Winter - Service Wire

Transcription

The Magazine for Buyers, Specifiers and OEM Integrators of Electric Motors, Drives, Motion Control & Automation Systems
Conference
Show Issue
A Webcom Publication
Winter 2009
Volume 10 / Issue 5
Visit e-Drive Magazine Online: www.e-DriveOnline.com
Features
Continued
Figure 1. Pitting
Figure 2. Fluting
Users of variable-frequency drive (VFD) cable have a new wiring and installation method that includes the use of new connector
and termination kit designed by Service Wire Co. that minimizes the effects of problems associated with VFD. The ServiceDrive ASD/
VFD Cable System helps when used as the connection method between the VFD
and the motor. It consists of cables specifically designed to build in all the optimum
components along with matching connectors to provide the best low impedance path
between the drive and motor assembly.
This cable system is used in industries like pulp and paper, life science and steel
and cement and provides labor saving and the performance as a complete solution
has reduced unscheduled shut-down that can cut on the bottom line of any process.
An end-user experiencing problems with shaft bearing currents on few of their large
motors at the Chiller Plant decided to install ServiceDrive cable system on two 200
HP motors to test the performance. The test showed improvements and the bearing
currents were virtually eliminated even when a very sensitive oscilloscope was used.
Now the end user is changing the VFD cable to ServiceDrive cable on several motors
across the organization.
Insulated Gate Bipolar Transistor (IGBT) technology has gained popularity among
PWM AC inverter applications because of the performance benefit. The advantage of
ServiceDrive ASD/ VFD Cable System
IGBT is that device rise and fall time switching capability is five to 10 times faster, resulting in lower device switching loss and a more efficient drive. The inverter technology is also creating new problems with its application.
For the drives, the faster output voltage rise time of the IGBT may increase the dielectric voltage stress on the motor and cable due to
a phenomenon called reflected wave. Most AC drives, in addition to their normal three phase output voltages, create a fourth unintended
voltage to ground, known as Common Mode Voltage (CMV). These high switching frequencies become a sensitive issue for proper drive
operation since IGBT introduced voltage stresses on motors and cables impact system performance and reliability.
For the motors, IGBT PWM drives can sometimes create insulation breakdown between the phase windings
because of high transient voltage peaking. End users notice reduced bearing life on motors soon after additions
or upgrades to PWM drives. On inspection, minute pits Figure 1 are discovered on inner and outer bearing races
as well as on the balls in the motor bearings within few weeks. Another observation that confirms the presence of
a bearing current is a phenomenon known as fluting. Upon start-up of a motor an audible “groan” is
usually heard coming from the motor that changes pitch and becomes quite noisy as the speed increase.
Such a symptom usually points to bad motor bearings that have fluting damage as shown in Figure 2.
The incidence of damage caused by bearing currents has increased during the past few years because
of variable speed drives with fast rising voltage pulses and high switching frequencies that can cause
current pulses through the bearings whose repeated discharging can gradually erode the bearing races.
on page
Brushless Wound-Rotor
Doubly-Fed Electric Motor
Systems: More Cost
Performance than
Permanent Magnet Electric
Motor Systems
- page 16
IN APPLICATION:
Machine Builder Keeps
Motion Control Separate
- page 7
Motor, Drive & Automation
Systems 2010
7
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World-Class Conference Highlights Latest Technology
Advancements and Industry Trends
Motor, Drive & Automation Systems 2010, January 28-29 in Orlando, is an industry-leading conference highlighting the latest trends, advancements impacting motor,
drive and automation systems. Join hundreds of peer and potential business partners
and discover how new technologies are improving performance, energy efficiency and
providing cost savings.
This conference is designed for OEM design and systems engineers, product developers that integrate motors, drives & automation systems into
their products and equipment; developers and manufacturers of
motors, drives and integrated systems; component, material and
technology providers.
If you are involved in the motor, drive or automation industries
or if your products and systems use these technologies, this is a
must attend event.
Visit pages 12-15 for conference details.
Departments
Motors / Drives . . . . . . . . 4
Power . . . . . . . . . . . . . . 6
In Application . . . . . . . . .7
Components . . . . . . . . . . 8
Industry News. . . . . . . . 20
Webguides. . . . . . . . . . . 22
Marketplace. . . . . . . . . . 22
www.e-DriveOnline.com
Motors / Drives
Brushless Servo Motors Introduced in Three
Different NEMA Frame Sizes
Pittman brand AB series brushless servo motors have
released a family of powerful motor solutions in three different NEMA frame sizes (each available in various lengths) to
accommodate a wide range of design
envelopes. Their brushless technology
contributes extended service life for
applications ranging from medical and
industrial equipment to instrumentation
and automation machinery.
These motors (AB23000, AB34000 and
AB48000) in NEMA sizes 23 (2.25 in.),
34 (3.54 in.) and 56 (4.75 in.) can provide
continuous stall torque from 0.42 Nm to
12.88 Nm (3.75 lb-in to 114 lb-in) and peak torque from 1.28 Nm
to 38.3 Nm (11.3 lb-in to 339 lb-in), depending on model. Rated
speeds range from 2,800 RPM to 5,200 RPM and voltage ratings
up to 325 VDC for offline drives can be achieved.
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Telephone: (+1) 204.632.5636 Fax: (+1) 204.633.7780
E-mail: [email protected]
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analysis. 12:55 PM Page 1
Project1:Layout
1 10/23/09
All versions are designed with medium to high Ke to accommodate low buss voltage applications, feature rugged
IP65 construction, incorporate heavy-duty 0.5 inch shafts and
front shaft seals and are CE, UL and cUL approved.
Volume 10, Issue 5
Specialty Motors Create Solutions in
Multiple Applications
Editor & Publisher
David Webster
Wittenstein has released capabilities to offer specialty motors in North America.
The specialty motors from Wittenstein are designed for
challenging applications, going beyond manufacturing
standard brushless DC motors and extending limits to
develop technology capable
of withstanding demanding
environments. Wittenstein’s
custom motor solutions
address specific application
needs in form, function and
environment including clean
room, ultra-high vacuum, extreme temperatures and radioactive environments.
Compact 24 Volt DC Servo Motor Features
Integral Analog Tachometer
Midwest Motion Products has released a new DC Servo
Motor, with Integral Tachometer. Accepting 24 Volt DC (or
greater) power source, this servo motor measures 2.25 inches
max diameter, by 5.4 inches
long, and has a 0.25 inch
diameter output shaft by
0.79 inch long. Easy mounting is accomplished with
four face mount M5 threaded
holes, equally spaced on a 40 mm Dia. B.C. The output of this
reversible Servomotor is rated for 35 inches per ounce torque,
at 2,600 RPM, and 210 inches per ounce peak. Despite its
compact size, and weight of approximately 2.6 pounds, it’s an
efficient design, requiring 3.4 Amps at 24 volts DC to generate
its full load torque.
Standard options available for volume applications are
custom output shaft diameters and lengths, custom mounting
flanges, motor windings for 36 V, 48 V, 60 V and 80 VDC,
tachometer voltage gradients of 1.0, 3.0, 7.0 and 14.0 V/
KRMP, integral encoders and brakes, precision planetary
gearing with standard ratios from 3:1 to 729:1 and fully compatible servo amplifiers – 8 amps continuous, 15 amps peak
analog command.
Director of Content
Shannon Given
Associate Editor
Nick Depperschmidt
Assistant Editors
Joanna Larez, Heather Krier
News Editors
Sue Hannebrink, Jessi Albers,
Jeremy Fleming, Laura Mayo
Director of Administration & Events
Marsha Grillo
Advertising, Sales & Marketing
Jessi Albers, Director of Sales
Sue Hannebrink, Account Executive
Jennifer Graham, Marketing Assistant
Production Manager
Julie Hammond
Office Manager
Julie Williams
Director of Circulation & Data Services
Marc Vang
Data Entry
Ross Webster
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Winter 2009
www.e-driveonline.com
Motors / Drives
New Powerex Single Chip Inverter Provides Solution for Applications up to 100 W
Powerex has released its M81500FP, a high voltage three-phase motor driver fabricated by a 500 V high voltage SOI (Silicon on Insulator) process. This power module
utilizes a compact SMD package to reduce the PCB space required (11.93 mm by 17.5
mm) and to simplify the PCB production process.
The M81500FP contains level shift high-side driver, low-side driver, bootstrap
diodes, IGBTs and free-wheel diodes. Also included are protective functions for overcurrent, under-voltage and thermal shutdown.
Key features of the driver are 500 V floating supply voltage, built-in bootstrap
diodes, built-in free-wheel diodes and three-phase IGBT output.
Applications for M81500FP include exhaust fans, dishwashers, air conditioners,
small servo motors and small motor controls. Samples of M81500FP are available
from stock to 12 weeks. Pricing in quantities of 1,000 is $4.71.
NMB’s New Series of Standard
Hybrid Stepper Motors
NMB Technologies Corp., a Minebea Group
Company has released a new line of standard
hybrid stepper motors.
The standard hybrid line includes the popular models in NEMA size 17, 23 and 34. NMB
also offers, as a standard, a 2.9 inch round
model with the same mounting as a NEMA 23,
providing more torque with a larger rotor but
not increasing mounting
layout motor size. These
motors are perfect for the
medical, industrial and
valve markets.
Inventory for these
standard motors is currently available at our distribution partners, otherwise lead time of 3 weeks will apply. The standard
hybrid line is available for both distribution and
OEM quantities.
New 180 W Plug-In Minidrive
With CANopen Interface
PIM3605 is a new, pluggable intelligent
minidrive particularly adapted for motion control
applications where space is critical. Manufactured
with simple pins, the drive has an architecture
that allows for faster assembly and installation,
which lets the user insert the drive in seconds. Its
miniature size and weight (67 mm by 43 mm by
20 mm, 27 g) allows
it to be placed inside
the machine or near
the motor. The drive
controls brushless,
DC, linear or step
motors up to 180 W
(36 V, 5 A) continuous and 600 W (36 V, 16 A) peak power.
