Efficient Vmoor Control With Power Drives Systems - Transcript

Efficient Motor Control with Power Drives Systems Energy University Course Transcript
Slide 1: Efficient Motor Control With Power Drives Systems Welcome to Efficient Motor Control with Power Drives Systems. Slide 2: Welcome For best viewing results, we recommend that you maximize your browser window now. The screen controls allow you to navigate through the eLearning experience. Using your browser controls may disrupt the normal play of the course. Click the Notes tab to read a transcript of the narration. Slide 3: Objectives At the completion of the course, you will be able to: Define the components of a Power Drive System Review the different types of motors Identify opportunities for motor efficiency Review the different types of gears and transmissions Identify opportunities for gears and transmissions efficiency This course continues in our module on 'Active Energy Efficiency with Motor Speed Control' where we'll learn about the great potential for energy savings in power drive systems through controlling the motor speed. Variable speed control can yield from 20% to 70% savings depending upon application type. But first, let's learn about other ways of improving efficiency. Slide 4: Power Drive System (PDS) A power drive system (PDS) consists of a few major components. First, it includes the motor and its sensors. The purpose of the motor is to transform energy into mechanical power.. The gear, or transmission, conveys that power from the motor, to the machine that is performing the work. The variable speed drive module controls the speed of the motor and supports smooth startup. As we just mentioned, our class on Active Speed Control will go into more details about variable speed drives. Process control collects input data from sensors, and provides outputs to the power drive system to regulate the use of the machine: for example, to turn it off when the process is complete.
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Now, lets turn our focus to motors and gears. Slide 5: Energy Efficiency in Motors Motor driven systems account for 60 - 70% of the electricity consumed by industry in regions as diverse as Europe, the US and China. They are used in many applications like pumps, conveyors, refrigeration equipment, material handling and many other processes. There is a huge potential for energy savings, because many of these motors are oversized, not speed controlled and not regularly maintained. Inefficient or poorly maintained power drive systems can lead to great waste of energy, downtime, and safety issues. For example, in a conventional pumping system, around 70% of the energy consumed is wasted. An efficient system uses less than half the energy to do the same work. (Source: De Keulenaer, H., 2004. Energy Efficient Motor Driven Systems, Energy & Environment).
Slide 6: Why Focus on Power Drive Systems? The US Department of Energy estimates that industrial motor energy use could be reduced by 11 to 18 percent if facilities managers undertook all cost-effective applications of mature proven technologies and practices.
Investments in efficient components such as variable speed drives and high-efficiency motors can yield rapid payback. On average, 97% of the life cycle cost of purchasing and operating a motor is energy-related. Yet too often the only factor considered when selecting a motor is the initial purchase price. Reducing the consumption of a motor by 10% can save enough to buy three more motors. This gives us three compelling reasons to focus on power drive systems. Motors are everywhere and consume a high proportion of total energy (60% - 70% of industrial use) Many are oversized and inefficiently controlled Since 97% of the cost of ownership is energy, it makes sense to focus on operating costs more than initial purchase price
Reference: Motor U.S. Department of Energy Tip Sheet #10 June 2008 Slide 7: Motors About 95% of todays motors are AC induction. These motors have become popular because they are reliable and low cost compared to other technologies like DC motors and synchronous permanent magnet ones. Fewer than 5% of motors are DC. These motors are easy to control in speed and have very good performances in torque and speed precision. But they require a fair amount of manufacturing and maintenance cost, and they need a DC supply. For these reasons, they are less prevalent.
Slide 8: Permanent Magnet Motors A smaller subset of motors is called permanent magnet or PM synchronous motors. In this design, the rotor is fitted with rare earth magnets in order to achieve increased field strength in a small volume. Due to their cost they are reserved for high performance applications (like fast-cycle machines). However, as their energy consumption is less than induction motors, they come up more and more in some applications like lifts and extruders. Slide 9: Asynchronous Motor Asynchronous motors are the most commonly used motors today. They can be found throughout industry, infrastructures and buildings. They are very simple, robust and low cost Their main drawbacks are : A high starting current (5 to 7 times the rated load) They have uncontrolled acceleration Their speed decreases slightly with the load - This is a called, slip. Well talk about this more in a moment. And they feature losses due to slip, stator resistance and magnetic coupling Slide 10: Asynchronous Motor Basic Principle Here is the operating principle of an asynchronous motor.
