Saving energy and costs in electrical drive systems
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Transcript of Saving energy and costs in electrical drive systems
Getriebemotoren \ Industriegetriebe \ Antriebselektronik \ Antriebsautomatisierung \ Services
Driving the world
Saving energy and costs in electrical drive systems 1
EML / Doppelbauer / March 2007
Dr.-Ing. Martin Doppelbauer
Manager Motor Development and DesignSEW Eurodrive GmbH & Co KGD-76642 Bruchsal
Getriebemotoren \ Industriegetriebe \ Antriebselektronik \ Antriebsautomatisierung \ Services
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Saving energy and costs in electrical drive systems 2
EML / Doppelbauer / March 2007
Outline
• SEW Eurodrive – Who we are and what we do
• Basic facts on energy consumption; Worldwide standardization
• Some technical aspects of electrical energy efficiency in drives
• Case studies, real life examples
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Saving energy and costs in electrical drive systems 3
EML / Doppelbauer / March 2007
SEW Eurodrive GmbH & Co KG
1.5 billion € Turnover 11 Production Plants 1.5 mill. Geared Motors p.y.11.000 Employees 60 Assembly Plants100% privately owned (all figures 2006)
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Saving energy and costs in electrical drive systems 4
EML / Doppelbauer / March 2007
SEW industrial product range
Induction Motorsfrom 0.1 kW to 200 kW
Permanent Magnet Motorsfrom 0.5 Nm to 100 Nm
Standard Frequency Invertersfrom 0.37 kW to 132 kW
Servo Controllersfrom 2 A to 100 A
... and much much more
Helical-, Bevel-, Worm-, Spiroplan-Gearboxesfrom 50 Nm to 50,000 Nm
Industrial Gearboxesfrom 10 kNm to 10,000 kNm
Mechanical Motor Brakes from 0.5 Nm to 2,000 Nm
Automation Controls(Axis Controller, PLC, Industrial Networks, ...)
Automation Systems(Electric Monorail Systems, Automatic Guided Vehicles,Roller Conceyors, ...)
Helical-, Bevel-, Planetary- Servo-Gearboxesfrom 25 Nm to 3,000 Nm
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EML / Doppelbauer / March 2007
Consumption of Electricity in Germany in 2002
Total: 60,7 Mio t coal equivalents = 494,3 billion kWhSource: VDEW-Materialien, M-19/2003, http://www.ag-energiebilanzen.de
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Classes of Industrial Motors
# of Pieces Total Powerin Germany 2005 in Germany 2005
Small-Power Motors 162 Mio 13 Mio kWDC / Single-Phase; 5 W ... 500 W(Domestic and Automotive Market)
Three-Phase Induction Motors 4.4 Mio 14 Mio kWLow-Voltage; 500 W ... 500 kW(Industrial Market)
Large Motors 7600 4.7 Mio kWHigh-Voltage; > 500 kW(Industrial Market)
(Source: Statistisches Bundesamt / ZVEI)
>75% AutomotiveVery low total operating time
Typical Efficiencies > 95%
Typical Efficiencies 70%...90%Largest saving potential
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EML / Doppelbauer / March 2007
Worldwide standards on energy efficiency motorsUSA, Canada High-Efficiency mandatory (EPACT, CSA C380-98),
Premium-Efficiency is implemented (NEMA MG1)
Panamerika High-Efficiency currently being implemented (Bs As CT 152)
Brasilien High-Efficiency is implemented (NBR 7094)
Indien High-Efficiency is implemented (IS 12615:04)
Japan High-Efficiency is imlpemented (JIS C 4212)
China High-Efficiency is implemented (GB18613),Two Premium-Efficiency Classes are under discussion
Taiwan High-Efficiency is implemented (CNS C4482-2003)
Thailand High-Efficiency is implemented
Australien/NZ High-Efficiency is mandatory (AS/NZS 1359.5),Premium-Efficiency is implemented
IEC 60034-30 New project has been started (2/1422/CD)
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Sales share of 4-pole eff1, eff2 and eff3 motors
Source: ZVEI, 2007
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Saving energy and costs in electrical drive systems 9
EML / Doppelbauer / March 2007
Energy efficiency of eff1 and eff2 motors
70,0
75,0
80,0
85,0
90,0
95,0
100,0
1 10 100
eff1
eff2
%
Motor power [kW]
15...20%cost increase
15...20%cost increase
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Energy saving potential of eff1 compared to eff2 motors
2 shifts per day240 working days per year100% average workload
10 cts per kWh energy cost
0
1
2
3
4
5
6
7
8
9
10
1 10 100Motor pow er [kW]
Ener
gy S
avin
gs [%
]
0
50
100
150
200
250
300
350
400
450
500
Ener
gy S
avin
gs [€
per
yea
r]
% €/year
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EML / Doppelbauer / March 2007
Super Premium – the next step ?
high
low
Ene
rgy
Effi
cien
cy
low highCosts
BelowStandard
*Standard
**High
***Premium
Cage induction motors
SuperPremium ?New
Technologies
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Saving energy and costs in electrical drive systems 12
EML / Doppelbauer / March 2007
Preconditions for effective use of high-efficiency motors
• High number of daily operating hours• High average motor load• Few starts/stop (S1 continuous duty)• Combination with gearboxes which
also have a good efficiency (helical,bevel – no worm-gearboxes)
• Belt and chain conveyors• Worm conveyors• Roller conveyors• Magnetic stirrer• Cooling tower drives• Pumps / Fans / Compressors• ...
• Palletizer (cyclic operation)• Hoists (cyclic operation)• Roller tables (cyclic operation)• Garage door openers• Gate openeres• ...
