SMMA 2003 Fall Technical Conference

"New Technologies for the Motors & Drives Industry"

Wednesday, November 5

* denotes SMMA member company

8:30-5:00 - SMMA Motor & Motion College Course: Brushless Permanent Magnet Motor Design

Instructor: William H. Yeadon, P.E., President, Yeadon Energy Systems Inc.*

The purpose of this course is to provide fundamental concepts and knowledge about bldc motors. Those interested in attending include application engineers and technical sales people as well as motors and drives industry professionals who would benefit from a basic understanding of bldc motors. Course content will cover the following areas:

1. Basic Configurations of BLDC Motors

2. Steel Selection

3. Magnet Characteristics and Selection

4. Mechanical Considerations

5. Magnetic Circuit Modeling

6. Motor Drive Types

7. Performance Calculations

William H. Yeadon, P.E., Yeadon Energy Systems Inc., Iron River, Mich. has over 39 years experience in the electric motor industry including work in design and development, production, quality assurance and engineering management for A.O. Smith, Warner Electric and Barber-Colman Co., Motor Div.

1:00-5:00 - Electric Motor Education and Research Foundation (EMERF) Workshop: Combining the EMERF Lamination Steels Database with Motor Simulation Programs

Instructors: Steve Sprague, Sales Manager, Proto Laminations Inc.*, and Dan Jones, President, Incremotion Associates Inc.

The EMERF Workshop will include an overview of the EMERF database for soft irons and steels used in electric motors. This data, available on the EMERF Lamination Steels, Second Edition CD, provides an additional tool for more accurate motor design including magnetic saturation (first quadrant) curves and core loss curves. The EMERF data will be combined with PC-BDC, a SPEED brushless permanent magnet motor design program to illustrate the basics of precision motor design. The workshop will also cover the selection and evaluation process for soft irons, steels and permanent magnets, as they pertain to overall motor performance.

12:00-4:30 SMMA Board of Directors Meeting

1:00-4:00 Table Top Exhibitor Set-Up

6:00-7:00 Registration

6:00-7:00 Beer & Pretzels Reception with Table Top Exhibits

Dinner on Your Own

7:00-9:00 COMMITTEE MEETINGS

· Marketing/Membership

· Motor & Motion College

· Technology

Thursday, November 6

7:30-8:00 Continental Breakfast with Table Top Exhibits

8:00-12:00 MEETING IN SESSION

8:00-8:15 Welcome Dave Beth, VP Engineering, Emerson Tool Co.*, and President, SMMA, and Jerry Lloyd, Director of Electrical Engineering, Emerson Motor Co.*, and SMMA 2003 Fall Technical Conference Chair

SESSION I: EFFICIENCY

8:15-8:30 - The Lamination Steels Third Edition CD-ROM from EMERF: A New Reference Standard for Motor Designers - Steve Sprague, Sales Manager, Proto Laminations Inc.

EMERF, The Electric Motor Education and Research Foundation, initiated the Lamination Steels Research Project to bring up to date the body of information available to motor designers pertaining to those soft magnetic alloys commonly used in electric motors. The Project has two phases, the first being the collection of existing information, published on CD-ROM, and the second being a program of original research into material properties at high frequencies and at non-sinusoidal excitations, now embodied in the Losses Consortium at Clarkson University under the supervision of Dr. Pragasen Pillay. The findings of Phase One have been published in two editions of the Lamination Steels CD-ROM and include both published and previously unpublished material data from numerous worldwide steel producers, along with summaries of international standards and a bibliography of research into the properties of lamination steels. The Third Edition, containing material data from over 14 worldwide steel producers, is currently in production and will be the most comprehensive single volume of lamination steel properties yet published. Enhancements found in the Third Edition will include core loss and magnetization data presented in both Imperial and Metric values for rolled steels as well as for a selection of amorphous and powdered metal core materials. Steve Sprague, Editor of the Lamination Steels CD-ROMs, will discuss the history, progress and potential of the program.

