Motors In Industrial Applications Research Articles

Recycling Potential in the European Union (EU) of Low Voltage Three-Phase Induction Motors Up to 75 kW of Power: Quantitative Analysis

This article quantifies the recycling potential of the metallic materials that make up three-phase induction motors. The data on the use of electric motors by type and power determines that the most significant recycling potential lies in this low-voltage motor which powers up to 75 kW. The work aims to show the possibility of such recycling in the European Union (EU). The metals used to make the various parts of the induction motor and the main recycling methods that allow their reuse are listed. It evaluates which part of the motor can apply these recycling methods relatively easily (stator) and which part is more complex (rotor). A calculation process is used to exhaustively quantify the metals that incorporate different motors selected for other powers to determine the amounts of material that can be recycled and reused to manufacture new equipment. The recycling potential is quantifies by parts (stator and rotor) employing approximate equations obtained from the study and by materials (copper, aluminum, magnetic sheet, steel). The data calculated, the economic volume, the possibilities of energy-saving, and the environmental advantages of dedicating efforts and resources for collecting, recycling, and reusing the materials in three-phase induction motors for industrial applications show. The withdrawal of electric motors in industrial applications, due to causes related to the restructuring of production processes, manufacturing systems, breakdowns, or directly due to aging, generates considerable possibilities of reusing the metals used in their manufacture.

Predictive Firing Algorithm for Soft Starter Driven Induction Motors

Soft starters are a well-known solution for starting induction motors in industrial applications. With a predictive algorithm approach the losses in motor and soft starter can be lowered significantly. This article presents an algorithm which can be implemented in industrial devices with a concomitant speed control option. This speed control is necessary to fit the users requirements for start-up. Besides the speed control, the characteristic behavior of the predictive algorithm is analyzed in detail. The suitability of the novel predictive closed loop approach for different representative industrial applications is proven by measurements and discussed in detail.

Parameter identification of Preisach model based on velocity-controlled particle swarm optimization method

The Preisach model is widely used to simulate the magnetic performance of transformers and motors in industrial applications. However, its parameter identification problem is still a complicated task. This paper proposed a new parameter identification method based on the velocity-controlled particle swarm optimization (VCPSO) algorithm combined with the closed-form Everett function. Firstly, the Preisach model is built through the closed-form Everett function, which gives an explicit form Preisach model. Secondly, the Preisach model’s parameter identification is realized by using the VCPSO algorithm, which only needs the limiting static hysteresis loop of the material. During the optimization process, the particle velocity is automatically adjusted to avoid falling into the optimal local solution. Finally, the obtained results are compared with the experimental hysteresis loop of the B30P150 silicon steel.

A Study on the Rotor Design of Line Start Synchronous Reluctance Motor for IE4 Efficiency and Improving Power Factor

As international regulations of motor efficiency are strengthened, the line-start synchronous reluctance motor (LS-SynRM) is being studied to improve the efficiency of the electrical motor in industrial applications. However, in industrial applications, the power factor is also an important performance index, but the LS-SynRM has poor power factor due to the saliency characteristic. In this paper, the rotor design of LS-SynRM is performed to improve the efficiency and power factor. First, the barrier design is performed to improve the efficiency and power factor using the response surface method (RSM). Second, the rotor slot design is performed according to the length of bar for synchronization. Lastly, the rib design is performed to satisfy the power factor and the mechanical reliability. The final model through the design process is analyzed using finite element analysis (FEA), and the objective performance is satisfied. To verify the FEA result, the final model is manufactured, and experiment is performed.

