Super Premium Efficient Line Start-Up Permanent
Super Premium Efficient Line Start-Up Permanent
Abstract –Induction motors are the workhorses of industry Permanent Magnet Synchronous Motor (LSPMSM)
and represent nearly the entire installed base of constant-speed technology is under development that may increase motor
and most variable-speed motors. But the power factor and efficiency while reducing the size and weight of the motor by
efficiency of induction motor are limited by its squirrel cage reducing the amount of active material used. For the past
rotor. In the past, the colleagues all over the world tried to years, Super premium efficient LSPMSM have been
research and develop supper premium efficient electrical motor
researched, designed, built and tested. With advanced Finite
to replace the Premium® efficient induction motor. The supper
premium efficient line start-up permanent magnet synchronous Element Analysis (FEA) and test facilities, the rotor
motor is the one of choice for industry application. This paper optimization, Permanent Magnet (PM) material
presents the design and development of the supper premium characteristics, mechanical stress and thermal, flux density
efficient line start-up permanent magnet synchronous motors, and harmonics, noise and vibrations, and starting
including design techniques for key parameters and performance have been scrutinized. Two 4 pole prototypes,
performances, advanced digital simulation for the design, 7.5kW and 950kW, were built and tested. Compared with
improvement and verification, prototype build and test, design PEIM, the results show the efficiency, power factor, starting
and test data analysis and comparison. This may increase the torque, phase current, temperature rise, etc., are much better
motor efficiency level while reducing the size and weight of the
over the wide range of the output power. In fact, LSPMSM
motor by reducing the amount of active material used. Also, the
comparisons with Premium® efficient induction motor on power
creates low-loss, high power density industrial motor that is
factor, efficiency, material consumption, frame size, etc. are easy to install and use and more efficient, lighter, and smaller
presented. The results show that the supper premium efficient than Premium® efficiency IM. Also, LSPMSM can start up
line start-up permanent magnet synchronous motor has much and run at constant-speed without Variable Frequency Driver
better power factor, efficiency and power density, smaller frame (VFD) and run at variable speed with a simple standard
size and less material consumption. (volts/hertz) VFD without position sensor. Also, LSPMSM
can achieve at least a 15% reduction in motor losses, 35%
Index Terms--AC motors, Electric machines, Induction smaller in volume, 30% lower in weight, & higher power
machines, IM, Line start up, Permanent magnet machine,
factor than PEIM. From energy-saving, investment and long-
Permanent magnet, Permanent magnet motor.
time running cost point of view, the LSPMSM can be a
general-purpose motor and replace existing IM for a wide
I. INTRODUCTION
range of line start-up and variable-speed applications.
pmVE0 pmV 2 1 1
Tem = sin θ + − sin 2θ (5)
ω0 X d 2ω0 q
X X d
1
22.5MPa and its limitation of the rotor material is 115MPa.
0.5 So the safety factor of rotor shear stress is more than 5. The
0 maximum equivalent stress is 42MPa and its limitation of the
-0.5
0 0.2 0.4 0.6 0.8 1
rotor material is 235MPa. Therefore, the safety factor of
-1 rotor equivalent stress is more than 5.5. The evaluated results
Slip
-1.5 on mechanical stress issue can assure the both prototype
Fig. 2. Starting performance of 7.5kW prototype motors can normally run without mechanical trouble.
It should be noted that the key evaluated torques in the
motor starting-up processing are: start torque Ts at s=1,
minimum torque Tmin at s=smin, maximum torque Tmax at
s=smax and pull-in torque Tpi. Normally, it is not easy to
figure out more accurate data for starting performance of
LSPMSM. FEA should be applied to evaluate key starting
performance data to ensure the motor can start up.
