BY DAN JONESACTING CHIEF ENGINEER

REVOLUTION MOTOR INDUSTRIES(RMI)

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Motors Need for Energy Improvement

Governing Bodies & Current Standards

Important Applications

EU Motor Standard – Scope & Effective Dates

AC Motors- Dominate

Competing Motor Types

How to Achieve Higher Motor Efficiency

RMI Dual Winding Technology Review

RMI Motor Test Summary & Targets

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Test Data 1.5 Kw Motor Using RMI Technology

Test Data – 37Kw Motor Using RMI Technology

Test Data – 225Kw Motor Using RMI Technology

Final Comments

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HAS BECOME A GLOBAL

COMMITMENT

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May 16, 2016 Incremotion - 5

(IEA 2011, Paul Waide and Conrad U. Brunner, Energy-Efficiency Policy Opportunities for

Electric Motor-Driven Systems, International Energy Agency, Paris, France, 2011, p. 33)

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Compressors 32%

Mechanical Movement 30%

Pumps 19%

Fans 19%

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AC induction motors are our dominant motor technology in terms of consuming electricity.

They typically run continuously for long periods of time and possess a measurable efficiency.

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SINGLE PHASE AC INDUCTION MOTORS

3 PHASE AC INDUCTION MOTORS

BRUSHLESS PM MOTORS

SYNCHRONOUS RELUCTANCE MOTORS

SWITCHED RELUCTANCE MOTORS

HYBRID MOTORS

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May 16, 2016 Incremotion - 15

I2R

Losses

55%

Magnetic

Core

Losses

20%

Friction &

Windage

Losses

9%

Stray

Load

Losses

16%

$1000Electricity

Input

5 HP89.5%

Efficiency

$895Electricity

Output

$105 Efficiency

Loss

Total Losses

10.5%

Longer Rotor & Stator Lengths

Better Magnetic Steel Laminations

Thinner Stator Laminations

More Copper

Synchronous Motor Types

Change Rotor Slot Shapes

Change The Stator Windings (Dual Windings)

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CONVERTED A 1.5Kw (2HP) MOTOR FROM IE1 TO IE2

CONVERTED A 37Kw (50HP) MOTOR FROM IE2 TO IE3

CONVERTED 225Kw (300HP) MOTOR FROM IE1 TO IE3

WORKING ON CONVERTING A 3.7Kw (5HP) MOTOR FROM IE3 TO IE4

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Increases motor efficiency (by 1-IE level) at 100% load.

Lowest Incremental cost for IE2 to IE3 & IE3 to IE4 efficiency level improvements.

Lowest Motor current levels for designated load points.

Significantly lower cable loses,(this results in system efficiency that increases significantly, greater than the motor efficiency gain alone).

Lower starting or inrush current(allowing lower cost total system design).

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Can be run as a Line S tart motor, no VFD necessary for improved performance.

Superior Power Balance.

Raises motor efficiency at 25% and 50% load points.

Increases motor's power factor to near unity at 100% load.

Improves power factor levels at lower 25 % & 50% loads.

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RMI-Design Auxiliary & Main Winding Concept

RMI-Design has Main and Auxiliary windings 90 electrical degrees apart, proper Power Balance, and

improved Efficiency in wide range of Loads

Near Unity Power Factor typically reduces motor Line Current by 15% and up to 20% (for 6-pole

motors)

R

S

T

S

T

a

x

y b

c

zA

X

Y B

C

Z

T

SR

R

A

B

C

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Main winding

Auxiliary winding with 90 el deg shift

S.Kolomeitsev US Patent 8,093,857

Power Balance Unity Plus vs. RMI-Design

Auxiliary winding in Unity Plus design is acting as break (but does

occupy ~30% of the slot)

Both windings in RMI-Design are motoring

Unity Plus RMI-Design

-5,000

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

0.0

00

0

0.0

02

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0.0

06

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08

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0.0

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0.0

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0.0

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0

Inst

ant

Po

wer

Time

G50hp 100% Windings Instant Power [ V x Amp ]

MainWinding Instant Power AuxWinding Instant Power

-5,000

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

0.0

00

0

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Inst

ant

Po

we

r

Time

D50hp 100% Windings Instant Power [ V x Amp ]

MainWinding Instant Power AuxWinding Instant Power

Main =12,590 W; Auxiliary= - 162 W Main = 10,683 W; Auxiliary =

1,745 W

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RMI 50HP 100% Windings Instant Power [V x Amp]STD 50HP 100% Windings Instant Power [V x Amp]

Self-Excitation Issue

Wanlass & Unity Plus design Motor Voltage rises up to 40% above

nominal after disconnecting from power (this can overstress

capacitors, motor winding insulation,

and can be hazardous)

Motor Leads Voltage

Voltage

D50_100_T_OF

-500

0

500

0.4 0.5 0.6 0.7 0.8 0.9 1

s.