The two most important parts of a motor are the stator and the rotor. The rotor is a cylindrical component which fits within the stator. Slide 11: Asynchronous Motor Basic Principle The stator is equipped with three-phase windings, positioned at 120 degree intervals.
As the electrical current rises and falls in each of the phases, a rotating magnetic field is created. This field causes electrical currents in the rotor. Electromagnetic interactions, between the rotor currents and the rotating magnetic field creates torque, causing the rotor to turn. This then rotates the motor shaft. The rotor follows the rotating field but rotates a little bit slower. This is referred to as slip between the stator rotating field and the rotor. This slip generates the torque which moves the rotor. The slip also increases with torque. This means that the speed of an asynchronous motor decreases slightly with load.
Slide 12: Asynchronous Motor Squirrel cage type The most common and most cost effective motor technology is the so called Squirrel-cage motor.
The squirrel cages rotor is comprised of metal bars short-circuited at their extremities by conducting rings. Depending on the supply voltage, the winding can be connected in different ways. By Star coupling, where one end of the stator coils are linked to a common node and the other ends to one of the phases of the power supply. Or by Delta coupling, where the windings are connected to form a triangle and each corner is connected to a phase of the supply; there is no common node. Slide 13: Asynchronous Motor Rating plate It is critical to know how to read the rating plate of an asynchronous motor - Particularly when using variable speed drives or soft starters because these parameters have to be entered before starting. On this nameplate, the different lines give the rated specification for the chosen winding coupling (star or delta). On this nameplate, the different possible windings are shown here, and here.
Slide 14: Asynchronous Motor Rating plate The rating plate includes the motors Rated voltage Rated supply frequency Rated speed, which is the speed of the rotor under rated load, i.e. the synchronising speed minus slip Rated mechanical power, which is the power available at the shaft. Note that on this nameplate the power is given in kilowatts. On this one, it is given in horsepower. The cosine of phi, which is the motor power factor And the rated current at rated voltage and rated load
Slide 15: Energy Efficiency in Motors Motor Sizing A motors maximum efficiency is obtained when operating at 60% to 100% of full load. Too often, electrical motors are oversized. Typically the designers of motor applications oversize the motor because they are not very concerned about energy efficiency - They want to ensure that there is no chance of the motor being overloaded. When energy is cheap, this approach is a low-cost trade off against overload risk. But as energy costs rise, this oversizing rapidly becomes a wasteful and expensive answer to this design issue.
Significantly over sizing a motor increases the capital cost, decreases the functional motor efficiency, and can increase the motors operating speed, and therefore, the motors energy consumption. Slide 16: Motor Efficiency Classifications The International Electrotechnical Commission or IEC has defined 4 grades of efficiency for low-voltage cageinduction motors up to 375 kW. Standards are in progress for other motors up to 800 kW and 600 kV. In Europe, these standards are replacing the EFF standards. In other regions, local standards may apply, but usually show good alignment to the IEC standards.
Most countries are engaged in programs to drive higher standards for minimum energy performance standards. In Europe, the IE2 standard is already in effect. From January 1, 2015 only IE3 motors will be acceptable for direct connection in the range 7.5 kW to < 375 kW. Starting on January 1, 2017 this will be extended to small motors down to 0.75 kW. IE2 motors will only be accepted when managed by speed drives. In the USA and Canada, the Epact standards that define standard efficiency and high efficiency motors will give way to the NEMA Premium Efficiency standard already in effect. In China, India and Brazil, standards will continue to evolve.
Motors of a higher efficiency class are more complex to design and produce, and contain more metal, different metals, or higher grade metals to provide conductors with lower losses. The motor price will increase accordingly. In relation to the motor lifetime the purchase price is only a few percentage points and, due to the saved energy cost, the pay-back period is short. To learn more about how to calculate the savings from improved efficiency, take our class on Motors: Loads, Losses and Operating Costs. Click here to learn more about the IEC standard. Click here to learn more about the NEMA standards. Slide 17: Efficiency Gains With IEC Standards The efficiency gains from investing in a premium efficiency motor can be considerable. For smaller motors the difference between IE2 high efficiency and IE3 premium efficiency is around 3%. Between IE1 and IE2 the improvement can be as high as 10%. The efficiency improvement tends to be smaller in larger motors, but with the higher energy consumption, improvements of just 1% can rapidly pay for themselves.
