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Ultra Premium Efficiency (IE5) Three-Phase Flux Reversal Motors

 Company EMACH has developed Three-Phase Multipole Flux Reversal Motor (FRM) shown in Fig. 1. The FRM shown in Fig. 1 consists of the toothed stator and rotor. In FRM the magnets are fixed on the stator surface. The FRM toothed rotor is very simple: there are no electrical conductors or permanent magnets on it.

Fig.1

  Due to increasing number of poles the FRM efficiency is increased and its weight and size are reduced in comparison with motors of other manufactures. The results of the experimental comparison are presented below.

Table 1. The characteristics of 1500 W 3000 rpm motors

Motor type

Induction motor

Synchronous reluctance motor

Synchronous motor with magnets in the rotor

FRM

Manufacturer

ABB

ABB

Hyosung

EMACH

Pole number

2

4

8

22

Supply frequency, Hz

50

100

200

550

 Eff1,%(torque 100%, speed 100%)

84

87.9

89.3

92.7

Eff2, % (torque 50%, speed 75%)

83.5

84.3

86.9

92.1

Eff3, % (torque 25%, speed 50%)

75.4

79.1

78.5

89.6

Efficiency class

(New standard IEC 60034-30-2)

IE3

IE4

IE5

IE5

Rotor diameter, mm

81

91.4

73.5

59.4

Rotor weight, kg

4

3.5

2.1

1.2

Rotor moment of inertia, g·m2

5

2

1.4

0.34

Magnets weight, g

-

-

235

115

Fame size, mm

90

90

71

63

Weight, kg

15.5

13

7.5

6

  In table 1 Eff1 is the efficiency at the rated speed and rated torque,  Effis the efficiency at the speed equal to 75% of the rated speed and the torque equal to 50% of the rated torque,  Effis the efficiency at the speed equal to 50% of the rated speed and the torque equal to 25% of the rated torque.

  The efficiency of the motors was measured according to IEC 60034-2-3 "Rotating electrical machines – Part 2-3: Specific test methods for determining losses and efficiency of converter-fed AC induction motors" (Method 2-3-C: Input-output method).

  Fig. 2 shows the experimental comparison of the EMACH’s FRM (green line) with the induction motor (blue line), synchronous reluctance motor (purple line) and synchronous motor with magnets (red line) at the pump load (quadric dependence of torque on speed). Fig. 2 shows that the efficiency of the EMACH’s FRM is much higher than the induction and synchronous reluctance motors efficiencies and higher than the efficiency of the synchronous motor with magnets in wide range of speed and power. 

  The FRM weight is 2.6 times less than of the induction motor, 2.2 times less than of the synchronous reluctance motor and 20% less than of the synchronous motor with magnets in the rotor.

Compared to Synchronous motor with magnets in the rotor the magnet weight of FRM is reduced by more than two times. So the FRM allows saving the expensive rare-earth permanent magnets. Also FRM has not only higher efficiency but also has lower production cost.

  Among the significant advantages of FRM there are low weight and low moment of inertia of its rotor. Moment of inertia of the FRM rotor is four times less and weight of the FRM rotor is two times less than of the rotor of the synchronous motor with magnets in the rotor (Table 1). Low moment of inertia of FRM assures significant reduction of acceleration time and of deceleration time of motor. This advantage of FRM is especially important for highly dynamic systems such as servo drives and electric spindles. Designing the motors of middle and high power  with the reduced mass of the rotor makes it possible to decrease the load in the bearing unit and mechanical losses in comparison to the traditional types of the motors.

  The FRM can replace the induction or synchronous motors with magnets in the rotor and can be applied in variable speed drives such as pumps, fans, compressors, extruders, conveyors, mixers, electric vehicles, power tools, household appliances, servo drives, electric spindles etc.

  Also FRM can be used as generator in following applications: inverter generators; variable speed diesel or petrol generators; variable speed natural gas generators; integrated starter-alternator; wind generators.

  Now EMACH develops a low-speed FRM which can be used in the various gearless applications such as wind generators, electric elevators, wheel hub motors for electric vehicle etc.

  The FRM technology developed by EMAСH is protected by the patent.

  EMACH can develop FRM in the various housing (general-purpose, explosion-proof or any housing chosen by client) in wide range of power.