PIM3605 extends Technosoft’s plug-in
minidrive series by increasing the power capabilities offered by PIM2401 (25 W) and PIM2403
(75 W). The hardware structure of PIM3605 is
based on a cost-optimized design that integrates
all the basic motor control functions on a single
module. A series of I/O signals, both digital and
analog, are available for easy interfacing with
the application. Incremental encoders, digital
and linear Halls are incorporated by default. The
drive is fully programmable with the EasyMotion
Studio software and Technosoft Motion Language (TML). A complete set of high-level TML
instructions allows the user to define and start
complex motion sequences from a CAN master
via PC / PLC (using the appropriate motion library), or to execute pre-stored motion sequences
selected from I/O lines, in a stand-alone mode.
Continued
on page
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• IGBTs
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A pioneer in high power applications, Powerex turns ideas
into cost-effective products and is leading supplier of discrete,
modular and integrated high power semiconductor solutions.
DIPIPM is a registered trademark of Mitsubiishi Electric Corp.
For information
call the Power Line at
1-800-451-1415
173 Pavilion Lane
Youngwood, PA 15697
Fax: 724-925-4393
www.pwrx.com
6
Winter 2009
5
Motors / Power
PIM3605 is able to run complex motions without requiring any external controller. The movement sequences can be programmed directly on the drive, while system
control functions are handled from the supervising PC or PLC. Motion modes as
contouring, profiling, gearing, electronic camming or PVT are easily executed in
stand-alone or multi-axis configurations.
The PIM3605 drive’s embedded intelligence, plug-in design, high power and miniature size make it a valuable motion control solution for all industrial applications that
need high-precision control and limited space integration.
DynaMotor Motor Features Variable Speed Controller
The new DynaMotor is a patented high performance brushless AC motor providing
integrated control of speed, torque and direction. With innovative new solid-state light
technology and high torque motor design, the DynaMotor delivers control while offering advantages not possible with traditional motors. At DynaMotors.com, a new Web
site showcases both the technology and its advantages.
Precision speed control is provided by LED arrays controlling solid-state switches
embedded in the rotor. This unique and innovative motor design delivers reduced
installation time and costs, GFCI circuit compatibility, and the elimination of additional
gearboxes or speed reducers; all with virtually zero RFI/EMI interference.
The single-phase variable-speed DynaMotor produces high
torque at low speeds and delivers motor/drive solutions from
1/4 to 2 horsepower. By integrating a variable-speed controller
with a high torque motor in one package, the need for gearboxes,
speed reducers and an inverter can be eliminated. Visit the new
DynaMotor Web site to learn more about how this new motor
technology provides original equipment manufacturers and end
users solutions to their motor and drive problems–problems not easily solved with
more traditional motor designs.
Universal Input/Programmable Power Supplies
Acopian has expanded its WL7 line of programmable constant voltage/constant current 1U switching power supplies to include higher voltage models with outputs to 135
VDC. The new supplies are available with an output power rating up to 450 watts.
In addition to models with slot output voltage ranges +/- 1 VDC from the nominal,
others have wide adjustment ranges from 0-5 to
0-135 Vdc. All models can be used to provide
either a constant voltage or a constant current.
Models with wide output voltage ranges can
be adjusted down to 0 volts, and both voltage
and current can be programmed with 0 V to
10 V control voltage inputs. Voltage
and current monitor
outputs and an inhibit
terminal are included
on the pluggable connectors that enable easy wiring of the control and
input leads. Provisions for N+1 redundancy and
paralleling for higher current are optional.
Other features include universal input, PFC,
soft start operation, “Vout OK” indicator and “no
load” operation. They are 1.7 inches high, and so
can be mounted on a rack panel as small as 1 U.
Transfer Switches Simplify
Selective Coordination
New Russelectric RTS series Transfer Switches
are UL labeled and listed for 30-cycle closing and
withstand ratings based on testing per UL Standard 1008. These switches dramatically simplify
selective coordination of overcurrent/short circuit
devices in emergency and backup power systems
for healthcare and other mission critical facilities.
Capable of closing in on and withstanding 30
cycles of fault current, Russelectric RTS series
Transfer Switches
have the withstand
capacity to allow downstream
devices to clear
a fault before
upstream devices.
They simplify the
engineering task of
selective coordination for emergency
and legally required
standby systems
mandated by the National Electrical Code. RTS
series switches are available in single and dual
motor versions in ratings from 100 to 4,000 amps
for either open- or closed-transition switching.
30-cycle-rated RTS Series Bypass/Isolation
Switches are also available in load-break bypass
and no load-break bypass versions.
Russelectric RTS Series switches come
equipped with the RPTCS, a versatile microprocessor-based transfer control system.
Send New Press Releases to Joanna Larez
at [email protected]
6
Winter 2009
In Application
Machine Builder Keeps Motion
Control Separate
Continued from the cover
To avoid motor bearing damage, it is essential to
provide a proper path for high frequency and allow stray
currents to return to the inverter frame without passing
through the bearings. The magnitude of the currents can
be reduced by using symmetrical motor cables.
ServiceDrive cable helps minimize the effect of high
frequency noise induced into the plant ground system
as a result of faster switching speeds of the IGBT drives
and to provide an alternative to continuously welded
aluminum armored cable (CCW) or conduit.
Proper cabling and grounding method can change
the effect of high frequency and bearing currents.
Standard equipment grounding practices are mainly
designed to provide sufficiently low impedance path
to protect people and equipment against system faults.
A variable speed drive can be effectively earthed at the
high common mode current frequencies, with the use
of symmetrical motor cables. A cable that contains a
symmetrical arrangement of three phase leads and three
ground conductors and provides a low impedance path
for common mode current to return to the inverter can
avoid bearing currents. The best and easiest way to do
this is to use shielded motor cables. The shield must be
continuous and the connections at both ends need to be
made with 360° termination.
VFD installations need water tight cable connectors
that can provide a 360° electrical bonding of the galvanized steel interlocking armor and the copper tape shield.
Motor assembly has been an industry-wide need that
has not been met since each component manufacturer
focused on individual component.
Continued on page 11
Filamatic, a division of National Instruments Co.
LLC and a manufacturer of liquid filling machines used
chiefly in pharmaceutical, personal care,
chemical specialties,
cosmetics and household products, has
resisted the growing
popularity of the PAC.
Short for Programmable Automation
Controller, the PAC
is a controller that
combines logic, motion and sometimes human-machine
interface (HMI) in one device.
“We’ve kept motion control and logic separate
largely because it’s more customer friendly where
our general customer base is concerned,” said Jack
Chopper, chief electrical engineer at Filamatic.
“If troubleshooting is ever needed, it’s easier to
perform it when dealing with separate motion and
logic controls.”
Chopper said that should a customer request
that a machine’s controls architecture be built
around a PAC, Filamatic can meet such a request
easily enough. “But again, for our general customer base, keeping logic and motion separate is
our standard approach.”
For the logic side of
machine functionality,
Filamatic relies on PLCs
from Rockwell.
“Trio’s MC206X
motion controller has
been a standard controls component in Filamatic machines for the
past five years,” said Chopper. “It’s capable of
controlling five axes of motion, and with many
machines we build that will continue to suffice.
But in some of our more complex machines
where more axes of motion are involved, we’ll
be switching to the MC464.”
A new offering from Trio, the MC464 can
support up to 64 axes of motion. Yet it’s the size
of a small book. Also attractive is the MC464’s
digital drive interface.
“It provides a plugand-play connection
between the motion
controller and various
Intelligent Power Module: IPM
digital drives,” said
Chopper. “This gives
3 in1: Driver, semiconductor, cooling
us the opportunity to
significantly reduce
400 kW – 1,8 MW
wiring while enjoying
a much higher axis
5 x higher thermal cycling capability
count compared to
what is available in
Sintered chips,
comparable motion controllers.”
for high operation temperature
The MC464 also has increased communication capabilities for programming, monitoring,
and data exchange between itself and other devices, such as vision systems and bar code readers.
“In addition,” Chopper said, “we can re-use the
Most powerful IPM on the market
exact core code modules that we have already
Imrs [A]
SKiiP®3 SKiiP®4 More power
written, tested, and debugged. This will save us
1200V
750A
1030A
37%
significant development time.”
1700V
775A
1030A
33%
Less hardware and less wiring lead to a
Calculation prerequisites:
more robust machine design with increased
Vdc=650V, Vout=400V, fSW=5kHz, cosᵠ=0,85, Ta=40°C,
dependability. “The increased communications
150% OL, fout=2 - 50Hz, 4 half bridges in parallel,
same heat-sink
3600A
capabilities provide us with more flexibility to
1800A
2400A
cleanly interface with other devices,” Chopper
Australia +61 3-85 61 56 00 Belgium +32 23 00 07 93 Brasil +55 11-41 86 95 00 Cesko +420 37 80 51 400 China +852 34 26 33 66 Danmark +45 58 10 35 56 Deutschland +49 911-65 59-0
adds. “We can provide customers with more
España +34 9 36 33 58 90 France +33 1-30 86 80 00 India +91 222 76 28 600 Italia +39 06-9 11 42 41 Japan +81 68 95 13 96 Korea +82 32-3 46 28 30 Mexico +52 55-53 00 11 51 Nederland +3155-5 29 52 95
Österreich +43 1-58 63 65 80 Polska +48 22-6 15 79 84 Russia +7 38 33 55 58 69 Schweiz +41 44-9 14 13 33 Slovensko +421 3 37 97 03 05 Suid-Afrika +27 12-3 45 60 60 Suomi +358 9-7 74 38 80
functionality and performance, while reducing
Sverige +46 8-59 4768 50 Türkiye +90 21 6-688 32 88 United Kingdom +44 19 92-58 46 77 USA +1 603-8 83 81 02
[email protected]
www.semikron.com
the hardware footprint.”