Slide 18: Efficiency Gains With NEMA Standards The efficiency gains from investing in a premium efficiency motor can be considerable. For smaller motors the difference between standard efficiency and NEMA premium efficiency is around 3%. The efficiency improvement tends to be smaller in larger motors, but with the higher energy consumption, improvements of just 1% can rapidly pay for themselves.
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Slide 19: Energy Efficiency in Motors Motor Efficiency Electrical motor efficiency () is the ratio between the mechanical shaft output power and the electrical input power. Internal losses include electrical, mechanical, and magnetic losses. If you have details such as input voltage, current and power factor of the motor, you can determine the electrical input power using this equation. The electrical power is equal to the square root of three multiplied by the three phase voltage, current and power factor. The mechanical power output by the motor can be found by multiplying the electrical input power by the efficiency of the motor. Also note that the mechanical power is the product of the torque and the angular speed of the motor. Slide 20: When to Replace Motors All motors will eventually need to be replaced or rewound. In general, a motor should be run until it fails. An exception to this rule is cases where a motor is only working at about a quarter of its capacity, and therefore less optimal to begin with. It might also make sense to replace a motor if federally-backed incentives emerge. Slide 21: When to Rewind Motors Motors can "burn out" if they are overloaded or if they experience abnormal input voltages. When the electrical winding of the stator overheats, the insulation can be damaged and then electricity will pass between the damaged sections. The motor can be repaired by rewinding it. However, this may not be a good plan. Rewinding motors generally costs about 60% of the cost to replace them. Its important to note that when motors are rewound, their efficiency drops slightly. The best policy might be to rewind highly efficient motors, and sell or salvage those that are not. Lets now move on to discuss gears and transmission. Slide 22: Gear Purposes Gears have three purposes: Transmission of power, reducing speed, and increasing torque. The objective is to transmit power efficiently. As we will see, there are a variety of gear designs, with different levels of efficiency. Reducing speed is often necessary because standard motors operate at specific standard speeds, such as 850 RPM. If the machine powered by the motor requires only 120 RPM, then a gear will be used to reduce the speed. Torque is rotational force. It is the product of the force and the distance from the center of the shaft
If the radius is 20 cm, and the force is 2 Newtons, the resulting torque is 2.0 N x 0.2 m = 0.4 Nm (Newton-meters). If the radius is 6 inches, or half a foot and the force is 4 pounds, the resulting torque is 4 lb x 0.5 ft = 2.0 ft-lb (foot pounds). In torque amplification, gear sets are specifically configured to enable the motor to perform more force at low speed. Slide 23: Gear Purposes Most of this work is achieved through gear ratios. This is the output gear size versus the input gear size. A gear ratio can be determined through a comparison count of the number of gear teeth or simply a measurement of each gear radius. The gear ratio is:
The output speed can be controlled very simply in the following manner. If the input gear with 20 teeth rotates at 10 revolutions per minute (rpm) and its connected to an output gear containing 100 teeth, that output gear will rotate at 2 revolutions per minute. The gear ratio in this example is 100:20 or 5:1 So the formula for speed is: output speed = input speed gear ratio What if we wanted to control torque using gear ratios? The formula for this action is: input torque X gear ratio = output torque Lets say the input torque is 8 Newton-metres (N-m), or 6 foot-pounds (ft-lb). Using the same gear configuration as in our speed control example, that would be: 8 N-m X 5 = 40 N-m 6 ft-lb X 5 = 30 ft-lb Slide 24: Gear Purposes Another factor to consider is inertia adaptation. Some machines include heavy rotating parts, for example, large conveyors or flywheels. Due to inertia, these loads take more power to start and accelerate than they do to keep running once started. That would require more torque.