F. Permanent Magnet Demagnetizing
The permanent magnet bulks can be demagnetized due to (a) (b)
high temperature, strong demagnetizing field, etc. The Fig. 3. Shear stress and equivalent stress distribution
LSPMSM should be justified by demagnetizing effect on the B. Thermal Flow and Temperature Rise Analyses
motor. The following formula is applied to verify the
demagnetizing of PM motor [1] [2]: For new LSPMSM design and development, the thermal
λex (1 − K adm )
and temperature rise issues are more important to ensure the
bmd = (11) motor normally runs without any stator winding insulation
1 + λex
damaged and PM demagnetized by high temperature in the
where bmd is maximum demagnetizing point, λex is total motor. It is very difficult to figure out accurate thermal flow
permeance (PU) of external magnetic circuit, Kadm is the and temperature rise with the conventional analysis,
magnetic configuration coefficient. For the rotor especially for LSPMSM due to the rotor complex
configuration with series and parallel magnetic path, Kadm configuration. The advanced digital simulation technique has
should be as (12) for series and (13) for parallel [1] [2]: to be applied to evaluate the thermal flow and temperature
0.045 mK ad K w N I adm rise for 7.5kW and 950kW prototypes [3]. Fig. 4 shows the
K adm = (12) 7.5kW prototype flow velocity distribution as (a) and the
pKl H cb hm
temperature distribution as (b). As shown in Fig. 4 (b), the
o
0.09 mK ad K w N I adm maximum temperature rise is 46 C. It is much less compared
K adm = (13) o
with temperature rise limit 90 C (RTD) at ambient 40 C.
o
pKl H cb hm
Unit: M/S Unit: K
where Kad is a d-axis armature reaction factor, Iadm is the
maximum d-axis current, Hcb is the coercive force of PM
and hm is the width of PM in magnetizing direction. For
LSPMSM design, bmd should be more than knee point of
demagnetizing curve of PM under the hottest running
temperature. Normally, for F insulation LSPMSM, the motor
o
maximum running temperature is 120 C, bmd should be more
than 0.35 for PM NdFeB-N35H. Also, the demagnetizing of (a) (b)
the machine at worst case can be evaluated by FEA. Fig. 4. Flow velocity and temperature distribution on 7.5kW LSPMSM
C. No-load Voltage and Harmonics the iteration has to be used in analysis design. The d- and q-
For various LSPMSM, the no-load voltage and axis synchronous reactance can be obtained with above d-
harmonics, starting-up performance, cogging torque, the and q-axis reactance plus stator leakage reactance Xδ, which
curve of output power/torque to power angle, d- and q-axis would be evaluated by the formula of the conventional
reactance, etc. are more important electrical performance for electrical machine design. Also, FEA can be applied to
machine steady and transient running. Due to complex evaluate d- and q-axis armature reactance of LSPMSM.
configuration of LSPMSM, an advanced digital simulation In the design stage, the d-axis and q-axis inductances are
tool has to be applied for electrical performance evaluation. the most important parameters for the performance
The commercial FEA software was used to electrical predictions. This is particularly important when introducing
performance evaluation for 7.5kW and 950kW LSPMSM the motor in a drive. The d- and q-axis inductances depend
[4]. Fig. 5 shows the flux distribution and Fig. 6 (a) shows on the stator current and its configuration, the air gap length
the phase EMF waveform and harmonics for 7.5kW and the rotor configuration. In LSPMSM, the energy Wmagn
LSPMSM. Further FFT of the induced phase voltage stored in machine is as [5]:
waveform has been done and the frequency spectrum is 31 1
Wmagn = L I2 + L I2 (14)
shown in Fig. 6 (b). The amplitudes of the fundamental and 22 d d 2 q q
main harmonic components and the ratio of harmonics to That is:
fundamental are shown in Table I. B
r r
4
Ld I d2 + Lq I q2 =
3 ∫∫∫ ∫
V
( H (b) • db )dv
0
(15)
)= 23 I 2π 2π
−j
(I
j
+ jI q +Ibe e jψ (16)
3
+Ice 3
d a
where ψ is angle between the d-axis and stator phase axis.