SKiiP
®
4th generation
33% more power, same volume
Winter 2009
7
Components
Motor and Drive Measurement Solutions
Yokogawa offers a complete line of test instruments to provide a total measurement solution for the applications in areas such as design, development and production
testing of Electric Motor, Variable Speed Drives and Efficiency testing. Products include precision digital power
analyzers and digital and mixed signal oscilloscopes.
The flagship Model WT3000 power analyzer is
designed with the most advanced feature set to meet the
needs of design, development and production test engineers. It provides high precision and stability, with a basic
power accuracy of 0.02 percent of reading to meet industry requirements specified in Motor Testing Standards.
Standard power measurements, harmonic analysis and
motor speed and torque measurements can all be made simultaneously. Total system
performance tests can be done, measuring electrical input and output and mechanical
power in a single instrument.
For inverter and VFD design applications, the digital oscilloscopes are well suited
with bandwidths from 200 MHz to 1.5 GHz and up to 32 channels of logic inputs.
The unique capability of the DL750 offers high vertical resolution, long acquisition
memory and isolated inputs for power electronics circuits.
Schmidt 5D Couplings Handle Axial, Angular and Parallel
Shaft Misalignments
New Schmidt 5D Couplings from Zero-Max are well suited for applications requiring
large axial, angular and parallel shaft misalignments. This all-in-one coupling design will
handle all shaft displacements providing low backlash
for precision high torque applications such as roll forming and similar heavy duty fabricating equipment.
Designed to fill an important need in the ZeroMax family of torque-rigid couplings, 5D couplings
allow for easy adjustment to any possible misaligned
shaft position without imposing heavy side loads on
shafts, bearings or other machine equipment. The coupling can accommodate up to
5° of angular misalignment and as high as 1.5 inches of parallel misalignment while
maintaining undisturbed power transmission at
constant angular velocity. Acting forces within
the coupling can be precisely calculated, assuring reliable, trouble-free system operation,
which is especially important in heavy-duty applications. This unique design will tolerate high
shock and reversing loads with minimal or no
maintenance required.
Additional features include space-saving
Type
Type 343
343 (stiffer):
(stiffer):
design and easy installation, as couplings can be
More
More easily
easily directed
directed and
and
mounted to shaft hubs or directly to existing ma“fed”
“fed” through
through tight
tight spaces.
spaces.
chine flanges (no need to reposition either shaft
Type
Type A397
A397 (more
(more flexible):
flexible):
being coupled). The couplings are available in
Readily
Readily conforms
conforms to
to sharp
sharp
standard and inverted hub configurations in bore
bends
bends and
and turns.
turns.
sizes from 1.500 inches to 6.375 inches or 38 mm
Varglas A397 and 343 Acrylic Sleevings to 160 mm. Custom designs can take this couAvailable as either A397 (flexible) or 343 (less flexible),
pling design beyond the catalog specifications.
both Varglas Acrylic Sleevings are resistant to most acids,
The 10 different model sizes handle speeds up to
oils, organic solvents, water, cut–through and abrasion. They
1,000 RPM and torque from 2,800 to 500,000 inare compatible with a wide range of wire enamels and are
designed to perform for long periods in a Class 155˚C range,
lbs. Special design modifications are available.
Who says you can’t...
have it both ways?
as well as at low temperatures, with no loss of electrical or
physical properties.
Varglas A397 and 343 Acrylic Sleevings are available in a
variety of colors and sizes in coils, cut lengths, or on spools.
Send for our free sample folder.
Under UL’s Component Program, both A337 and 343 Varglas Acrylics in Grade A are
recognized for 155˚C, 600 volt service-FiIe E63450. CSA FiIe LR58486. Conforms to
MIL-I-3190/3 and is listed on the Qualified Products List (QPL) for 155˚C service. Grade C-3
complies with VW-1-UL File E53690.
Varflex Corporation
512 W. Court St., Rome, NY 13440
315-336-4400 • Fax 315-336-0005
1-800-648-4014 • www.varflex.com
E-Mail: sales @ varflex.com
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8
Winter 2009
20 Design/Development Engineering
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Mfg/Production
MagneMover Lite LSM Transport
System Provides Intelligent, Clean
Alternative to Chain Conveyors
MagneMotion, a developer and manufacturer
of Linear Synchronous Motor (LSM) transport
systems used for process
automation, assembly
automation and transportation applications, has
released its newest product line, the MagneMover Lite Transport System.
MagneMover Lite is an electro-magnetic
transport system that specifically addresses applications requiring the movement of smaller,
lighter payloads weighing less than 2 kg, and
is well suited for a wide range of packaging
applications. MagneMover Lite precisely and
accurately moves loads on small 60 mm carriers
or pucks with the ability to independently control
the motion of hundreds to thousands of pucks
in a track network. The production units will be
available to order in the third quarter of 2010.
A selection of standard MagneMover Lite track
building blocks, including but not limited to 1-meter and 1/4 meter straights, 90° and 180° curves,
and merges / diverges, fit together in a plug-andplay manner to form an almost endless variety of
layout options. The track pieces are the linear motors and contain all the propulsion and intelligent
routing control elements, along with the guidance
and attachment features for structural supports
to allow for rapid assembly and track configuration. The system is well suited for environments
requiring clean operation and/or wash down (IP
65) capability and can also support track and trace
requirements as each puck is uniquely identified
and constantly tracked everywhere along the track
network by the MagneMotion control system.
Components
New Deutsch DRC Series Electrical Connector
New Sigma Trac SGT Linear Motor Actuator Design
LADD Industries, Inc. has released the addition of the DRC22-40PA to the Deutsch
Industrial DRC product family. DRC series connectors are high density pin count
rectangular connectors specifically designed for environments where moisture, dirt and
rough terrain can contaminate or damage electrical connections.
The DRC22-40PA accepts 40 size 20 contacts rated at 7.5 amps each. The highperformance thermoplastic body includes an integral flange for environmentally sealed
bulkhead mounting. With seals and grommets that will withstand high engine and
transmission temperatures, the DRC22-40PA is well suited for internally or externally
mounted electronic modules. The DRC22-40PA is shock and vibration resistant, and
meets all the standard specifications for the heavy-duty Deutsch product line.
Yaskawa has released the new Sigma Trac SGT series of linear
motor actuators. The products listed within are available to order now
and delivery of these actuators is described below.
Sigma Trac integrates our linear motor components into a factory
engineered and assembled linear actuator. The original Sigma Trac design (STF series)
was introduced in 2002. The new Sigma Trac design has been finalized throughout the
past two years to accommodate the requirements in the majority of applications. The
result is a new Sigma Trac design (SGT Series)that features factory assembled, fully
integrated linear motor driven slide design reduces machine design complexity and
commissioning time, automatic motor recognition by Yaskawa amplifiers eliminates
the need for user to input motor coil parameters, a wide variety of stroke lengths,
extremely high top speed and acceleration capability, smooth motion and accurate
positioning, large integrated cable carrier allows space for peripheral cables and hoses
and covers and additional accessories available.
Integrated Servo Motor Actuator Combines 2,000 lbs. of
Force, Compact Design for Increased Dynamic Performance
The new integrated-motor actuator (IMA) from Tolomatic, Inc. combines a servo
motor with Tolomatic’s proven rod-style actuator to provide a compact package.
Compared to traditional rod-style actuators, the IMA’s integrated
design provides higher
dynamic performance by
eliminating the need for
separate motors, couplers,
motor mounts, gearing and
belts. The result is reduced
Simplify motion control:
component costs, assembly
An incremental modular encoder that will simplify engineering, purchasing, and inventory all in one.
time and failure points.
The AMT has been designed with proprietary, capacitive, code-generating technology and represents a breakthrough in cost
The Tolomatic IMA provides high force
vs. resolution. It is unique among modular encoders because it is capacitive (the same technology used in digital calipers)
(up to 2,000 lbf) along with high speed (23 in./
and not optical. This eliminates handling of the sensitive optical disk and issues related to LED burnout from the photo diode.
sec.) and positional accuracy (+/- 0.00984 in. or
+/- 0.25 mm). The IMA can be ordered in any
incremental stroke length from 6 to 18 inches.
TheMA is offered with multiple ball screw
leads, and a choice of motor winding voltages.
The patent-pending screw lubrication system allows for easy re-lubrication without disassembly
for extremely long service life.
ENGINEERING
no optical disk
PURCHASING
Unique Capacitive Encoder is
Versatile
CUI, Inc. has developed a unique and
versatile modular incremental encoder.
The AMT utilizes
CUI’s proprietary capacitive
technology, which
has advantages
over the optical technology
typically used in
today’s modular encoders. The AMT’s design allows users to select from a range of
resolutions via an on-board dip switch, creating flexibility for those utilizing multiple
encoders in their applications. Additionally,
common problems associated with optical
encoders, including fragility of the optical
disk, LED burn-out, limited temperature
range and high current consumption are
eliminated by capacitive technology.
The AMT comes standard with a DIP
switch on the PCB which allows the user
to set the resolution from 48 to 2048 PPR.
It also includes an index pulse as a standard feature. The AMT is available in
two mounting options: AMT102 is radial
(straight orientation) and AMT103 is axial
(right angle orientation).
With the disk built-in to the top cover, the
assembly is very quick and easy. The design
is a drop-in replacement for other industry
standard optical units, but is easier to assemble and approximately half the height.