Idvc Based Hysteresis Controller For Three-Phase Induction Motor Drive

Induction Motor is the most commonly used motor in industrial applications due to its characteristics like self-starting, reliable and easy speed control. The objective of the proposed system is to provide efficient speed control with lesser current harmonics. The Indirect Vector Control (IVDC) method is been presented for speed control of induction motor due to its high dynamic and low drift property. Though there were many classical methods for speed control like Ward-Leonard method etc.; in later years, power electronics circuits were preferred due to its high efficiency, reliability and accuracy. But the presence of static converter in drive circuits results in harmonics, giving in high feedback complexity. Therefore, the Hysteresis controller with conventional Proportional Integral and Differential (PID) control for speed and PI controller for flux is used to control the current harmonics at the point of common coupling. The simulation for speed control in squirrel-cage induction motor is carried out using the MATLAB/Simulink and the parameters like torque, speed, current and Total Harmonic Distortion are analyzed to show optimal response of drive system.

Bayesian graphical model based optimal decision-making for fault diagnosis of critical induction motors in industrial applications

Bayesian graphical model based optimal decision-making for fault diagnosis of critical induction motors in industrial applications

A novel hybrid topology for power quality improvement using multilevel inverter for the reduction of vibration and noise in brushless DC motor for industrial applications

The proposed research involves the design and implementation of a novel hybrid Topology for Power Quality Improvement using Multilevel Inverter to reduce vibration and noise in BLDC motor for industrial applications. The utility of power electronics device plays a vital role for various applications in recent days. Similarly, the power consumption is also important for all processing units. The power electronic devices contain a lot of converters for processing the energy. During such cases, the harmonics are produced in different ways. Hence, a system analysis is necessary to find the problem at conventional methods. Hence the problem is identified on the distribution static compensator (DSTATCOM) component module whose harmonics are high, and it is important module for the circuit, hence preventive action to be taken to reduce the harmonics. To limit or reduce the harmonics, it is required to modify the triggering mechanism and control unit of Multi level inverter. Hence, the proposed hybrid method is implemented with the developed H-bridge and diode clamped topology with a brushless dc motor. In addition, the vibrations and the noise level are also reduced due to the reduced total harmonic distortion. The proposed module is simulated on MATLAB Simulink, and an experimental analysis is carried out to verify functionality tools with various operating conditions, the proposed method proves more efficient than the switches and complex networks present in traditional methods.

The impact of demagnetization on the feasibility of permanent magnet synchronous motors in industry applications

Permanent magnet (PM) motors are rapidly replacing the dominant induction motors in industrial applications including pumps, fans, and compressors. PM motors are also gaining ground in critical sustainable energy applications such as wind systems, photovoltaic pumping systems and electric vehicles. Compared to induction motors, PM have higher efficiency. In this paper, the financial feasibility of replacing induction motors by PM motors at various operating conditions was analyzed on a preliminary basis. The impact of partial demagnetization and full loss of excitation on the feasibility of the replacement was also preliminarily investigated. It is found that the feasibility of replacement was less sensitive to reduction in the life time of PM motors than reduction in efficiency due to partial demagnetization. While detailed and lengthy studies are planned in the future, investigation outcomes suggest that the replacement remains feasible despite risks of demagnetization when utilization rates are above 50%. Details of the investigation are reported in the paper.

Comprehensive Analysis of Demagnetization Faults in BLDC Motors Using Novel Hybrid Electrical Equivalent Circuit and Numerical Based Approach