Applying a pure d-axis and q-axis current to the field
solution, the corresponding d- and q-axis magnetic field
energy is calculated from (15). Furthermore, Ld and Lq can be
evaluated.
For 950kW and 7.5kW LSPMSM prototypes, d- and q-
axis armature reactance have been calculated with both of
Fig. 5. Flux distribution for 7.5kW LSPM conventional analysis and FEA method. The results for
7.5kW prototype are shown and compared as Fig.7 and
Fig.8. The good uniformity results can be found from the
conventional analysis and FEA methods.
(a) (b)
Fig. 6. Phase EMF waveform and harmonics for 7.5kW LSPMSM
TABLE I
FUNDAMENTAL AND MAIN HARMONIC COMPONENTS
Fig. 7. d-axis armature reactance and comparison
VI. ACKNOWLEDGMENT
The authors gratefully acknowledge the contributions of
W. Qi, L. Huang, S. Huang, M. Chao and L. Lin for their
work on the mechanical simulation, prototype build and test.
Fig. 13. Phase current comparison
VII. REFERENCES
D. LSPMSM Improvement Design and Comparison [1] Renyuan Tang, “Modern Permanent Magnet Machines,” Beijing,
China Machine Press, 1997.
The 7.5kW LSPMSM prototype has been built, tested and [2] L. Liu, Y. Zhang, W. Qi, L. Huang and X. Feng, “Report on Design
it shows very good performance compared with the and Development of Supper Premium Efficient Line Start-up
Premium® efficient (IE3) IM with same frame size. Permanent Magnet Synchronous Motor,” Interior Report and
Especially its efficiency has exceeded the IEC suggested Presentation on LSPMSM Project at Teco-Westinghouse Motor
Company, October 2009, Round Rock, Texas, USA
super premium efficiency (IE4) level. The output power, [3] ANSYS Software User’s Guides, ANSYS Inc., 2009
speed, frame size of the 7.5kW prototype are based on the [4] MagNet Software v7 User’s Manual, Infolytica Corporation. 2009
standard of NEMA Premium® (IE3) IM. Per 7.5kW [5] X. Feng, K. Hameyer and R. Belmans, “Aspects of the Rotor Design
for Axially Laminated Synchronous Reluctance Motors," in Proc. of
LSPMSM prototype design analysis and test data, 11kW XII International Conference on Electrical Machines, pp. 314-319
output power of LSPMSM can be designed into same frame
and core length of the 7.5kW LSPMSM prototype with VIII. BIOGRAPHIES
supper premium efficiency (IE4) and higher power factor. X. Feng was born in Chongqing, China. He graduated from the Faculty of
This improvement design can be compared with 11kW Engineering, Katholieke Universiteit Leuven, Leuven, Belgium, majored in
Premium® (IE3) IM which frame size is larger than the electrical machine and control with Doctor and Master degrees and
improvement design. Table VI shows the performance Shanghai Jiaotong University, Shanghai, China, majored in electrical
machine and control with Master degree.
comparison and very good performance can be found for His employment experience included HAAS Automation Co. and
11kW LSPMSM. All other performance comparison such as United Technologies, USA and Chongqing University, China. His special
efficiency, power factor, phase current with different output fields of interest include electrical machine and control.
power, etc. have similar results as shown in Fig. 11 to Fig. 13 J. Kang was born in Taipei, China. He graduated from the National Cheng
in last paragraph. Also, estimated temperature rise of 11kW Kung University in Taiwan.
o He has been working in the motor field for 32 years. Especially, he has
improvement design of LSPMSM is less than 60 C. good experience at motor design .Because most of his career is on research
TABLE VI and development of motor in the R&D department, he owns 18 patents for
his innovations. He is a Chief Editor of Monthly Magazine on Electrical
LSPMSM COMPARISON WITH PREMIUM® IM (15HP) Machine and Control in Taiwan, China.