Its versatility means that it can be used for a
variety of applications. The cost of the AMT
starts at $30 for one piece.
starts under $30 for 1 piece
INVENTORY
2,000 encoders in one
built-in PCB with
DIP switch
motor shaft sleeves
line driver
AMT102
vertical mount
available through
800.275.4899
www. amtencoder.com
Winter 2009
9
Components
CSS / CSSH Series Features Metal Plate Technology
Many types of motor controls and industrial power supplies have environments
that most SMD current sense resistors simply can’t handle. The CSS / CSSH series
from Stackpole offers a unique metal plate
technology to allow operation up to 275ºC
Jaro Thermal Releases Extreme Pressure Fans
where most other SMD current sense resistors
Jaro Thermal, Inc. has released two new sizes of its ultra-high-static pressure Revoare limited to only 155ºC to 170ºC. In addilution series of brushless DC fans.
tion, the CSS / CSSH series is the first current
The new sizes specifically address the market’s increasing demand for maximum
sensing chip series that is rated for full power
performance, capability, lower power consumption and specific size. The 140 by 140
operation up to 100ºC instead of 70ºC. This
by 51 tops out at a cool 316 cfm with 0.83 inches static pressure, and the 120 by 120
allows engineers to use smaller chip sizes for
by 38 delivers a 262 cfm with 1.2 inches static pressure.
their application, or keep the same size part
Due to a unique design, the revolution maximizes static pressure as it simultaneand reduce the overall heat generated by the
ously optimizes air flow. The superior fixed blade design, combined with a slick airpower circuit.
guiding frame, brings this fan to the top of today’s thermal cooling revolution. Other
The CSS / CSSH series is available in chip sizes 1206 at 0.5 watt, 2010 - 1 watt,
sizes include: 38 by 28, 40 by 28, 60 by 38, 70 by 38, 80 by 38 and 92 by 38.
2512 at 2 watt and 3 watt, 2725 at 4 watt, and 2728 - 3 watt and 4 watt.
TCR’s range from 15 ppm to 50 ppm and tolerances down to 0.5 percent are
available as standard product. This series is
available in 7-inch reels with embossed tape and
New High Performance
quantities of 1,000 or 2,000 pieces depending
Piezoelectric Pinch Valve
on size. Pricing varies with size, tolerance, and
resistance value and ranges from $0.175 each to
$0.50 each in full reel quantities. Contact Stackpole for volume pricing. Thirty-three (33) part
numbers are available and in stock at Digi-key.
Infolytica Corp. Releases MagNet,
ElecNet and ThermNet Version 7
Benefits
•
•
•
•
•
•
Flow Rate: 0-2500 ml/min
Tubing OD/ID (mm): 5.0/3.0
Accuracy: 0.3% of max
Repeatability: <1%
Open/Close time: 100 ms
Response time: 50 µs
• Ultrasonic piezomotor
• Dual function “cut-off”
& “flow-control” valve
• Faster open/close time
• More precise flow control
• Faster reaction time
• low voltage & low energy
• No overheating/burnout
Flexible Shafts and Drive Cables
●automotive ●industrial ●medical ●defense
SUHNER Mfg., Inc., Rome, GA 30161
Phone: (706) 235-8046, Fax: (706) 235-8045
info.usa @ suhner.com
www.suhner.com
A New eRA IN FlOw CONTROl TeChNOlOgy
www.dti-piezotech.com
Discovery Technology International
Sarasota, Florida 34238 | Toll Free: 877-725-3384
47121 PIEZO PINCH VALVE AD 4_7-8x3_3-8".indd 1
4/11/09
Infolytica Corp. has released MagNet, ElecNet
and ThermNet version 7 with multi-threaded 3D
solvers which take full advantage of the speedups
possible with multicore computers for even faster
results than before.
MagNet is the electromagnetic field simulation software based on finite element analysis
which is well suited for the design of motors, generators, transformers, sensors or any
electromagnetic component. ElecNet is an
electric field simulation tool used for predicting
the performance of surge arresters, bushings,
insulations, cables and several high voltage
applications. ThermNet couples to MagNet for
accurate and seamless 2D/3D electromagneticthermal analysis.
In Version 7, the 3D solvers have been parallelized to run on multiple cores simultaneously
and allow for multi-threaded operations. This
change, along with other improvements to the
solvers, has resulted in significant speed ups.
Some of the other new features in version 7
17:07:33
are refreshed user interface with better toolbar
management, improved post-processing visualizations, new CAD functions for easier model
creation and improved charting functions.
US Digital
1400 NE 136th Avenue
Vancouver, WA 98684
Contact: Josh Barton
Phone: 800-736-0194 • Fax: 360-260-2469
[email protected]
www.usdigital.com
Manufacturer of motion control products,
including absolute and incremental encoders,
inclinometers, interfaces, drivers and more.
10
Winter 2009
Feature Article
Continued from page 7
The ServiceDrive connectors provide a 360° contact
and keep the continuous low impedance path on cable’s
shield or armor from the motor to the drive or drive
cabinet to avoid leakage of stray currents at the connection points. Connection of the copper tape shield
to the connector body in ServiceDrive connector is accomplished by an integral and self retaining grounding
collar that automatically provides a 360° connection as
the connector is tightened after slipping it on the matching cable size. Connector assembly is also designed to
ensure against loosening of threads due to vibration.
The VFD cable should be able to withstand the
operating conditions like repetitive 1,600 volt peak
voltage spikes from low voltage IGBT drives and at the
same time not deteriorate the performance of other drive
system components. In the perfect cable power delivery
system the net instantaneous current flowing
in the total cable system, including all phase
conductors, all ground conductors and shield,
should be zero.
In ServiceDrive VFD cable multiple grounds
are placed in all interstices under tight manufacturing tolerances so that the effective distance
from all phases to ground (affects the phase
impedance) is identical, thus producing an electrically ‘balanced’ cable. Additionally the ground
sizes combined with the shield offer a higher
than normal ground conductor size, offering a
very low ground return impedance which helps
to minimize common mode currents.
In the past, typical cabling solution has been
unshielded cable with thermoplastic (THHN )
insulation, which is the most common commercial/ industrial cable and is most often misapplied for the VFD use. The use of over designed
cable was a common practice when the thermoplastic insulation deformed upon subsequent
heating and could not withstand the voltage
peaks present in VFD application and failed.
The ServiceDrive ASD/VFD Cable System
thermoset insulation tends to maintain its form
and can withstand voltage spikes due to corona
discharge. Corona inception voltage determines
the voltage at which the insulation begins to
radiate electrical noise. By over-engineered
XLPE compounds all noise is contained instead
of radiating the noise. The multi-conductor
cables are tested via Corona inception voltage
to levels more than 1,600 volts for the thinnest
insulations for example 45 mils on #16 AWG
through #2 AWG. The larger sizes such as #1
AWG and larger have thicker insulation levels
of 55 mils. The resistance to Corona inception
is proportional to the insulation thickness and
hence the resistance to corona inception is even
higher than 1,600 volts. The end-result is a 600
volt class insulation that easily withstands in
excess of 1,600 volt spikes without degrading
its insulating (containment) properties.
Research shows solutions related to the
power cable dictate a construction that must
provide an effective electrostatic shielding for
isolation of the high frequency currents and potentials, and an effective low impedance path to
ground for draining canceling ground currents.
Circulating bearing current occurs when, the
current, instead of circulating completely inside
the motor, flows via the shaft and the bearings
of the gearbox or driven machinery and in a
structural element that is both external and
common to the motor and the driven machine.
Use of continuous welded cable and conduit
is prevalent in VFD application but the hazard
of high frequency travelling on the armor or conduit and then dissipating into the ground system
is of concern. Metal coverings of galvanized
steel interlocking metal armor provides the benefit of
mechanical protection and labor saving and also acts as a
backup low impedance path if necessary while the electrical field containment and rejection properties reduce the
effect of crosstalk. In ServiceDrive cable, the copper tape
shield over the binding tape and below the interlocked
metal armor acts as the primary low impedance path.
Heavy-duty copper tape shield applied over the entire
core assembly offers a high level of EMI screening. Skin
Effect is a physical phenomenon that relates to AC current traveling on the outer surface. At very high frequency
the entire current flows on the outer skin of the surface.
Fifty percent overlapped helically applied flat copper-tape
in VFD cables provides more surface area and has five
times longer impedance path for high frequency current
to travel and minimizes the effects of reflected wave.
The termination kit completes the whole picture. In
the new method recommended by Service Wire one end
of the tinned copper braid is terminated at the copper
tape while the other end is bolted at the closest point
on the metal backplane of the drive panel. Since high
frequency prefers flat surfaces, it is drawn to the large
surface area of the backplane. Care should be taken to
separate the drive from sensitive equipment to assure
that the common mode noise is kept away from PLC’s
and other equipment that are susceptible to noise but
due to the nature of the drive there is still residual circulating current present in the panel box. This residual current is pulled back by the braid in the termination kit on
the designated high frequency path between motor and
drive to return to the drive capacitor. If this isn’t done,
high-frequency current can get in the ground plane and
can impact expensive electronic equipment.
www.servicewire.com
Winter 2009
11
Motor, Drive & Automation Systems 2010, January 28-29 in Orlando, is
an international, industry-leading conference highlighting the latest trends,
advancements impacting motor, drive and automation systems. Join hundreds
of peer and potential business partners and discover how new technologies are
improving performance, energy efficiency and providing cost savings.
This annual conference will feature more than 25 presentations on new motors,
drives & automation systems, power electronics and improving system preformance, reliability and efficiency. Sessions will also cover market and financial
aspects such as demand, supply and pricing outlooks, testing and predictive
maintenance, mechatronic developments and trends in new growth markets.
Wednesday, January 27th
Pre-Conference Workshops
Electric Motor Power Measurement & Analysis, presented by Yokogawa Corp.
of America, GMW Associates
This workshop will provide attendees with a three step process for making precision
electrical and mechanical power measurements on AC motors and variable speed
drive systems in order to measure and calculate the system power efficiency. Topics
will include a review of basic electrical and mechanical power measurements, threephase AC motor power measurements and PWM motor drive power measurements.
Motor Control, AC Drives and Servo Systems, presented by Drivetech, Inc.
This workshop will provide fundamental concepts on motor control theory and
in-depth knowledge and skills in designing high performance motor drives. The
workshop starts with the magnetic and mechanical structure of the various motor
types to understand torque production mechanism and to derive a machine model for
various control techniques.
Design and Optimization of BLDC and Induction Motors, presented
by Infolytica
The workshop, divided into two sessions, will cover permanent magnet BLDC motors and induction motors in the afternoon. Topic covered will include output based
sizing of motors, discussions of motor template and geometry selections, motor
dimensioning, winding design and motor analysis methods. The attendees will learn
to select motor types base on performance requirements as well as engineering and
financial constraints.