Brushless Direct Current (BLDC) motors are the type of Permanent Magnet Synchronous Motors (PMSMs) with trapezoidal back-EMF. Due to high proliferation of BLDC motors in industrial applications, these motors are extensively been operated for longer durations. During the continuous heavy operation, these motors are subjected to environmental, physical and thermal stresses which can lead to faults. Fault can be on the stator windings or on the Permanent Magnets (PMs) of the rotor of a machine, which can manifest into electrical quantities like currents and/or voltages, magnetic quantities like flux density and thermal characteristics of a machine. This paper shall explore in detail about the demagnetization fault in PMs of a BLDC motor. Modeling of a machine can be done through different available techniques such as Electrical Equivalent Circuit (EEC) based method or analytical method which accounts several assumptions in order to simplify the analysis. While the Numerical Methods (NM) such as Finite Element Method Magnetics (FEMM) gives more authoritative solutions. This paper aims to combine both these approaches and contribute by developing a novel Hybrid EEC-FEMM model for a closed loop BLDC motor drive using a Hysteresis Current Control (HCC) technique. The developed model is simulated both under healthy and faulty conditions. In order to simulate the effects of fault in the machine, demagnetization is introduced in the PM through various methods like change in magnetic coercivity, placement of broken magnets, partial demagnetization and lastly by replacement of a PM with a non-magnetic material which is an extreme case of demagnetization. The investigation on the machine performance through change in quantities like stator current, back-EMF, electromagnetic torque, mechanical speed and magnetic flux density is analyzed. Further using the Maxwell 2D tool, a Finite Element (FE) model of a BLDC motor is developed and its performance is examined under both healthy and demagnetization fault conditions. The experimental validation of demagnetization fault supports the inferences drawn from the simulation results.

Neural Network-Based Diagnostic Tool for Detecting Stator Inter-Turn Faults in Line Start Permanent Magnet Synchronous Motors

Three-phase line-start permanent magnet synchronous motors are considered among the most promising types of motors in industrial applications. However, these motors experience several faults, which may cause significant financial losses. This paper proposed a feed-forward neural network-based diagnostic tool for accurate and fast detection of the location and severity of stator inter-turn faults. The input to the neural network is a group of representative statistical and frequency-based features extracted from the steady-state three-phase stator current signals. The current signals with different numbers of shorted turns and loading conditions are captured using the developed finite element JMAG ™ model for interior mount LSPMSM. In addition, an experimental set-up was built to validate the finite element model and the proposed diagnostics tool. The simulation and experimental test results showed an overall accuracy of 93.125% in detecting the location and the size of inter-turn, whereas, the accuracy in detecting the location of the fault is 100%.

Reliable Detection of Rotor Faults in IM Using Frequency Tracking and Zero Sequence Voltage

The AC Alternating Current Induction Motor (IM) is the most commonly used AC motor in industrial applications because of its simplicity, robust construction, and relatively low manufacturing costs. To avoid expensive repairs in IM, early faults detection is needed. In this context, this paper presents a novel approach used to detect rotor asymmetries in induction motors. The Zero Sequence Voltage (ZSV) defined as the potential difference between the null point of the supply voltage system and the neutral of the star connection of IM stator winding is measured and employed for tracking the amplitude of the most sensitive harmonics in the spectrum of ZSV. This detection leads to make a criterion to take a decision about the state of the machine without a Prior knowledge. Simulation and experimental results obtained from real tests are presented to validate the study.

Experimental Comparisons Between Modular Multilevel DSCC Inverters and TSBC Converters for Medium-Voltage Motor Drives

This paper makes an intensive comparison in operating performance between a modular multilevel double-star chopper-cells (DSCC) inverter and a modular multilevel triple-star bridge-cells (TSBC) converter. Both inverter and converter are intended to drive medium-voltage motors in industrial applications. First, it makes numerical comparisons, thus, resulting in revealing that the torque and frequency of a driven motor produce a significant effect on capacitor-voltage fluctuation and arm or cluster current in the individual DSCC inverter and TSBC converter. Next, a three-phase DSCC inverter and a three-phase TSBC converter with the same rating as 400 V and 15 kW are designed and compared to drive the following two general purposes and specially-designed induction motors; one is rated at the 380-V, 15-kW, 50-Hz four-pole motor, and the other is at the 320-V, 15-kW, 38-Hz six-pole motor. This experimental comparison based on the two downscaled drive systems confirms the validity of the numerical comparison. Finally, this paper concludes that the DSCC inverter is more suitable for driving medium-voltage high-speed motors loaded with quadratic-torque-to-speed profiles like fans, blowers, pumps, and centrifugal compressors. On the other hand, the TSBC converter is more suitable for driving medium-voltage low-speed high-torque motors like mills, kilns, conveyors, and extruders.

