Arçelik A.Ş. Electric Motor Plant

Arçelik A.Ş.
Electric Motor Plant
ELECTRIC
MOTOR PLANT
&
ELECTRIC
MOTORS
SYNCHRONOUS
RELUCTANCE
MOTORS
(SynRM)
PERMANENT
MAGNET
SYNCHRONOUS
MOTORS
(PMSM)
INDUCTION
MOTORS
(IM)
ELECTRIC MOTOR
PLANT
Electric Motor Plant
 Çerkezköy/Tekirdağ/Türkiye
 110 km away from the Atatürk Airport
 Total Campus Area
: 150.000 m2
DP
28.000 m2
EMP
40.000 m2
Electric Motor Plant
Approximately 13 million motors / year are produced in Electric Motor Plant
Electric Motor Plant
Application
Threephase
Motors
Singlephase
Motors
Inverter
Entegrated
Motors
Motor
Type
Power
Speed
Model
Motor Description
IE3
0,75-90kW
3000, 1500,
1000
50
IE2
0,75-110kW
3000, 1500,
1000
55
IE1
0,75-110kW
3000, 1500,
1000
204
Brake
0,12-5,5kW
3000, 1500,
1000, 750
48
Run
Capacitor
0,18-3kW
3000, 1500
25
Singlephase induction motors
• Run capacitor
• With Electronic Relay
(Run&Start capacitor)
Threephase induction motors
Run&Start
Capacitor
0,18-3kW
3000, 1500
21
IE3
0,75-22kW
3000, 1500,
1000
26
IE2
0,75-22kW
3000, 1500,
1000
26
IE3
0,75-90kW
3000, 1500,
1000
25
IE2
0,75-110kW
3000, 1500,
1000
95
Special Motors
• CE, TSE, UL Approved
• F and H class
• 2-4-6-8 poles
• Double speed, double voltage
Three phase inverter
entegrated motors
. Compactness
. Inverter motor parameters are
adjusted
• Double speed, double voltage
• Seperate winding (2/12 pole)
• Special voltage, frequency,
power
• Special bearing, end-shield
ELECTRIC MOTOR
Electric Motor
Electrical Energy
U, I
Mechanical Energy
M, n
Electric motor: electromechanical system that converts
electrical energy into mechanical energy.
Electric Motor
Some areas in which mechanical energy is used;
elevator
pump
fan
crane
Gear box
compressor
Electric Motor
IE1
IE2
IE3
TÜRKİYE
2012
2015
AB
2011
2015
ARÇELİK
2010
2012
Electric Motor
IE4
IE3
IE2
Super Premium
Efficiency
Premium
Efficiency
Yüksek Verimli
Electric Motor
IE2
• Induction Motor
IE3
• Induction Motor
IE4
• PMSM *
• SynRM **
• Induction Motor ***
*PMSM : Permanent Magnet Synchronous Motor
**SynRM: Synchronous Reluctance Motor
***IM: Induction Motor
PMSM
PMSM: Permanent Magnet Synchronous Motor
PMSM
stator
magnet
Synchronous Type
Solution with magnet
Compactness
stator
winding
magnet
rotor
Driven by inverter
PMSM
PMSM Motor Type
Surface
Insert
Outer rotor
Spoke
PMSM steady state torque production equation:

mp
T
E q1I q  I d Iq (X d  X q )
w
Magnet
torque
Reluctance
torque

Field Weakening
Hybrid
PMSM
7,5kW
7,5kW
PMSM
IM
132Fr
5,5kW
IM
90Fr
5,5kW
PMSM
[kW]
5,5
5,5
[rpm]
2950
3000
[Nm]
18,0
17,5
[A]
9,4
8,8
90,9
90,9
Eff Class
IE4
IE4
Weight [kg]
60
18
Performance Data
IM rotor
PMSM rotor
Efficiency [%]
SynRM
SynRM: Synchronous Reluctance Motor
SynRM
Synchronous Type
No magnet - Al - Cu
Driven by inverter
Ld – Lq
SynRM
d
q
SynRM motor steady state torque production equation:

0
mp
T
Eq1I q  I d I q ( X d  X q )
w
Magnet
torque
Reluctance
torque

SynRM
IM
SynRM
132Fr
5,5kW
IM
112Fr
5,5kW
SynRM
90Fr
5,5kW
PMSM
[kW]
5,5
5,5
5,5
[rpm]
2950
3000
3000
[Nm]
18,0
17,6
17,5
[A]
9,4
9,1
8,8
90,9
90,9
90,9
Eff Class
IE4
IE4
IE4
Weight [kg]
60
24
18
Performance
Data
PMSM
Efficiency [%]
*PMSM: Permanent Magnet Synchronous Motor
**SynRM: Synchronous Reluctance Motor
**IM: Induction Motor
IM
IM: Induction Motor
IM
Wound
stator
Cage rotor
IM
Input Power
Stator
losses
WindageFriction
losses
Rotor
losses
Iron
losses
Stray
load
losses
Output Power
IM
LOSSES
RATIO
METHODS FOR IMPROVEMENT
STATOR LOSSES
%25-40
-
Increasing the copper diameter
Shortening the winding head
ROTOR LOSSES
%15-25
-
Increasing the slot area
Increasing the area of end-ring
IRON LOSSES
%15-25
-
Using high-grade electrical steel
Using low thickness electrical steel
WINDAGE-FRICTION LOSSES
%5-15
-
New fan design
Efficient bearing
STRAY LOAD LOSSES
%5-10
-
Precising in design and production
IM
Classical Methods
Lstk
 Increasing stack length
 Using more copper
 Decreasing the winding head
IM
Design Power
New Material
Process Improvement
IE4 Induction Motors
IM
Design Power
Electrical Design
Mechanical Design
IM
New Material
 Efficient bearing
 High Grade stell
SKF
IM
Process Improvement
New Process Definitions
New Tolerances
New Casting Methods
Eccentricity
Forces on stator teeth
Cost
(Motor+
Inverter)
Cost
(Motor)
Producability
Max Eff
PMSM
3
3
2
1
SynRM
2
1
3
2
IM
1
2
1
3
THANK
YOU