Emerging Motor Technologies, presented by AiME
In recent years several new motor technologies have emerged that can have significant performance advantages in specific applications, such as Internal Permanent
Magnet (IPM), Transverse Flux (TFM), Integral Harmonic Gear IHG), Hybrid,
combines two or more magnetic effects. This workshop is intended as an overview
over these different technologies and their main performance characteristics.
Sponsors & Exhibitors
This conference is designed for OEM design and systems engineers, product developers that integrate motors, drives & automation systems into their
products and equipment; developers and manufacturers of motors, drives and
integrated systems; component, material and technology providers.
Our Commitment to You
Whether this is your first time participating at the Motor, Drive & Automation Systems conferences, or if you have attended in the past, the 2010 event
will provide you with the most up-to-date developments and technologies in
the market.
Keynote & Featured Presentations
Economic Outlook and Strategies for Success
The market for motors and drives has been subject to intense competitive pressure
worldwide. Cost and price fluctuations have many manufacturers struggling to maintain a competitive edge. Learn the competitive options for manufacturers. This session
will provide economic data, market forecasts and recommendations for small and large
manufacturers of motors and drives.
David Jacoby, President • Boston Strategies International
Motors, Drives and Motion Control: A Global Market Update
Hear the latest data on the low voltage AC induction motors and large motors markets
and discover market updates on motion control, as well as low voltage and medium
voltage motor drives. The market updates will include an estimate of the worldwide
market sizes in 2008, as well as a discussion of growth, both over the past few years,
and a forecast for the next five years. This session will provide industry sector and
geographic region breakdowns.
Alex Chausovsky, Research Manager, Motion & Drives Group • IMS Research
CleanTech Motor and Drive Panel
Discover how motor and drive systems are improving energy efficiency and reducing
operational costs.
John Petro, CTO • NovaTorque, Inc.
Jordon Bass, Business Development Manager • SNTech
Advancements in Motor and Drive Systems Panel
Discover the latest advancements in motor and drive systems; from new materials
and components to energy efficiency. The panel will also discuss how and where the
technologies are being used.
Khoi Vu, General Manager/Vice President • Kollmorgen
David Berkowitz, Dir. of OEM Test Services • Advanced Energy
George Holling, Technical Director • Rocky Mountain Technologies
Technical Improvements in Industrial IGBT Modules Required for Reliable
Operation in Vehicle Traction Drives
Learn the technical challenges involved in designing high production volume, low cost IGBT
modules for the industrial market that will also operate reliably in commercial and agricultural
vehicle (CAV) applications. The specific technical issues are mechanical vibration, thermo mechanical wear out mechanisms, such as power and thermal cycling, calculation of mission cycles
and control of silicon junction temperatures.
David Levett, Power Electronics Design and Applications Engineer • Infineon
Gold Sponsor
12
Register Online at www.e-DriveOnline.com
Thursday, January 28th
8:00 Keynote Presentation
Economic Outlook and Strategies for Success
3:55
Smart Sensor Bearing for Efficient e-Motor Drives
Stephane Moisy, Project Manager, Automotive Development Center • SKF France
David Jacoby, President • Boston Strategies International
9:15 Featured Presentation
Advancements in Motor and Drive Systems Panel
Khoi Vu, General Manager/Vice President • Kollmorgen
David Berkowitz, Dir. of OEM Test Services • Advanced Energy
George Holling, Technical Dir. • Rocky Mountain Technologies
Technical Improvements in Industrial IGBT Modules Required for Reliable
Operation in Vehicle Traction Drives
David Levett Ph.D., Power Electronics Design and Applications Engineer
Infineon Technologies Industrial Power, Inc.
5:00
Cocktail Reception
10:00 Networking Break
10:30
Motor Systems Efficiency and Advancements
Brian Taylor, Senior Vice President • Power Efficiency Corp.
Using Servo Motor and Drive Technologies in an Extreme Environment
Otto Fanini, Staff Engineer • Baker Hughes, Inc.
Dr. Dal Ohm, President • Drivetech, Inc.
11:10
New Motor and Drive Technology Provides Energy Savings and Improved
Reliability for Cooling Tower Installations
Robbie McElveen, Sr. Development Engineer • Baldor Electric
Registration Information
Two Day Pass - Provides access to both days of the conference. Includes all
networking and expo activities and reception.
Using Electric Motors on More Electric Airplanes
11:50
Real-Time Simulation Technologies to Improve The Development of Electric
Motor Drives
Single Day Pass - Provides access to either one of the individual days of
the conference.
$595
A Radial Airgap Pancake Motor for the 21 Century
Federal Pass - Discounted rate for Federal, State, County and local entities,
including military.
$595
Kaz Furmanczyk, Principal Engineer • Crane Aerospace and Electronics
Christian Dufour, Simulation Specialist • Opal-RT Technologies, Inc.
st
David Hall, Vice President, Proprietary Products • Automation Controls Group
12:30 Networking Lunch
1:30
An Exploration of Ultra-Low Cost Motor Drive Design
Patrick Heath, Marketing Manager • Microchip Technology, Inc.
Daniel Torres, Applications Engineer • Microchip Technology, Inc.
A Highly-Efficient High-Performance Electric Motor Constructed with Low
Cost Materials
2:10
Structured Design Method Application to Improve PLC Programming Efficiency
William Lydon, Managing Director • PLCopen North America
Energy Savings in a Minerals Processor Using Copper-Rotor Electric Motors
(1 person)
$995
(2 people)
$895
(3 people)
$795
Expo Only Pass - Provides access to the exhibit area only. Exhibit Only
Pass does NOT include conference CD-ROM, admittance to conference
sessions or food/beverage.
Expo Only Pass:
$50
Pre Conference Workshops - Visit www.e-DriveOnline.com for
pricing information.
Magnetics 2010 Conference Upgrade - Provides access to both days of the
conference and all conference proceedings.
Magnetics 2010 Upgrade:
$300
Ways to Register
By Phone: 800-803-9488
By Web: www.e-DriveOnline.com
David Brender, National Program Manager • Copper Development Association, Inc.
2:45
Networking Break
3:15
MR Feedback Systems: Improvements in Magnetoresistive Sensor and
Processing Systems
Brian W. Winter, Encoder Product Manager • Avtron Industrial Automation
Planetary/Cycloidal Reducer Applications, Opportunities and Solutions
John D’Amico, COO; Kris Kras, V.P. of Engineering • Onvio LLC
Hotel Information
Motor, Drive & Automation Systems 2010 will be held at the Hilton
Disney in the Walt Disney World Resort. A special room rate of $199 a
night is available for conference attendees. Be sure to reserve your room
by January 6th, 2010 and mention “Webcom Communications” to receive
this special rate.
1751 Hotel Plaza Boulevard • Lake Buena Vista, Florida 32830
Phone: 1-800-782-4414 • Web site: www1.hilton.com
13
Friday, January 29th
Co-Located Conference
8:00 Keynote Presentation
Motors, Drives and Motion Control: A Global
Market Update
Alex Chausovsky, Research Manager,
Motion & Drives Group • IMS Research
CleanTech Motor and Drive Panel
12:45
New IGBT Modules for Three Level Inverters
Eric R. Motto, Principal Engineer, Applications
and New Product Development • Powerex, Inc.
1:25
Reverse Conducting IGBT for Drives: CostPerformance Optimization for Consumer Drives
Magnetics 2010 is a leading global event within
the magnetics market, bringing together worldwide magnetics experts. The conference will focus
on the latest advancements in magnetic applications, technology and materials.
2:05
An Interactive Simulation Tool for Power
Semiconductor Circuits
Motor, Drive & Automation Systems Conference
will be co-located with the Magnetics 2010 conference. We feel this addition to be a natural fit,
one that will provide added benefit to attendees,
exhibitors and sponsors of both these world class
technical events.
Peter M. Stipan, Sales, Marketing &
Business Development • Infineon Technologies
Jordon Bass, Business Development Manager • SNTech
10:00 Networking Break
10:30
Automation on a Budget
Glen Michalske, Consultant
Glen Michalske Business Development
Paul Moore, Sales Engineer • Semikron
Tom Rantala, Manager • Semikron
2:45
Conclusion of Conference
MEMS Technology Renders New Miniature
Inductive Encoder
Kirk Barker, Electronics Product Manager
Maxon Precision Motors
11:10
Single and Multiple Axis Linear Motion Systems
Attendees to either event will have access to the
combined exhibit halls and networking breaks,
receptions and luncheons. For a nominal “conference upgrade” fee, attendees will have access to
both conference programs.
Magnetics 2010 is designed specifically for OEM
developers of products that utilize magnets and
magnet systems, design engineers, OEM developers involved in EMC technology and magnetic
effects, magnetics manufacturers and integrators,
and material suppliers in the magnetics industry.
Jonathan Schroeder, Business Development Manager
PBC Linear
Regenerative Braking of BLDC Motors
Debraj Deb, Applications Engineer
Microchip Technology, Inc.
Presentations from industry-leading companies
including Arnold Magnetic Technologies Corp.,
LE USA Walker Scientific, Molycorp Minerals,
Advanced Magnet Lab, Dexter Magnetic Technologies, Electron Energy Corp., Moving Magnet
Technologies and Quadrant Magnetics.
11:45 Networking Lunch
Exhibitor Previews
On-Line Design Support from Infineon
Infineon offers a broad range of leading edge
Power Semiconductors for industrial drives,
renewable energy, transportation, power supplies,
consumer appliances and medical equipment.
Now get online support using the new Infineon
Power Simulation program (IPOSIM) - select the
right modules or disc devices by determining power losses and thermal calculations
for: rectifiers (1, 3 and 6 phase), AC switches (1 and 3 phase), IGBT modules for
inverters (single and three-phase, 2/3-Level) and IGBT modules for DC converters
(buck and boost).