If the inertia ratio between load and motor is too high, such as greater than 10:1, there can be a mismatch which leads to system oscillations during acceleration and deceleration. This can be a problem on fast cycle machines. It can be managed by using larger motors, so that the inertia ratio is reduced, or by changing gear ratios, or by reducing the control gain. Slide 25: Gear Trains Some common gear trains are pulley, planetary and axial. Each is configured differently and has a different purpose. In a pulley configuration, a motor spins one gear, which has a pulley belt wrapped around it. The belt is also wrapped around another gear known as the pulley wheel. This second gear is, usually different in size, in order to create different torque or speed. The pulley gear train is commonly used in fan driven applications. Its a low cost solution but not able to transmit very high torque, the belt ages quickly and overall dimension is big. For more torque and reliability its more common to see pinion chain transmissions. These transmissions resemble the sprocket and chain on a bicycle. Slide 26: Gear Trains Another common gear train is called planetary for its resemblance to the planets in our solar system. This gear train is best used for applications where a gear ratio must be achieved along with the output gear travelling in the same direction as the input gear. This instance is most often found in an electric screwdriver, where it is critical to increase torque and have the axis of the input gear the same as that of the output gear. This illustration is an axial gear train. The quintessential application for this gear train is the differential or rear axle of an automobile. It allows for a 90 degree torque transition. Lets move on to discuss gear efficiency, the most efficient gear trains, and how to calculate gear efficiency. Slide 27: Gear Efficiency With regard to motors, the greatest determinant of gear efficiency lies in how efficiently various speed reducers drive a load from the input power. Efficiency is determined primarily by the manner in which the gears intersect. For example, a very widely used gear train, called a worm drive, is comprised of a worm wheel positioned at a right angle to the drive shaft. The shaft is known as a worm gear and is a gear in the form of a screw. This results in a relatively large area of contact. This contact area can be larger or smaller depending on the speed reducing requirements.
If the same gear train were arranged such that the input shaft turned a helical gear before turning the worm gear, this would take some pressure off the worm gear that would otherwise be handling 100% of the friction. In a helical gear the leading edges of the teeth are set at an angle, which makes the shape of the tooth to be a segment of a helix. The angled teeth run more smoothly and quietly, because they engage more gradually. Replacing the worm gear with a helical bevel is a more costly arrangement, but in terms of efficiency, is a wise choice as it reduces friction and therefore facilitates rotation using less power. Slide 28: Gear Efficiency Selecting the most appropriate gear set requires evaluation of a few factors: Determine the torque or power required at the input shaft of the machine Determine service factors to be applied to the gear Determine the efficiency of the gear The torque or power required by the machine at its input shaft has to be determined first. There may then be a need to compensate for various conditions. Conditions such as frequent stops, temperature and other environmental and usage factors can impact performance of the gear used for speed reduction. The service factor is a multiplier, which is applied to the known load, which redefines the reducer ratings in accordance with the drive conditions at which the reducer will be used. The service factor varies with the type of application in which the reducer is to be used, the kind of prime mover involved and duty cycle. The factors are used with gears only, and should not be applied to the selection of the motor. For our example, lets consider a requirement for 0.75 kW or 1 hp on the driven equipment shaft. If the equipment starts and stops more than 10 times per hour, and operates 24 hours per day with uniform load, the service factor for that might be 1.25. Rating required = 0.75 kW * 1.25 = 0.94 kW Rating required = 1.00 hp * 1.25 = 1.25 hp Notice how the requirement for frequent starts increases the required rating of the gear. This factor is only used when determining the rating of the gear to be used. It is not used to choose the motor. Slide 29: Gear Efficiency Once the gear has been selected taking into account the service factor, we can consider the efficiency of the gear. Efficiency may not be published in the gear specifications, but it can be calculated if the manufacturer has published the input power, torque or wattage along with output values. Efficiency is always output divided by input. So if the spec gives examples of input and output power, calculate efficiency using Efficiency = example output power/example input power
