5

0.984

0.98

0.984

0.988

0.991

0.965

0.965

0.989

0.985

0.985

0.963

0.958

60

70

86

142

24

30

38

60

142

168

218

253


WEG PERMANENT MAGNET SYNCHRONOUS MOTOR LINE

PREMIUM EFFICIENCY - EUROPE 400V 1500 rpm

Output

FRAME Current (A)

(kW)

Efficiency

(%)

Pow er

Factor

DRIVE (A)

37

45

55

75

90

11

15

18.5

22

30

160M 21.3

160L

28.4

180M 36.2

180L

39.9

200L 56.0

225S/M 65.8

225S/M

78.6

250S/M 95.8

280S/M

129.0

280S/M 159.0

94.1

94.4

94.6

95.2

95.3

91.2

91.8

93.4

93.7

93.9

0.870

0.880

0.880

0.880

0.860

0.820

0.830

0.800

0.860

0.830

45

60

70

24

30

38

86

105

142

180

PERMANENT MAGNET MOTORS - 400V - 1500 rpm

FRAME Current (A)

Efficiency

(%)

Pow er

Factor

DRIVE (A)

132S

132M

160L

180M

180L

200M

200L

225S/M

250S/M

250S/M

17.9

24.1

30.2

35.3

47.9

60.5

71.9

89.2

118.7

145.2

93.6

94.0

94.4

94.9

94.9

95.9

96.0

96.1

96.7

96.7

0.953

0.956

0.945

0.974

0.965

0.954

0.945

0.948

0.938

0.92

38

45

60

24

24

30

70

86

142

142


INDUCTION MOTOR

15kW – Frame 160M

108,1 kg

0,0312 m 3

PERMANENT MAGNET

SYNCHRONOUS MOTOR

15kW – Frame 132S

70,3 kg

0,0178 m 3

REDUCTION

WEIGHT: 37,8kg = - 35,0%

VOLUME: 0,0134 m 3 = - 42,9%


Output

(kW)

15.0

18.5

22.0

30.0

37.0

45.0

55.0

75.0

90.0

110.0

132.0

160.0

EUROPEAN MARKET 3000 rpm

INDUCTION MOTOR

FRAME

160M

160L

180M

200L

200L

225S/M

250S/M

280S/M

280S/M

315S/M

315S/M

315S/M

WEIGHT

(kg)

108.1

120.8

172.1

225.0

240.9

407.1

455.6

643.3

682.5

806.0

868.5

995.3

PERMANENT MAGNET MOTOR

FRAME

WEIGHT

(kg)

Weight

Reductio

132S

132M

160M

180M

180L

200M

225S/M

225S/M

225S/M

250S/M

250S/M

250S/M

70.3

546.5

569.7

594.8

- 35.0 %

75.1

- 37.8 %

140.8

- 18.2 %

201.6

- 10.4 %

218.6

- 9.2 %

281.1

- 31.0 %

392.5

- 13.9 %

463.8

- 27.9 %

503.2

- 26.3 %

- 32.2 %

- 34.4 %

- 40.2 %


EUROPEAN MARKET 3000 rpm

Output

(kW)

15.0

18.5

22.0

30.0

37.0

45.0

55.0

75.0

90.0

110.0

132.0

160.0

INDUCTION MOTOR

FRAME

VOLUME

(m 3)

160M

160L

180M

200L

0.0312

0.0336

0.0461

0.0668

200L 0.0668

225S/M 0.1035

250S/M 0.1162

280S/M 0.2027

280S/M 0.2027

315S/M 0.2356

315S/M 0.2356

315S/M 0.2356

PERMANENT MAGNET MOTOR

FRAME

VOLUME

(m 3)

Volume

Reductio

132S

132M

160M

180M

0.0178

- 42.9 %

0.0196

- 41.7 %

0.0312

- 32.3 %

0.0461

- 31.0 %

180L

200M

0.049

- 26.6 %

0.0633

- 38.8 %

225S/M 0.1035

- 10.9 %

225S/M 0.1035

- 48.9 %

225S/M 0.1035

- 48.9 %

250S/M 0.1162

- 50.7 %

250S/M 0.1162

- 50.7 %

250S/M 0.1162

- 50.7 %


MOTOR EFFICIENCY - 400V - EUROPE - 3000 rpm

99

98

97

96

95

94

93

92

91

95.8

95.8

95.8

96.2

93.4

93.8

94.2

94.5

92.7

92.4

91.9

15 18,5 22

93.3

30

96.4

96.9

96.6

96.6

95.4

95.6

94.8

95.1

97.1

97.3

97.4

95.8

96.0

96.0

97.5

96.2

95

95.2

95.4

95.6

94.3

94.7

94

93.7

37 45 55

Output (kW)

75 90 110 132 160

IE3 IE4 WMagnet


MOTOR EFFICIENCY - 400V - EUROPE - 1500 rpm

98

97

96

95

94

93

92

91

90

93.6

93.6

91.4

11

94

94.0

92.1

94.4

94.3

92.6

94.9

94.7

93

94.9

95.0

93.6

95.9

95.3

93.9

96

95.6

94.2

96.1

95.8

94.6

15 18.5

22

IE3

30 37

Output (kW)

IE4

45

WMagnet

Howest Technical Seminar – 7 th October 2010 – Belgium

55

Sebastião L. Nau

96.7

96.0

95

75

96.7

96.2

95.2

90

Permanent Magnet Motor X Induction Motor

Motor

Output (kW)

Frame

Rated voltage (Vrms)

Poles

Rated speed (rpm)

Rated current (A)

Rated torque (Nm)

Efficiency at 100%load (%)

Power factor at 100%load

Insulation class

Service factor

Duty cycle

Enclosure

Aprox. weigh (kg)

Three-Phase PM Motor

37

180M

380

6

3600

63,2

98,1

95,8

1,00

F

1,0

S1

IP55 (TEFC)

201,6

Three-Phase Induction Motor

37

200L

380

2

3600

71,1

98,0

93,2

0,88

F

1,0

S1

IP55 (TEFC)

246,5


Derating Curve for Induction Motor and PM Motor

1.1

1.0

0.9

0.8

0.7

0.6

0.5

Induction Motor PM Motor

0.4

0.3

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

Frequency / Rated Frequency


PM 50 kW x Induction 55kW

95

90

85

80

75

PM x INDUCTION

Number of poles: 6 x 2

Frame: 180 x 225

Weigh: 100kg x 410kg (+410%)

Volume: 9.61cm ³ x 36.1cm ³(+375%)

5000 6000 7000

70

0 1000 2000

PM

3000 4000

SPEED (RPM)

Induction


Thank you!

Sebastião L. Nau slnau@weg.net


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