8:30-9:00 - Recent Progress on Losses in Lamination Steels - Pragasen Pillay, Ph.D., Professor, Department of Electrical & Computer Engineering, Clarkson University

A number of SMMA member companies have formed a Consortium to develop a better understanding of iron losses at high frequencies, high excitations, and non-sinusoidal waveforms, and ultimately, to develop an industry standard. Consortium member companies include motor and control manufacturers, steel and lamination manufacturers, an instrument company and a magnetic software company. The Consortium directs the research efforts of Professor Pillay and his students at Clarkson University. To date, Consortium members have shared test data and Professor Pillay has begun to formulate new equations to predict iron losses under the extreme excitations found in many DC and electronic motors. Consortium members presently fund the work; however, the Consortium is seeking federal grant monies. Professor Pillay will discuss results of recent Consortium work

9:00-9:30 - Development of New Magnetic Parameters to Characterize Cold Rolled Motor Lamination Steels and Predict Motor Performance - Authors: Ken Blazek, Staff Scientist, Ispat Inland Inc.*, and Craig Riviello, Global Manager of Materials Engineering, A.O. Smith Electrical Products Co.* Presenter: Craig Riviello

An analytical computer model has been tuned to predict the operating parameters of both single-phase and three-phase induction motors as a function of motor lamination material property curves. One material characteristic commonly used today, 1.5 Tesla permeability, is not effective in predicting motor efficiency. Newly defined magnetic parameters, Integrated Average Core Loss (IACL) and Integrated Average Permeability (IAP), have been shown to be excellent predictive parameters of the efficiency of motors and these parameters are considered the best for specifying motor laminations. It has been shown that IACL is closely correlated with the 1.5 Tesla core loss, and the IAP is closely correlated with the 1.0 Tesla permeability. The IAP is also strongly correlated with the 1.5 Tesla core loss for semi-processed materials. Therefore, the 1.5 Tesla core loss alone can be used to specify semi-processed CRML materials for motors. Due to the rotational fields found in a motor, the directionally averaged magnetic properties from 0 to 360 degrees to the rolling direction should be used to predict motor performance. For all cases studied, it has been shown that the directionally averaged IACL and IAP are almost the same as the L&T properties. Therefore the L&T properties, obtained via conventional Epstein testing, can be used in lieu of the directionally averaged properties.

9:30-10:00 - Efficiency Measurement of Brushless Permanent Magnet Motors - Keith Hoemann, Principal Research Engineer, Emerson Motor Co.*

Motor and system efficiency calculations require measurement of mechanical output and electrical input power. Accurate measurement of mechanical output is fairly straight forward with the range of torque transducers and amplifiers available today. The measurement of electrical power between the motor and drive, as well as the input to the drive, requires equipment with significantly more capability than is used to measure conventional sinusoidal power. This presentation will focus on the requirements for measuring the electrical input power to BLDC motors and systems. Topics include: practical bandwidth requirements, phase shift and common mode errors, external shunt limitations, 2 wattmeter measurement method for 3 phase motors

10:00-10:30 - Networking Break with Table Top Exhibits

SESSION II: MOTORS

10:30-11:00 - Starter/Alternator Systems Based on the Switched-Reluctance Machine - David A. Torrey, Principal, Advanced Energy Conversion LLC

The switched-reluctance machine (SRM) is typically used as a motor. Like all other machines, it can also be used as a generator. Starter/alternator applications require use of the same machine as both a motor during engine starting and a generator after the engine is running. This paper will compare and contrast the starting requirements with those for generating, illustrating how they tend to be in conflict for any choice of electric machines. The paper will discuss how one can go about designing an SRM to handle both starting and generating requirements. The paper concludes with a discussion of controlling the SRM when it is generating.