Visit http://web.transim.com/Infineon-IPOSIM to perform a calculation of switching
and conduction losses, taking into account thermal ratings and even different control
algorithms. Thermal conditions may be adjusted by selecting custom or predefined
heat sinks, air or water cooled. Transient temperatures following a load profile may
also be calculated. Data files and results can be saved in tabular and graphic form for
later revision or future reference. Join us in January at Booth # 200 for a personal
design consultation.
Visit Us at Booth 200 - Gold Sponsor
New Generation of Intelligent IGBT
Power Modules from Semikron
SKiiP4, the new generation of intelligent IGBT
power modules, boasts a longer service life than
non-sintered modules and can be used in higher
temperature applications. In SKiiP4 modules, the
semiconductor chips are not soldered to the ceramic
substrate but are joined using sinter technology,
meaning that higher operating temperatures are
possible with no compromise to, or in some cases even increased, reliability. The
SKiiP power pack is the most powerful intelligent power module on the market and
14
delivers 33 percent more power than its predecessor SKiiP 3 out of the same volume.
Like its predecessors, SKiiP 4 is based on well matched components: heat sink, power
module, driver and protective sensors/functions. Here, the mounting and connecting
technology, which is based on a pressure system, plays a crucial role. The IPM is used
predominantly in wind and solar power applications, traction applications, elevator
systems and industrial drives with high outputs of between 400 kW and 1.8 MW.
Visit Us at Booth 210
Powerex
Powerex turns ideas into cost-effective products and
is a supplier of discrete, modular and integrated high
power semiconductor solutions, supporting many markets including AC, DC and servo
drives (low and medium voltage), aircraft, alternative energy, distributed power and
electric vehicles.
Powerex and its strategic partners maintain a commitment to research and
innovative product development to meet customer power semiconductor requirements,
including decreased component size, reduced costs and increased energy efficiency.
The Copper Development Association, Inc.
The Copper Development Association Inc. is the market
development, engineering and information services arm of the
copper industry, chartered to enhance and expand markets for
copper and its alloys in North America.
Membership in CDA is open to copper producers worldwide and to brass mill, wire
mill and foundry fabricators of copper and copper alloys with production facilities in
the USA. Membership provides the opportunity to be part of an industrywide market
development and technical service program so large and diverse that no one company
would be prepared to undertake it alone.
Electro-Thermal Actuator Technology
Thermotion has introduced
its newest Electro-Thermal
Actuator technology, the
Thermo-Magnetic Actuator.
This hybrid combines high
output force, long-stroke
capability of thermal actuation
with low steady-state current
draw of magnetic holding.
Thermo-Magnetic Actuators draw less than 1 watt at
steady-state, offer life expectancies in excess of 250,000
cycles, and deliver fail-safe spring return functionality.
The Thermo-Magnetic Actuators have rotary or linear
outputs. Torques to 5 in-lbs. (0.57 n-m) through 90
degrees. Strokes to 1 inch (25 mm) at 20 lbs(90 n). The
Thermo-Magnetic Actuators are available for 12 V, 24 V,
110 V, 220 VAC/DC in aviation, transportation, HVAC,
and appliance industries.
Visit Us at Table 5
Precision Non-Inductive Thick
Film Resistors
EBG RESISTORS LLC is a leading manufacturer of
standardized and customized precision non-inductive
thick film resistors. Avoiding the mass-produced
commodity items with less exacting requirements, EBG
develops highly reliable products to fill the creative
requirements of the design and development engineer in
today’s fast moving world. EBG produces High Voltage
(up to 100KV), High Power (up to 1700W), Shunts,
Dividers, Networks, and many custom design resistors,
with very high stability, low TCR’s, VCR’s and tight
tolerances. We have over 200 standard styles and the
in-house ability to produce custom versions and add new
series to our product line yearly. Our resistors are used in
various applications for load banks, switching controls,
regen energy, dynamic breaking, capacitor charging and
discharging, just to mention a few and are used in many
different fields such as aerospace, military, medical,
motor drive, alternate energy, welding, test equipment,
power supplies, electrostatic, and many others.
Visit Us at Table 6
Advanced Energy
Advanced Energy operates
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Advanced Energy helps clients prepare an appropriate
motor specification for application(s), conduct endurance
testing to ensure warrantee problems are kept to a
minimum and help customers with ongoing motor
quality monitoring programs. Congress passed the
Energy Independence and Security Act of 2007 requiring
that OEMs who include a wide range of motors in their
products must comply with higher efficacy standards by
December 2010. Those considering new motor and drive
suppliers, conducting design changes to comply with this
law, or experiencing high warranty claims, contact us for
an expert and independent analysis.
Avtron
Avtron is a Cleveland, Ohio based technology leader
in providing automatic test equipment, automation
systems, and products to industries ranging from
aviation to paper mills. Avtron specializes in product
development and long term support. Our reputation is
that of a State of the Art designer and manufacturer who
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the value expected of us.
Avtron’s quality system has been recognized as
meeting the highest level of ISO 9000 certification. In
1998, Avtron passed the most extensive assessment
possible, ISO 9001, which includes Engineering
and Design in the qualification process. This assures
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service and value provided, as well as on the high
reliability of our products.
Yokogawa Corporation
Since our establishment in the United
States in 1957, Yokogawa Corporation
of America has become a leading
manufacturer and supplier of test,
measurement, field instrumentation, process control and
information products for North America.
Headquartered just south of Atlanta, Georgia,
Yokogawa Corporation of America has sales offices
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with a network of representatives and distributors that
reflect this commitment.
Trusted ePlatform Services
Founded in 1983, Advantech has provided leadership
for innovative ePlatform products and services for over
25 years. With comprehensive product ranges, customercentric design services, and an extensive global network,
Advantech is your most trustworthy partner to empower
numerous innovations in the connected eWorld.
Aiming to provide customers with reliable
system components for a wide variety of industrial
automation applications, IAG combines connectivity,
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PC-based automation technologies. Aligned with
the open architecture movement, we empower our
customers with fully integrated platforms, open system
components and solution competence. In this way, we
help our customers realize streamlined and customized
solutions that improve efficiency & productivity. We
are fully dedicated to our slogan of “Open eAutomation
, Boundless Integration”, and are committed to this
direction by stretching the boundaries of technology
and service with cutting-edge open automation
products and solutions.
ElectroMagneticWorks, Inc.
ElectroMagneticWorks Inc. (EMW)
is a electronic design automation
(EDA) company. EMW focuses on the
development, marketing and support
of Computer Aided Engineering
(CAE) and Computer Aided Design (CAD) tools based
on electromagnetic principles and phenomena. With
products covering frequencies ranging from DC to
millimeter waves, EMW aims to meet the needs of its
clients with the highest quality products.
EMW has a long track record of successful
collaboration with SolidWorks Corporation and its
analysis division COSMOSM. Today, EMW is the only
company offering a complete electromagnetic analysis
software suite that is fully embedded in SolidWorks.
EMW’s products meet SolidWorks’s highest quality
standards and are certified Gold products by SolidWorks.
Encoder Interface From Heidenhain
Faster than Ever
The EnDat 2.2
encoder interface from
Heidenhain has doubled
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value, thus making shorter cycle times possible. This
means that EnDat 2.2 is now the fastest purely serial
interface for position encoders, based on the RS 485
transmission characteristics.
The EnDat 2.2 interface yields significant savings
in connection technology for the entire system as well
as a reduction of required installation space in the
machine. Since the analog scanning signals are digitized
and subdivided directly at the place of measurement,
characteristics of servo motors such as positioning
accuracy and speed stability can be further improved.
Along with the automatic self-configuration of encoders
and drives in automation systems, the transmission
of additional information, such as temperature, to the
subsequent electronics is possible without additional
wires. The online diagnostics capability of the interface
ensures the availability of machines and facilities and
simplifies maintenance.
Three Phase Rectifier Bridge in SIP
Package from Sanrex
SanRex’s new Three Phase Rectifier Bridge in a SIP
package, DF-NA series
is just one of the many
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for the design of high
performance and reliable
applications such as
motor drives, power
supplies, battery chargers,
welding and plasma cutting machines.
It is designed for applications requiring flat and
compact designs. The DF-NA series features a rectifier
bridge in a compact transfer mold SIP package. This
advantage typically reduces the needed connecting parts
and manufacturing cost. It also contributes not only
to lower cost but also high efficiency and reliability.
The modules are isolated for easy mounting with other
components or a common heatsink.
DC Link Film Capacitor from SBE, Inc.
SBE’s Power Ring
Film Capacitor offers
the inverter designer
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inverter performance.
Integrating the power
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The circular design, and ability to integrate the
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the metal end-spray on the surface of the capacitor
mitigates the differences in the CTE of the dielectric
and metal spray. Visit our booth at Motor, Drive and
Automation Systems to learn more.
15
Feature Article
Brushless Wound-Rotor Doubly-Fed Electric Motor Systems:
More Cost-Performance than Permanent Magnet Electric Motor Systems
By Frederick W. Klatt
Chief Technology Officer, Best Electric Machine
Electric motors or generators are categorized as
electric machines (EM), which consume more than 60
percent of all electricity produced and produce virtually
all electricity consumed. Electric machines are collaborative essentials for any energy efficiency, smart grid,
electric vehicle, alternative energy or renewable energy
technology. As the backbone of the electricity infrastructure, which is anticipated to grow 40 percent by 2030,
electric machines have strategic national and global
energy importance.
Electronic control of an EM or an electric machine
system (EMS) is essential for functional operation of the
EM, such as for the neodymium permanent magnet (PM)
EMS (PM-EMS), or provides optimum performance of
the EM. An EMS is classified as singly-fed or doublyfed and sub-classified as synchronous or asynchronous.