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Saving energy and costs in electrical drive systems 13
EML / Doppelbauer / March 2007
Speed characteristic of eff1 versus eff2 motors
Be aware when retrofitting eff2 motors with eff1 motors!
0
10
20
30
40
50
60
70
80
0 300 600 900 1200 1500
Torq
ue [N
m]
Speed [rpm]
eff2-motor
eff1-motor
. .
load
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Rotor inertia J and permissible start/stops per hour Z0
-60
-40
-20
0
20
40
60
80
100
1,1 1,5 2,2 3 4 5,5 7,5 11 15 18,5 22 30
[kW]
[%]
Rotor Inertia J increase
No-Load Switching Z0 decrease
Changing of high efficiency motors (eff1) in relation to standard efficiency motors (eff2)
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Partial load saving potential (voltage reduction)
Load dependant efficiency of a 1,5 kW eff1-motors when operated on different voltages.
DTE90L4
50
55
60
65
70
75
80
85
90
100 1000 10000P [W]
eta
[%]
eta-400eta-380eta-360eta-340eta-320eta-300eta-280eta-260eta-240eta-220DT90L4
Total saving potential: 0...10%
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Saving energy and costs in electrical drive systems 16
EML / Doppelbauer / March 2007
Saving potential by using Permanent Magnet Technology
Load dependant efficiency of a 1,5 kW eff1-Motor at constant flux and 1500 rpm at different voltages and frequencies compared to permanent magnet motor.
Vergleich eff1-ASM und SM (beide am Vektorumrichter)
0
1
2
3
4
5
6
7
8
9
10
100 1000 10000W
A
50
55
60
65
70
75
80
85
90
95
100
%
I1 SMI1 ASMeta SMeta ASM
Total saving potential: 5...10%
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Saving energy and costs in electrical drive systems 17
EML / Doppelbauer / March 2007
Comparison of worm gear and helical/bevel gearWirkungsgrad von Getrieben (i = 30...60, fB = 1)
75
77
79
81
83
85
87
89
91
93
95
0,1 1 10Abgabeleistung [kW]
Ges
amtw
irku
ngsg
rad
[%]
Stirn- und KegelradgetriebeSchneckengetriebe
(Source: Catalog data of SEW-Eurodrive GmbH&Co KG)
Total saving potential: 5...20%
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EML / Doppelbauer / March 2007
Direct Drive versus Geared Motor
Direct Drive
Speed
Pow
er
OutputPower
I²R Losses
Iron and Friction Losses
η =77,8%
η =50%
η =30%
Motor plus Gearbox
Speed
Pow
er
OutputPower
I²R Losses
Iron and Friction Losses
η =75,4%
Gearbox Losses
η =73,1%
(Helical and bevel gears)
Lower frequency, higher number of poles
Higher gearbox ratio
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EML / Doppelbauer / March 2007
Case study: Throttle versus speed control of a pumpsystemThrottle control Speed control
(Source: „Energiesparen mit elektrischen Antrieben“, ZVEI, 1999)
Total saving potential: 44%
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EML / Doppelbauer / March 2007
Case study: „Compressed air study“
(Source: „Compressed Air Systems in the European Union“, Peter Radgen, Edgar Blaustein, Frauenhofer ISI, 2001)
High-efficiency motor: 0,5 %
Speed control: 3,8 %
Air leaks: 16 %
Total saving potential: 33%
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Saving energy and costs in electrical drive systems 21
EML / Doppelbauer / March 2007
Case study: Conduit size optimization of a pump system
(Source: Norbert Gröning, KSB Aktiengesellschaft, Fachvortrag VEM Fachtagung, Wernigerode, Juni 2003)
Conduit size 50 mm: η = 0,37 Pw = 3,95 kWConduit size 80 mm: η = 0,83 Pw = 1,76 kW
... more savings are possible in partial load by using a speed control for the pump...
Total saving potential: 55 %
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EML / Doppelbauer / March 2007
Case study: Cold production with optimized speed control
(Source: Norbert Gröning, KSB Aktiengesellschaft, Fachvortrag VEM Fachtagung, Wernigerode, Juni 2003)
Pump with conventional speed control H = 30m = const. Pw = 156 kWPump with optimized speed control Pw = 97 kW
Total saving potential: 38 %
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Saving energy and costs in electrical drive systems 23
EML / Doppelbauer / March 2007
Case study: Industrial ventilator
(Source: Prof. Dr. Hans Witt, Witt&Sohn AG, Fachvortrag VEM Fachtagung, Wernigerode, Juni 2003)
70
75
80
85
90
95
100
1 10 100 1000
4-polige MotorenVentilatoren
%
P1 [kW]
Channel diameter 0,9 m: air resistance Δpt = 3050 Pa ∼ PWelleChannel diameter 1,0 m: air resistance Δpt = 2000 Pa ∼ Pwelle→ Saving potential 34%
Condiut bending radius 0,25 m: drag factor ξ = 0,4Conduit bending radius 0,5 m: drag factor ξ = 0,25→ Saving potential 37,5%
Total saving potential: 59 %
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EML / Doppelbauer / March 2007
Saving potential for industrial electricity use
0
10
20
30
40
50
60
70
Eins
parp
oten
tial [
%]
High-/premiumEfficiency
Motors
VariableSpeedDrives
OptimizedSystems
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EML / Doppelbauer / March 2007
New SEW DR-motor series
• One Motor for the world in all efficiency classes(Standard, High, Premium) from 0,11 kW up to 200 kW
• Second generation copper rotor technology• Introduction at Hannover Fair 2007 / available from 1.1.2008
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Saving energy and costs in electrical drive systems 26
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Conclusion
The Knowledge is there
The Products are there
... Let‘s use them !