11:00-11:30 -Improved Motor Energy Efficiency and Performance Through the Die-Cast Copper Rotor - Darryl Van Son, Consultant, Copper Development Association

The advantages to motor performance and energy efficiency of substituting copper for aluminum in the squirrel cage of an induction motor rotor are described. Performance data on motors equipped with die-cast copper rotors dynamometer tested by several motor manufacturers according to IEEE122b specification are presented. Overall motor losses were 14-23% lower in motors with copper rotors compared to the aluminum counterparts. The manufacturing technology for economical production of copper rotors by die casting has also been investigated and is summarized. The use of nickel-based alloy high temperature die materials is shown to greatly extend die life over that experienced with conventional die steels in the casting of copper with its high melting temperatures.

11:30-12:00 - The DynaMotor Electronic Brushless Repulsion Motor - Robert Klimo, Vice President Engineering, DynaMotors Inc.

The patented brushless repulsion (BLR) motor is a novel and inexpensive technology platform for adjustable speed, single-phase induction motors. The BLR utilizes solid-state switches embedded in the armature windings that provide many useful performance features. The classic repulsion motor is constructed with a wound field and would armature having a commutator that has the brushes shorted together, without connection to the stator field winding. The motor operates by induction, has a non-rotating field and will start rotating when the position of the shorted brushes permits current to flow in the armature coils to make unidirectional torque. Moving the position of the shorted brushes can control the direction of the motor rotation and its speed. The BLR motor operated in the same manner except there are no commutators or brushes. The BLR utilizes separate isolated armature coils distributed uniformly about the armature core with each armature coil connected to a solid-state switch. The switches control the armature current and therefore control the torque, speed and direction of the motor. Control of the switches is accomplished using an RF link or photo-optical devices that control the time and position of each switch closure. A simple internal optical encoder can provide speed feedback for accurate closed-loop speed control. The BLR motor eliminates the need for power control devices in the motor power leads. Switching occurs at low frequency thus reducing radiated and power line noise. The BLR motor operates with high efficiency having a torque-speed curve similar to a universal motor. It also has the advantage of an integrated control and motor construction.

12:00-1:00 Lunch

1:00-5:00 MEETING IN SESSION

SESSION II: MOTORS (CONTINUED)

1:00 - 1:30 - Brushless DC Motor Performance Improvement with DMC Rotor - John Calico, Senior Project Engineer, Moog Components Group

The Dynamic Magnetic Compaction (DMC) process has progressed to the point where it is now viable for mass production of permanent magnet rotors. This paper reviews this progress, the current status, and the performance improvement of brushless D.C. motors using the DMC rotor. A case study will be presented.

SESSION III INTERNATIONAL STANDARDS

1:30 - 2:00 - The Future of UL - Bruce G. Bohren, Engineering Group Leader, Underwriters Laboratories Inc.

Over the last several years, UL has been re-engineering our processes in order to improve our client service and all of our operations. UL has reached a critical stage as several of these changes are coming on line. We will briefly discuss these changes and the anticipated effects on our client service.

2:00 - 2:30 - Going to China: The CCC Mark - Katy Garkey, Associate Project Engineer, Underwriters Laboratories Inc.

The People's Republic of China implemented its newest certification mark on August 1, 2003. This new system requires manufacturers in 19 product groups which are divided into 132 product categories to bear the China Compulsory Certification (CCC) Mark. If you export to or sell in China, your products may require compliance with this requirement. Products shipped to China that fail to meet the CCC Mark requirements will be held at Chinese Customs and will be subject to other penalties. During this Conference segment, you will learn how to: determine whether your product requires a CCC Mark, obtain the implementation rules, consider your options for applying, and apply for the CCC Mark.

2:30 - 3:00 - A Hybrid Magnetic Field Solver Using a Combined Finite Element/Boundary Element Field Solver - Bruce Klimpke, Technical Director, Integrated Engineering Software

One of the key components of motor design is the magnetic analysis of the machine. From the magnetic calculations the motor parameters of interest can be derived. The magnetic calculations can be done using some lumped models within a motor analysis program or can be arrived at more accurately using Finite Element solutions for the magnetic fields. An alternative method to pure Finite Elements is the Hybrid solution in which Finite Elements are used in the nonlinear regions and Boundary Elements are used in the remainder of the problem. This method will be discussed and the advantages associated with it, namely the accurate calculation of cogging torque and the correct field calculations in the region exterior to the motor.