Performance-Oriented Precision LARC Tracking Motion Control of a Magnetically Levitated Planar Motor With Comparative Experiments

Magnetically levitated planar motor is a new-generation motion device in modern precision industry, while its advanced motion controller design is still of main concern. In this paper, a learning adaptive robust control (LARC) motion controller is proposed for a magnetically levitated planar motor developed in our laboratory to achieve good tracking performance. The planar motor consists of a Halbach permanent magnetic array as the stator, and a levitated platen containing four groups of three-phase windings as the mover. Based on the Lorentz force law, the mover placed in the magnetic field is subjected to vertical force for levitation and horizonal force for planar motion through dynamics decoupling and current allocation. An LARC control scheme containing adaptive robust control (ARC) term and iterative learning control (ILC) term in a serial structure is then proposed for the magnetically levitated planar motor to achieve high-performance tracking even there exist parametric variations and uncertain disturbances. Comparative experiments between traditional lead, ARC, ILC, and the proposed LARC are carried out on the planar motor to track sinusoidal, point-to-point, and planar circular motions, respectively. The experimental results consistently validate that the proposed LARC control strategy outperforms other controllers much, and possesses not only good transient/steady-state tracking performance but also parametric adaptation ability and uncertain disturbance robustness. The proposed scheme actually provides a practically effective technique for motion control of magnetically levitated planar motors in industrial applications.

Geometry Optimization of Five-Phase Permanent Magnet Synchronous Motors using Bees Algorithm

Among all types of electrical motors, Permanent Magnet Synchronous Motors (PMSMs) are reliable and efficient motors in industrial applications. Because of their superiority over other kinds of motors, they are replacing conventional electric motors. On the other hand, high-phase PMSMs are good candidates to be used in certain industrial and military projects such as electric vehicles, spacecrafts, naval systems and etc. In these cases, the motor has to be designed with minimum volume and high torque and efficiency. Design optimization can improve their features noticeably, thus reduce volume and enhance performance of motors. In this paper, a new method for optimum design of a five-phase surface-mounted permanent magnet synchronous motor is presented to achieve minimum Permanent Magnets (PMs) volume with an increased torque and efficiency. Design optimization is performed in search for optimum dimensions of the motor and its permanent magnets using Bees Algorithm (BA). The design optimization results in a motor with great improvement regarding the original motor which is compared with two well- known evolutionary algorithms i.e. GA and PSO. Finally, finite element method simulation is utilized to validate the accuracy of the design.

Design and Implementation of Embedded Processor Based Brushless Motor Drive using Lead Acid Battery as Source with Lithium Ion Capacitor

For the past two decades, Brushless DC motor has become more efficient and robust motor in industrial applications due to their simplicity in structure, reliability, good mechanical properties. The absence of brushes features these motors similar to AC motors whereas their speed performance is nearly equal to that of the DC motors. Thus the combined advantages of AC and DC motors make these motors more efficient in various applications. The design was based on the output equation similar to that of conventional dc machines. This generates high-resolution PWM outputs, used to control the switching pattern of the BLDC Inverter. By varying the PWM signal produced from the microcontroller, the speed of the motor can be varied. The Hall Effect sensing unit gives information about the rotor position and based on this rotor information, switching sequence of the MOSFET is decided. The firing pulses to the gate of the MOSFET are given by the Control Signal Generation Module. Based on the developed model simulation studies are performed in Matlab/Simulink environment and hardware implementation of BLDCM drive using Lead acid battery as source With Lithium ion capacitor system is done and results were analysed using Digital Scope Oscilloscope (DSO) and output Carried Out Sucessfully. DOI: http://dx.doi.org/10.11591/telkomnika.v14i3.7938

Digital Control of Power Converters—A Survey

Power converters offer a high capability to efficiently manage electrical energy flows. Until a few years ago, their primary use was in supplying motors in industrial applications and in electric traction systems. Nowadays, in addition to those fields they are employed in a very wide range of low, medium, and high power applications including residential applications, renewable energy systems, distributed generation, and automotive. Since digital control represents a key element of modern power converters, this paper presents a review on digital devices [microcontrollers, Field Programmable Gate Arrays (FPGA)], hardware and software design techniques as well as implementation issues useful for designing modern high-performance power converters.