All electric machines require two synchronously moving (rotating) magnetic fields on the rotor and stator,
respectively, for the basic principle of operation and for
average torque production. To avoid confusion with the
basic principle of operation, an asynchronous or induction
EMS requires low frequency current induction across an
air-gap to produce at least one of the moving magnetic
fields with the frequency of induction on par with the
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Winter 2009
angular velocity of movement (speed-based induction)
and a synchronous EMS does not rely on speed-based
induction across an air-gap. An excited multiphase
winding set or armature winding set produces a moving
magnetic field. Under the same voltage and frequency of
operation, a singly-fed EMS incorporates one armature
winding set, which is rated for full system power, and has
a constant torque speed range of synchronous speed and a
doubly-fed EMS incorporates dual armature winding sets.
The EMS are each rated for half system power, and must
have guaranteed stability throughout its constant torque
speed range of twice synchronous speed. By definition,
the PM-EMS with one armature winding set is classified
as a singly-fed synchronous EMS. The slip-energy
recovery wound-rotor induction EMS or the
field excited, synchronous EMS should never be
considered doubly-fed electric machine systems
because only one winding set actively participates
in the energy conversion process and continuous
control is not to twice synchronous speed.
Brushless and without magnetizing current, the
PM-EMS is perceived as having higher efficiency,
higher power density and lower maintenance (i.e.,
brushless) of any practical electric motor or generator system. The R+D investment in permanent
magnet material, analysis and electronic control
during the past several decades by government,
academia and industry is partially responsible
for the perception bias. As expected during these
times of energy consciousness, but in spite of the
expensive and delicate nature of PM materials or
the difficult manufacturing, handling, safety and
electronic reliability issues associated with the
persistent magnetic fields of PM, the PM-EMS is
quickly taking market share and is fulfilling the
prediction that almost all electric machines will
eventually be electronically controlled or an EMS.
Analytical reports show the entire global deposit
of PM raw materials, which is 90 percent indigenous to China, cannot meet the anticipated demand
expected from the wind energy and electric vehicle
industries. This is troubling considering the national and global importance of electric machine
systems. Yet, the PM-EMS industry, which is
predominantly controlled by Chinese affiliates,
inconceivably forecasts PM material pricing will
drop with increased demand.
The wound-rotor [synchronous] doubly-fed
(WRDF) electric machine system (WRDF-EMS)
is well understood by electric machine experts. By
compromising electromagnetic symmetry, the operating equations of the WRDF-EMS become the
basic study for all other electric machine systems,
including the PM-EMS. Studies published in
technical and professional journals since the early
60s document the WRDF-EMS as having highest
power density, highest peak torque density, lowest
cost, and highest efficiency of any EMS, which
are the direct result of WRDF-EMS symmetry
and the following attributes of the WRDF-EMS:
• With an armature winding set residing on the
rotor, the rotor real-estate of the WRDF-EMS
actively participates in the energy conversion
process, which is a clear metric for EMS size and
cost. In contrast, the rotor real-estate of any other
EMS, such as the PM-EMS, passively participates in the energy conversion process while
consuming physical volume
• With two independently excited winding sets
overall (the dual armatures), the WRDF-EMS
does not depend on speed-based induction across
an air-gap for operation and is the only synchronous doubly-fed EMS.
Feature Article
• Twice the constant torque speed range for a given
excitation frequency, voltage and torque (twice the power for a given frame size), which is a metric for EMS
efficiency and size. The constant torque speed range for
the WRDF-EMS is 7,600 RPM with two poles and 60
Hz excitation compared to 3,600 RPM for the PM-EMS.
• Low power electronic controller for controlling full
system power, a metric for EMS size, cost and efficiency. The electronic controller for the WRDF-EMS is rated
for 50 percent (or less) of full system power compared to
100 percent for the PM-EMS.
• With only active winding sets on the rotor and stator,
respectively, and no delicate PM to demagnetize, only
the WRDF-EMS features a true dual ported transformer
topology that stabilizes air-gap flux and mitigates core
saturation regardless of torque current. The WRDF-EMS
shows eight times the peak torque of other electric machines, including the PM-EMS.
Based on these attributes, the WRDF-EMS
theoretically shows half the size, half the loss and
at least half the cost of any other electric machine
system of similar power rating. Without discrete
magnetic fields of permanent magnets, the fully
electromagnetic WRDF-EMS design is straightforward with legacy criteria and templates.
Not without an Achilles’ heal, the acceptance of
the WRDF-EMS continues to be hampered
by three problems
without practical
solutions today. It
incorporates a high
maintenance, unreliFigure 1. Third Genera- able multiphase slipring-brush assembly for
tion Prototype
propagating multiphase
power to the rotor winding sets. When operating
under synchronous principles, doubly-fed control
is unstable at any speed because torque production
is a function of rotor position. When operating under induction (asynchronous) principles, doublyfed control is discontinuous at synchronous speed,
where induction ceases to exist.
Since the problems are less acute in generating mode where a prime mover stabilizes rotor
angular momentum, the WRDF-EMS is the
de facto generator for variable speed, constant
frequency generation (VSCF) applications, such
as wind turbines. During the period of WRDFEMS study, the so-called brushless doubly-fed
induction (asynchronous) or reluctance electric
machines systems (BDF-EMS) were conceived
and developed as brushless and stable alternatives to the WRDF-EMS by sacrificing its attractive attributes of high efficiency, high power
density, high peak torque density and low cost.
Without practical solutions however, it is no surprise the WRDF-EMS has been lost to antiquity
and today’s research overwhelmingly focuses on
the PM-EMS. Any resurrection of WRDF-EMS
study is focused on stable control over a limited
speed range where today’s advanced electronic
control has shown some success.
With considerable investment in fresh engineering approaches, Best Electric Machine (Engineering Devices, Inc.) has continued research
in WRDF-EMS technology and has obtained
patents pending for the only brushless, fullystable, and synchronous wound-rotor doubly-fed
electric machine system (BSS-WRDF-EMS)
available today. By modifying conventional offthe-shelf radial-flux electric machines, several
successive stages of prototyping have demonstrated multiphase brushless and stable synchronous operation (see Figure 1). The prototyping
is backed-up with CAD design and comparison
simulation developed by Best Electric Machine, which shows the BSS-WRDF-EMS to be
considerably less costly than the PM-EMS with more
efficiency, higher power density (KW/L), higher specific
power (KW/kg), and higher peak torque density than the
PM-EMS under comparative study (see Table 1 - BSSWRDF-EMS versus PM-EMS Performance). The CAD
comparison tool always includes the performance of the
essential electronic controller and, to guarantee equitable results, eliminates any manipulation by using the
same material, design, and qualification criteria between
contestants, such as excitation frequency, slot size, core
material, wire size, air-gap flux, air-gap dimensions,
voltage and rated torque. The next generation of BSSWRDF-EMS units focuses on the electric vehicle and
wind turbine market with 30 KW/7,200 RPM and 250
KW/160 RPM axial-flux production units, respectively.
Figure 2 is a rudimentary depiction that shows an
axial-flux form-factor stator or rotor electromagnetic
core assembly of the next generation BSS-WRDF-EMS.
Crucial structural, operational and electrical components, such as the frame and bearing assembly, the
cooling system and the winding sets are not shown for
simplicity and were left to the imagination of the reader.
The torque producing or electromechanical conversion
entity is the WRDF entity. The magnetic cores of both
the WRDF and HFRT incorporate a similar arrangement
of balanced multiphase winding sets (see Figure 3) but
the HFRT is designed for a much higher frequency of
operation (e.g., 12 kHz versus 60 Hz). The electronic
stage, which is placed in the cavity between the endturns of the WRDF and HFRT, converts the low frequency AC excitation of the WRDF to the high frequency AC
excitation of the HFRT magnetic core. In conjunction,
the electronic stage and HFRT magnetic core is an inteArticle Continued on page 18
Winter 2009
17
Feature Article
Table 1. BSS-WRDF-EMS versus PM-EMS Performance
gral component that propagates multiphase power to the
rotor winding set of the WRDF without electromechanical contacts (brushless). The mutual inductance of the
HFRT is considerably lower than the mutual inductance
of WRDF due to the difference in operating frequencies.
Since physics defines torque production as directly proportional to mutual inductance and mutual inductance as
directly proportional to winding-turns, magneto-motiveforce (MMF), air-gap flux density and air-gap area, the
HFRT exhibits virtually no torque and is considerably
smaller, more efficient, and less costly than the WRDF.
A fully assembled and functional BSS-WRDF-EMS
comprises two axial-flux magnetic core entities (see Figure 2) placed face to face by a frame support and bearing
assembly (not
shown for simplicity) that guarantees
consistent air-gap
dimension between the HFRT
and WRDF during
relative movement
under magnetic
Figure 2. BSS-WRDF-EMS Axial
flux. The fully asFlux Rotor or Stator Electromagsembled axial-flux
netic Core Assembly
BSS-WRDF-EMS
is referred to as a hockey-puck or pancake form-factor.
Simple non-smokestack, just-in-time tooling, was developed to manufacture axial-flux machines; in particular,
the BSS-WRDF-EMS. The pancake BSS-WRDF-EMS
has the following features:
18
Winter 2009
• Fully Integrated System: With an integral electronic
controller, the system is tested at the factory and connected with standard (or non-inverter grade) wiring at
the field site.
• Low Component Inventory: The rotor and stator
magnetic core assemblies are physically and electrically the same because of BSS-WRDF-EMS electromagnetic symmetry.
• Equal Rotor and Stator Cooling: The rotor and stator
magnetic cores and electronic assemblies are equally
exposed to the same cooling medium.
• Dynamic Structural Integrity: The winding sets are
supported by the magnetic core structure during rotation
because centripetal force is parallel to the winding slots.
• Optimized Real Estate: The HFRT and electronic
stage reside in the annulus space of the WRDF magnetic
core, which would otherwise be wasted space for other
EMS with their remotely mounted electronic controller.
• Low Torque Vibration and Ripple: Torque vibration
and ripple experienced by the PM-EMS with discrete
and persistent fields of permanent magnets are inherently
mitigated by the symmetrical and sinusoidal distributed
rotor and stator winding sets of the WRDF.
• Low Loss Magnetic Core: Low loss magnetic ribbon
is supported by the axial flux form-factor.