3:00 - 3:30 - Networking Break with Table Top Exhibits

3:30 - 3:55 - Motor Production Advancements - John Mazurkiewcz, Product/Marketing Manager, Baldor Electric Co.

An actual case study of improvements in a production facility will be presented. Reviewing before and after processes, you will see measurable improvements in part consistancy, productivity, and factory throught-put. Improvements similar to these will be part of the challenging requirements which are necessary for manufacturers to think about when they are competing with low cost labor markets.

3:55 - 4:15 - Automation for North American Motor Manufacturers - Rob Faulhammer, General Manager, Winding Division, ATS Automation Tooling Systems Inc.

The presentation addresses the degree of automation and some of the other criteria which have made the North American and Europian customers competitive vs. their competition in the lower wage countries, It also addresses other criteria for staying competitive in relatively high wage countries.

4:15 - 4:30 - GlobalSpec and the Motor and Drives Industry - Greg Johnston, Executive Vice President, Oriental Motor USA Inc.

A presentation of one example of on line technical reference information available to both suppliers and motor and drives manufacturers.

4:30 - 5:00 - A Comparison of Surface versus Buried Magnets Used in Brushless PM Motors - Dan Jones, President, Incremotion Associates Inc.

The buried magnet rotor structure, in its many configurations, has gained popularity over the last few years for a number of specific applications. It provides the design with an opportunity to shape the brushless PM motor’s performance in a different way than the more “conventional” surface magnet brushless PM motor. This paper will briefly review the various surface magnet and buried magnet configurations and describe some important advantages and limitations for each magnet configuration.

 

5:00-6:00 - EMERF Long Range Planning Committee Meeting

6:00-7:00 - Reception with Table Top Exhibits

7:00-9:00 - Dinner

Friday, November 7

7:30-8:00 Continental Breakfast with Table Top Exhibits

8:00-12:00 MEETING IN SESSION

8:00-8:30 - High Performance Polymers (HPP) for Electric Motor Applications - Glenn Cupta, Marketing Manager, and Kirit C. Desai, CAE Manager, Solvay Advanced Polymers

A key driver in the electric motor industry is cost reduction, but improved performance is also desired. So how can both these sometime opposing goals be achieved? One way is by using high performance polymers. Although the initial cost of these materials can be higher than traditional materials, like die cast metals or thermoset plastics, a cost reduction can be achieved through part consolidation, elimination of post machining operations and higher production rates. These materials can also provide product improvements such as lower weight, lower noise, double insulation and enhanced corrosion and chemical resistance. This paper will discuss how these goals can be achieved.

8:30-9:00 - Influence of Graphite Addition to Bronze Powder on Tribological Properties of Self-Lubricating Bearings Impregnated with a Fluorinated Oil - Patrizia Maccone, PFPE's Application Development Labs Manager, Solvay Solexis, S.p.A.

The scope of the work was to investigate the differences, if any, in the behavior of electro-mechnical devices equipped with sintered metal bearings, in which the production route based on impregnation with a PFPE (perfluoropolyether) oil was modified by adding different amounts of graphite to the premix bronze powder. Different graphite quantities were added to the premix and different bearings' series were obtained. Then the bearings were impregnated with a PFPE oil, capable of high temperature performance. Finally, the bearings were bench-tested on fans for electric ovens. This application is considered an excellent test with regard to mechanical needs, service life and noise restraints. After testing, the conclusion was that the PFPE-impregnated bearings demonstrated excellent performance, even without adding graphite to the premix bronze powder.