Volt

CURVE C2D_1Circuit / VoltageTimeR_VCA ;

t

Time

Voltage

Time

G50_100_T_OFF

-500

0

500

200 300 400 500 600

(E-3) s.

Volt

CURVE C2D_4Circuit / VoltageTimeR_VCA ;

t

Motor Leads Voltage

Unity Plus RMI Design

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Improve Both Motor Efficiency & Power Factor over a wide range of performance levels (0.75 to 375Kw).

Operate successfully in both WYE & DELTA hook-up configuration.

Use the added variable of the auxiliary capacitor value to optimize efficiency values.

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30

Load 37.5 Kw/50 HP KW/HP

% STD RMI

MOTOR 25 88.4 89.6

EFFICIENCY 50 92.3 93.3

75 92.9 94.1

100 92.2 94.0

MOTOR 25 0.51 0.72

POWER 50 0.72 0.89

FACTOR 75 0.81 0.93

100 0.85 0.94

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RMI300 & STD300 Field Test Preliminary Data

Annual Energy Savings of 69,800 kWH

$4,746 Annual Savings at average industrial rate of 6.8 cents / kWH

Motor Current (Current Demand) was reduced by over 18%

R300 D300

Motor Vortage, V RMS 482.2 489.1

Motor Current, A RMS 340.5 286.4

Input Power, kW 241.6 239.1

Cable Losses, kW 25.6 18.1

System Power, kW 267.2 257.24

System Power Saving, kW 0 9.96

Energy Annual Savings *, kWH 0 69,800

* 7000 Hrs

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RMI300STD300

300hp RMI-Design Certified Lab Test Results

RMI-Design Full Load Efficiency

95.81% is about .5% higher than

Standard 300 HP motor Tested

Efficiency of 95.3%

Power Factor is near Unity in entire

power range

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LOAD 225 KW/300 HP KW/HP

% STD RMI

MOTOR 25 ----- 91.1

EFFICIENCY 50 ----- 94.7

75 ----- 95.7

100 95.3 95.8

MOTOR 25 0.65 0.99

POWER 50 0.79 1.00

FACTOR 75 0.86 0.99

100 0.88 0.98

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Used FEA simulations to perform initial design activities

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300HP RMI-Design PF vs. Standard

0.5

0.55

0.6

0.65

0.7

0.75

0.8

0.85

0.9

0.95

1

0 0.5 1 1.5 2

Po

we

r Fa

cto

r &

Eff

icie

ncy

Load

D300 Power Factor & Efficiency vs. Load

Efficiency

PF

PF R300STD300

RMI300 Power Factor and Efficiency vs. Load

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200

400

600

800

1000

1200

1 5 9

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TOR

QU

E [

Nm

]

Torque of D-Design vs. Regular

D300 Standard R300

RMI-Design Motor Output vs. Standard at Rated RPM

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About .5% of RMI-Design higher average Torque relates to

higher Efficiency

Torque of RMI-Design vs. Standard Design

RMI 300

Standard R300

1165

1170

1175

1180

1185

1190

1195

1200

1205

1 5 9

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1

TOR

QU

E [

Nm

]

Torque of D-Design vs. Regular

D300 Standard R300

RMI-Design has slightly higher average Torque and about 40% lower Torque Ripple

RMI-Design Motor Output vs. Standard at Rated RPM

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Torque of RMI-Design vs. Standard

Design

RMI 300

Standard R300

RMI300 Inrush Current

RMI300 Inrush current is 1876 A. This is about 15% lower than typical

300hp.

(typical catalog value of 300 hp is 2200A)

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RMI HAS ACHIEVED THEIR OBJECTIVES OF IMPROVED EFFICIENCY & POWER FACTOR LEVELS ACROSS A WIDE RANGE OF POWER LEVELS AND LOADS.

ONLY THE WINDING HAS BEEN CHANGED & SMALLER CAPACITORS HAVE BEEN ADDED.

INTENSIVE TESTING BY 3RD PARTY COMPANIES WAS USED TO VERIFY IMPROVED PERFORMANCE.

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WORKING ON UPDATING 4-3.7Kw/5 HP AC MOTORS FROM IE3 TO IE4.

MORE FEA SIMULATION WORK TO MATCH THEORY TO MEASURED RESULTS.

SINCE RMI IS AN R&D COMPANY THEY ARE LOOKING FOR LICENSEES OF THIS EXCITING TECHNOLOGY.

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Q & A HERE

OR AT

STAND 41F41

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