No tooling cost process for induction motors energy efficiency improvements

In this paper, the analysis of some possibilities for increasing the induction motor efficiency using production technological process modifications is reported. This approach is known as the "no tooling cost" (NTC) strategy because it does not require a complete redesign of new laminations with a consistent cost in terms of investments. The paper shows the results obtained by a full experimental approach, using "ad hoc" prototypes. The NTC design modification and the technological processes analyzed in this paper have been done on totally enclosed fan-cooled standard induction motors. Obviously, the original motors have been compared from the energetic point of view with these prototypes. The energetic performance has been measured in accordance with the IEEE Std. 112-96 Method B. In particular, the following modifications, for obtaining an increase in efficiency, have been taken into consideration: rotor with copper bar included in the slot before the aluminum die cast, increase of the core axial length, and annealing of the stator core.     

Analysis of the Endwinding Cooling Effects in TEFC Induction Motors

This paper deals with the endwinding cooling problems of totally enclosed fan-cooled (TEFC) induction motors. In order to obtain information about the phenomena involved in the motor end space, three "ad hoc" prototypes have been built. The complete test-bench setup, together with the followed test procedures, is reported in detail. The measurement results have shown that all the motor-part overtemperatures (winding, endwindings, stator lamination, and external motor frame) decreasing, with the inner air speed increasing. The measured motor overtemperatures and losses allow the thermal-resistance identification of a simplified thermal model suitable to describe the thermal behaviors of the prototypes. By the endwinding-to-motor frame thermal resistance, the related heat-exchange coefficients have been evaluated as a function of the rotor speed. The proposed procedure allows separating the forced-convection contribution by the other thermal-exchange phenomena that occur in the end-space regions. The obtained heat-transfer coefficients are in agreement with the results reported in the past literature.     

Estimation of Iron Losses in Induction Motors: Calculation Method, Results, and Analysis

This paper intends to develop a more accurate approach for determining the no-load iron losses in pulse width modulation (PWM) inverter fed induction motors. The proposed method is validated by means of a prototype motor with a plastic rotor cage. The iron losses have been computed by the time-stepping finite element method, both with sinusoidal and PWM supply. The iron losses have then been estimated by adding up the contribution generated by orthogonal components of the flux density, as if the iron losses generated by these components were independent phenomena. The rotational hysteresis losses, as well as excess ones, have been calculated applying a correction factor based on experimental data. These factors are a function of the peak flux density and ellipticity of the B vector loci. Experimental validations are provided for several frequency and magnetic saturation values. In addition, this paper demonstrates the necessity to consider the harmonics initial phase in order to increase the accuracy in the iron loss prediction.     

Energy-efficient motors

The problem of the increment of the equivalent efficiency of the huge electric motors family is very far from losing its increasing social importance [1]. We first refer to the natural ambition people have to increase the world's life quality. This is deeply dependent on the amount of the electrical energy at disposal per inhabitant, which is also strictly connected to the utilization of electric motors [2] (see Figure 1). In fact, such a parameter can be considered as a sort of "well-being" index, where more disposal of electric energy may allow for more richness and life quality. In Figure 1, the energy consumed per inhabitant per year is reported as a function of an index depending on the personal income; the results are sorted by nations and by continents. The diagrams clearly suggest that the gross domestic product (GDP) increment of a country is in correlation with the increase of the electric energy consumption (2006).     

Evaluation of radiation thermal resistances in industrial motors

This paper deals with the role of the radiation thermal resistances in industrial motors and describes a test set useful for the resistance evaluation. The test set is based on a vacuum chamber and on a numerical acquisition system, and the resistances are obtained by monitoring motor temperatures during a heating test. An analytical model that describes how the radiation resistance depends on the motor temperature is also provided. Experimental results obtained on a totally enclosed fan-cooled 150-W induction motor are shown and discussed.     

Efficiency Analysis of PWM Inverter Fed Three-Phase and Dual Three-Phase High Frequency Induction Machines for Low/Medium Power Applications

A performance analysis of three-phase and dual three-phase (DTP) induction pulsewidth modulation (PWM) inverter-fed motor drives is conducted in this paper. The focus is on the efficiency performance of high-frequency DTP machines compared to their three-phase counterparts in low/medium power applications. For this purpose, a DTP machine, having two sets of stator three-phase windings spatially shifted by 30 electrical degrees (asymmetrical six-phase winding configuration), was tested for both six-phase and three-phase winding configurations under the same magnetic conditions. Simulation and experimental results are presented to evaluate the efficiency performance of three-phase and dual-three induction motor drives employing PWM voltage source inverters.     

Thermal analysis of induction and synchronous reluctance motors

In this paper, the thermal behavior of two induction motors (2.2 and 4 kW, four poles) and two synchronous reluctance motors [(SynRMs) transverse-laminated] are investigated and compared. Both motor types use the same stator but have different rotors. Using a lumped-parameter simulation program, a thermal analysis has been also carried out, and the obtained results have been compared with the experimental ones. A direct comparison of the thermal behavior of the two motor types has thus been made for constant load and constant average copper temperature conditions. Inasmuch as the SynRM has negligible rotor losses compared with the induction motor, it is capable of a larger rated torque, from 10% to more than 20%, depending on the relative size of end connections and motor length.     

Experimental High-Frequency Parameter Identification of AC Electrical Motors

In order to predict conducted electromagnetic interference in inverter-motor drive systems, high-frequency (HF) motor models are requested and the involved parameters have to be available. In previous studies, the authors have presented an accurate HF model for induction motors and they have defined the procedures to identify the model parameters. In this paper, these results are extended to several types and sizes of industrial ac motors such as induction, synchronous reluctance (without interior permanent magnets), and brushless motors. The model parameter-identification procedure has been improved, and it is based on a least-squares data fitting applied to the measured magnitude and phase-frequency-response curves of the phase-to-ground and the phase-to-neutral impedances. The aim of this paper is to provide quick indications to select the suitable values of the HF model parameters, with reference to the size and type of the ac motor, to evaluate the HF voltage and current components in inverted-fed ac motor systems