9:00-9:30 Design Concepts for Electrical Machines using Soft Magnetic Composite Materials - Authors: Göran Nord, Development Engineer and Lars Hultman, Manager Magnet Development, Höganäs AB, Sweden and Alan Jack, University of Newcastle upon Tyne Presenter: Göran Nord

Soft magnetic Composites (SMCs) are today a viable alternative to steel laminations in a range of new applications, such as rotating machinery, sensors and fast switching solenoids. SMC components are successfully manufactured using the powder compaction process. The isotropic nature of the SMC combined with the unique shaping possibilities opens up for 3D-design solutions. If carefully implemented advantages such as better performance, reduced size and weight, fewer parts and lower cost can be obtained. This paper focuses on design concepts for electrical machines using soft magnetic composite materials. A variety of 3D-designs suitable for SMC will be presented and compared to traditional laminated designs. In addition the effect of the design model on the motor key-characteristics will be analysed. Selected prototypes as well as commercial products will be presented.

9:30-10:00 - Advanced Magnetic Materials for Applications - Bhanu Chelluri, Ph.D., Program Leader for Materials Development, IAP Research Inc.

Rare earth magnets produce strong magnetic flux and thus have found use in a wide range of devices. The continuous improvement in performance of such magnets coupled with innovative design/processing is one of the key factor in reducing the size and weight of small motors. Nano composite magnets are a new system made of a hard phase exchange coupled to soft magnetic phase. These nano magnets promise higher Br and BHmax values than currently available in the pure rare earth system. In this presentation, progress achieved to date in nano composite magnets including anisotropic will be elucidated. Benefits in applying these new materials in motor applications will be discussed in contrast to conventional magnets. The developments in soft magnetic powder materials and examples of devices using these materials will be shown. The performance improvements achieved in rotors made from nano composite powders will be compared with those realized from regular neodymium iron boron powders.

10:00-10:30 - Networking Break with Table Top Exhibits

10:30-11:00 - Permanent Magnets? We Don't Make Them Here Anymore. Lessons for the The New Paradigm. - Stanley R. Trout, Ph.D., P.E., Principal, Spontaneous Materials

How things in the industry have changed, i.e. production has moved to China.

How things will be different from the way they were

How best to deal or take advantage of the new situation

11:00 -11:30 - High Energy Anisotropic Bonded Magnets - A New Generation of Magnets for Motors - James Bell, Ph.D., Director of Technology, Magnet Applications Group

Since the development of NdFeB nearly 20 years ago, there have been very few significant commercial improvements to magnet materials. The isotropic bonded NdFeB grades had a great impact on the ease of construction, and performance through the manufacture of thin walled net-shaped rings, but the energy product is limited to around 10-11 MGOe. The sintered NdFeB, with energy products in the 30 to 42MGOe range give excellent performance, but have been very difficult to make, and therefore very expensive, in radially aligned ring form. Now with the development and commercialization of Magfine products, by Aichi Steel in Japan, the performance of bonded NdFeB products has been increased dramatically but with a very cost effective process. This presentation will talk about the basics of the production process, the benefits and limitations of the Magfine range of products and details of several applications that are already in production in Japan.

SESSION VI: NEW TECHNOLOGIES

11:30-12:00 - MAGLEV-Off and Running at Old Dominion University - Tony J. Morris, President & CEO, American MAGLEV, Inc.

New transportation technology is required in order to meet our ever-growing need for transportation alternatives. The issues of sprawl and congestion, air quality non-attainment, and lack of transportation quality of life are quickly becoming dominant social issues across the U.S. and around the world. New transportation technology using magnetic levitation, or MAGLEV, offers the potential for low cost, low maintenance, and high speed mass transportation with the attributes that can compete favorably with the automobile. The first commercial deployment of U.S. MAGLEV technology is currently being completed on the campus of Old Dominion University in Norfolk, Virginia. This engineering development program will be the first all up commercial service using MAGLEV in the US and the only system currently in use in the world. With the technology mature and well understood, the focus on MAGLEV deployment is on low acquisition and maintenance costs. These lower costs represent a breakthrough with the potential to solve many objective transit problems in New York and throughout the U.S. The progress at Old Dominion University is an important next step in creating new transportation technology for mass deployment.

12:00-2:00 Table Top Exhibitor Tear Down

12:00-1:00 SMMA Board of Directors Luncheon

1:00-4:00 EMERF Board of Directors Meeting

* SMMA member company

 

updated 10.29.03