Monitoring of inter-turn insulation failure in induction motor using advanced signal and data processing tools

Detection of stator winding inter-turn insulation failure at early stages is crucial for promoting safe and economical use of induction motors in industrial applications. Whereas major insulation failures involving larger percentages of winding are easily discernible from magnitude of supply current, minor inter-turn insulation failures involving less than 5% of turns often go undetected. The present contribution reports experimental results of minor faults due to inter-turn insulation failures in stator windings of induction motor under different loading conditions being analyzed using data and signal processing tools combining Park's Transform and Cross Wavelet Transform. Rough Set Theory (RST) based classifier has been used for fault severity monitoring.

Multi‐dimensional switched reluctance motors for industrial applications

PurposeThe paper aims to discuss a new direction of design outline of four‐axis machine with multi‐dimensional motors. It proposes an integrated, direct‐drive machine based on switched reluctance (SR) principles. This includes how the machine is constructed and the structure of each axis of motion. The simulation and control results are also provided for performance prediction. The study aims to provide a solution and find applications for high‐performance, low‐cost manufacturing facilities.Design/methodology/approachThe study is based on simulation and experimental results for performance prediction of the multi‐dimensional motors. With the approach of grounded theory on SR machines, design and construction of each axis of motion is verified with finite element analysis. Then, corresponding control strategy is provided for the control of each axis of motion. Some corresponding experimental results are carried out to verify motor performance.FindingsThe paper provides a general design procedure for direct‐drive, integrated, multi‐dimensional SR motors. It suggests a mechanically robust, low‐cost and simple machine structure for potential applications of industrial multi‐axis machines.Research limitations/implicationsConsidering the performance from the prototype, it is expected to find applications in low‐level force and torque output such as automated small‐scale printed circuit board drillings.Practical implicationsOwing to the limitations of the present study, the machine needs further control tests for robust or adaptive applications. Therefore, researchers are encouraged to implement further advanced control strategies on the machine.Originality/valueThe authors attempt to provide a comprehensive solution of multi‐axis machine design based on direct‐drive, low‐cost multi‐dimensional SR motors.

Standards for Efficiency of Electric Motors

Electric Motors in Industrial applications consume between 30% and 40% of the generated electrical energy worldwide. In the European Union (EU), electric motor systems are by far the most important type of load in industry, using about 70% of the consumed electricity. In the tertiary sector (nonresidential buildings), although not so relevant, electric motor systems use about one-third of the electricity consumed. Their wide use makes electric motors particularly attractive for the application of efficiency improvements. Despite the wide variety of electric motors available in the market, three-phase, squirrel-cage induction motors (IMs) represent, by far, the vast majority of the market of electric motors [1], [2].

Fuzzy speed control and stability analysis of a networked induction motor system with time delays and packet dropouts

Connecting a spatially distributed system with sensors, actuators, and controllers as a networked control system by a shared data network can reduce the wiring and cost remarkably. Networked control strategy has been utilized in remote operation of linear systems. Nonlinearity is the major barrier in implementing a networked control scheme on an induction motor, which is the most widely used motor in industrial applications. In this case, we designed a sliding mode flux observer to linearize the induction motor model, such that the application of the networked control scheme is feasible. Due to the variable QoS, a fuzzy logic speed controller is proposed to adapt various network conditions. As part of the networked controller, a state predictor is designed to compensate the time delay in the feedback channel. In stability analysis, the upper bounds of time delays and packet dropouts are both given in terms of the Lyapunov theorem. Finally, simulations are conducted employing TrueTime toolbox to demonstrate the effectiveness of the control strategy.