If you need to convert power between kW and horsepower, use the conversion 1 horsepower = 0.746 kW. Many types of gears are efficient in the range 98% 99%. Some have lower efficiencies down as far as just 20%. A more efficient gear will waste less power and cost you less to operate. Of course, the total efficiency of the system will also depend on the efficiency of the motor and other components, not just the gear. Slide 30: Optimizing Gears Fine-tuning gear and belt designs is cost effective from the standpoint of efficiency. Selecting the correct drive components can also increase a drives capacity. A few factors influence drive efficiency. They are speed, load capacity, belt resistance, belt tension and pulley size. For a belt-driven design, it may be tempting to choose belts that have more than the required capacity. Overbelting can be detrimental to drive efficiency as they are less flexible around pulleys, thereby creating more resistance. Contrariwise, underbelting may lead to excessive slip or may stretch too much, leading to periods of downtime. Originally, motor belts were made of leather and had a flat profile. Today, most standard belts are V-belts which have a cross-section shaped like a trapezium. It is the sides of the trapezium that provide the drive surface - not the bottom of the belt. This shape matches the shape of the pulley, so it can't slip off, and provides better traction, but it doesn't curve well and tends to flex downward as it leaves the sheave. Cogged and synchronous belts are refinements of the standard belt. Cogged belts have notches cut into them as well as the V-shape. These notches provide curve around the pulley more effectively so that less energy is devoted to flexing and lost as heat. Switching from V-belts to cogged belts is easy and can yield an efficiency gain of up to 2 3%. Synchronous belts, also called timing belts, also have notches, which fit into matching teeth in the sheave. They provide more efficiency, but they have to be carefully engineered to match the belt and sheave with the application. Switching from cogged V-belts to a synchronous belt can gain an additional 2% of efficiency. However they are not a good choice for machinery that can easily become clogged, like a rock crusher or a trash pump dealing with debris in the fluid. This is because in the event of a blockage that prevents the cog turning, the motor is directly coupled to the machinery and there is no possibility of the belt slipping. The risk is that the motor will burn out. Slide 31: Optimizing Gears Types of gears, and how they connect with one another, are just as critical to efficiency. Gear ratios can greatly impact the amount of work a motor needs to perform. The motor will also operate more efficiently by using gears that minimize friction, thereby decreasing the amount of work the motor must perform. If we lower the gear ratio, we decrease friction. The result is a decrease in the losses associated with the drive. The ideal situation would be to use no gears, but low speed high torque motors are not standard, very expensive and bulky. The challenge, therefore, is to find the balance between the motor speed-torque capability and the machine speedtorque needs in order to minimize the ratio. Slide 32: Gear Maintenance Gears require almost no maintenance. They merely need to be well-lubricated, and then replaced as age causes a drop in efficiency. Pulley-belts need to be checked regularly for alignment, slip, belt tension and aging.
Slide 33: Conventional Versus Gearless Systems Conventional motors run at high speeds requiring drastic speed reductions using high torque gear trains. The load transmitted by the gear trains will be high, leading to losses and mechanical stress on the shafts and gears. A solution studied more and more is the gearless configuration, which can be found in applications such as elevators and extruders. Some advantages of gearless systems include a reduction of mechanical parts, reduction of space required, energy savings, and noise reduction. There are some drawbacks, however. Gearless systems require specific motors such as multi-poles, and synchronous motors with permanent magnets. Speed control is mandatory as gearless systems require very good motor control. Slide 34: Summary Lets summarize some of the information that we have learned in this course. So how can we make a drive system more efficient? We start by selecting the correct motor. Motors are responsible for 60% - 70% of the industrial electricity consumed. The lifetime cost of a motor is 97% energy, and only 3% initial purchase price and maintenance AC induction motors are used more for their simplicity and low cost but the standard ones are not the best in terms of efficiency New systems using an efficient motor can yield substantial energy savings - and the payback can be less than 1 year IEC standards have been defined for motors. For smaller motors the difference between IE2 high efficiency and IE3 premium efficiency is around 3%. Between IE1 and IE2 the improvement can be as high as 10% Under NEMA standards for smaller motors the difference between standard efficiency and NEMA premium efficiency is around 3% The efficiency improvement tends to be smaller in larger motors, but with the higher energy consumption, improvements of just 1% can rapidly pay for themselves Slide 35: Summary Other countries have similar standards Motors are most efficient when operated between 60% and 100% of full load Optimizing the motor size ensures that the motor does not operate under 60% of its full load Next, we need to select the correct gear train Be sure to select an efficient gear Choose the correct ratio Be sure to maintain belts taking note of tension and aging. Consider cogged or synchronous belts Lastly a big potential for energy savings in power drive systems is in controlling the motor speed. Variable speed control can yield from 20% to 70% savings depending upon application type. Learn more about this opportunity on our module on 'Active Energy Efficiency with Motor Speed Control. Slide 36: Thank You! Thank you for participating in this course.

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