• Power Stacking Method (patent pending): A method
of stacking more than one pancake BSS-WRDF-EMS
unit lengthwise along the rotating axis to accommodate
multiple increases in power rating:
o A single inventory of lower power BSS-WRDF-EMS
units can accommodate larger power capacity stacks
o The integrated electronic controllers of each stacked
BSS-WRDF-EMS can be electrically connected in series
(voltage stacking) or in parallel (current stacking)
o A high power BSS-WRDF-EMS stack is fixed to
the smaller diameter and length of the low power BSSWRDF-EMS unit in the stack
o Rotor and stator components of smaller BSSWRDF-EMS units or the BSS-WRDF-EMS unit itself
can be shipped and field assembled into the large BSSWRDF-EMS stack
o Comparably smaller BSS-WRDF-EMS units are
easier to manufacture
o A failure of a BSS-WRDF-EMS unit does not incapacitate the entire stack of units
o Individual units can be removed, replaced or repaired in the field
Figure 3 is a rudimentary electrical schematic of a
functional BSS-WRDF-EMS example that shows the
rotor and stator are electrically equivalent with the external three-phase electrical port of the stator being the
exception. Both the WRDF and the HFRT are separate
balanced-phase, position-dependent transformers.
As position-dependent transformers, the magnetic
path (mutual inductance) between the rotor and stator
winding sets changes with relative movement, which
similarly modulates the envelopes of the electrical
excitation signals of the winding sets with the angular
velocity and position component of the relative movement. Since the rotor or stator magnetic cores of the
HFRT and WRDF are integral with the rotor or stator
bodies, respectively, the HFRT and WRDF experience
the same relative movement and signal envelope modulation and as a result, the HFRT precisely emulates
the electromagnetic process of the WRDF regardless
of movement but at a higher frequency of operation.
As the torque producing entity, the WRDF is directly
excited with low speed-based frequency multiphase
alternating current (AC) from the power grid (60/50
Hz) for electromechanical power conversion. Each of
the low frequency AC phase signals exciting the stator
winding sets of the WRDF is respectively applied to
the stator electronic stage, which incorporates simple
synchronized electronic choppers (synchronous modulator-demodulators) that modulate and demodulate
the envelopes of the respective AC phase signals with
a carrier frequency that is compatible with the HFRT.
After modulation-demodulation by the rotor electronic
stage, the necessary multiphase signals for exciting the
WRDF rotor phase windings with the precise speedbased AC frequency and phase for synchronous operation of the WRDF
are provided
automatically and
instantaneously. As
a phase locked loop
(PLL) mechanism
that guarantees
absolute stability,
the HFRT electromagnetic processing is truly selfcommutation that
is tantamount to the Figure 3. BSS-WRDF-EMS
electromechanical Electrical Schematic
self-commutation of
the venerable direct current (DC) EMS but with significantly higher resolution of brushless control.
The direct AC-to-AC conversion method of the BSSWRDF-EMS comprises no DC Link Stage, no ancillary
speed-position resolver and no high power electronic
offline computer for intensive time consuming transformation, estimation, and frequency synthesis processing.
These are found in state-of-art conventional electronic
control of today, such as Flux Vector Control or derivatives (FOC). Without considering filtering, the synchronized high frequency choppers inherently confine the
high frequency to the compatible HFRT while virtually
isolating the high frequency from the incompatible power
source and the low frequency windings of the WRDF. In
contrast, other control means, such as FOC, directly drive
the winding sets and power source with high frequency
modulation and use brute force filtering to attempt to remove the harmonics that are responsible for bearing failure, insulation failure and electrical loss of the EMS. The
compact and efficient HFRT, which is a high frequency
AC-to-AC stage, replaces the bulky DC Link Stage of
other control means. The low mutual inductance HFRT,
which magnetically couples multiphase excitation to the
WRDF rotor phase windings with virtually no torque
effect, replaces the bulky multiphase slip-ring-assembly
(brushless) of the WRDF-EMS. The HFRT, which is an
inherent real-time electromagnetic processor, replaces
any position-speed transducer and intensive transformation, estimation and frequency synthesis processing
found in other control means.
Conventional electronic motor control, such as FOC,
comprises six controlled power semiconductors (i.e.,
switches) on the input stage and six controlled switches
on the output stage for a total of 12 controlled switches
that controls the full EMS power. The input and output
stages are separated by a DC Link Stage with low frequency reactive components, such as bulky, inefficient,
and expensive line reactors, capacitors or chokes. Since
the switches are in totem pole arrangements across the
DC Link Stage, the switches are rated for the multiphase
peak-to-peak AC voltage and current. The totem pole arrangement generates common mode voltages. At any instant of time, the turn-on current path is subjected to four
junction drops with four junctions of conduction loss at
the current and voltage of the DC Link Stage. Without
the extra cost, complexity and loss of additional stages
of high power controlled switches and reactive components for implementing soft-switching, the switches are
operated in switch-mode (hard-switching) with switching loss as another major source of loss. In contrast, the
BSS-WRDF-EMS comprises 12 controlled switches on
the rotor electronic stage and 12 controlled switches on
the stator electronic stage for a total of twenty four controlled switches that controls half the doubly-fed EMS
power. With direct AC-to-AC conversion, the controlled
switches, which are arranged as bi-directional switches
(synchronous choppers), are in line with the AC phase
and subject to the single phase peak AC rating, which
give another 3 advantage over the 3-phase peak-to-peak
AC rating experienced by switches across a DC Link
Feature Article
Stage. Together with the low power rating provided by
doubly-fed control, the controlled switches of the BSSWRDF-EMS have a 3.46 ( 3 x 2) cost-performance
advantage over conventional electronic control. Without
a totem-pole arrangement of switches, the direct ACto-AC conversion virtually eliminates common mode
voltages. Off-the-shelf power modules now available
for matrix electronic control are fully compatible with
the BSS-WRDF-EMS choppers, which will simplify the
overall switch configuration. At any instant of time, the
turn-on current path is subjected to four junction drops
with four junctions of conduction loss at the current and
voltage of the single phase AC while supplying half the
system power for full doubly-fed control. In addition, the
AC-to-AC conversion method of the BSS-WRDF-EMS
inherently provides soft-switching (resonant switching),
which virtually eliminates switching loss, field weakening, leading, lagging or unity power factor control.
The BSS-WRDF-EMS may appear to be substituting delicate PM material on the rotor with delicate rotor
electronics, but consider that without the rotor electronic
stage, a rotating transformer with the operating frequency
and mutual inductance of the WRDF would replace the
HFRT and as experienced by the BDF-EMS, the electrical
loss, cost and size of the EMS would effectively double.
Rotor electronics are being proposed or used by the industry as a convenient method to improve performance of the
conventional EMS. Rotor electronics have been used for
decades in brushless exciters for large turbo-alternators to
actually improve reliability. The axial-flux BSS-WRDFEMS equally exposes the rotor and stator electronics to
the cooling medium. Silicon-Carbide electronic devices
with heat immunity comparable to winding insula-
tion are becoming a reality. High performance PM materials are globally strategic and very expensive.
One niche for BSS-WRDF-EMS technology is the
EMS component for today’s wind turbines, which are
highly sophisticated systems with an EMS driven by a
multistage gearbox that increases the low speed of the
turbine blades to the high speed of the EMS. The WRDFEMS is installed in more than 70 percent of large wind
turbines because of low cost electronic control, comprehensive PF control and variable speed constant frequency
generation but its unreliable slip-ring-brush assembly
requires annual maintenance. The complex and expensive multistage gearbox has a history of high failure rates
and long delivery times. Wind turbine manufacturers are
asking for a brushless low speed EMS with a single stage
gearbox to eliminate the maintenance and gearbox issues
or a brushless direct drive EMS without gearbox. Without
a legacy WRDF-EMS design base for low speed generation, the redesigned EMS has opened the door to other
technology. Because of unfamiliarity with the brushless
and better cost-performance BSS-WRDF-EMS technology, the extravagantly expensive PM-EMS seems to be
the chosen technology. Without considering the additional
shipping and installation impact of its remotely mounted
electronic controller, the most state-of-art 1.65MW180RPM PM-EMS for the wind turbine market is approximately 10 ft. in diameter by 7 ft. deep and weighs 17
tons. Because of the difficult handling and safety issues
associated with permanent magnets, the PM-EMS must
be fully assembled at the factory, shipped to the wind
turbine site and lifted to the nacelle of the wind turbine in
its entirety with heavy shipping and crane equipment. In
the event of a failure, the wind turbine is out of commis-
sion until the entire PM-EMS is repaired or replaced with
the same heavy crane and shipping equipment. With the
Power Stacking Method, the pancake BSS-WRDF-EMS
units or even the disassembled rotor and stator components can be individually shipped to the wind turbine site
in smaller diameter (lower power) stackable units and
lifted to the nacelle for final assembly using light shipping
and crane equipment or even the internal crane of the
nacelle. For example, a Power Stacked 1.75MW-160RPM
BSS-WRDF-EMS is approximately 11 feet in diameter
by 4 feet deep and weighs in at 11 tons, including the
integrated electronic controllers, which is composed of
seven stackable CAD designed 250KW-160RPM BSSWRDF-EMS units. The rotor and stator components of
each unit are approximately 11 ft. in diameter by 0.5 ft.
deep and weigh in at less than one ton, each of which can
be incrementally shipped to the site, lifted to the nacelle
and assembled. In the event of a unit failure, the wind
turbine is partially incapacitated by the power rating of
the failed units. With the convenient disassembly and
replacement method provided by the Power Stacking
method, any failed unit or component can be repaired or
replaced with the convenience of the internal gantry of
the nacelle provided by Power Stacking method.
The BSS-WRDF-EMS has better cost-performance
than the PM-EMS, does not incorporate PM materials
with potential cartel control and as the only symmetrical
EMS, improves the overall logistics of field integration
as demonstrated by the wind turbine example.
Frederick W. Klatt hopes you found this article interesting and
appreciates suggestions or comments. Fred can be reached at
[email protected] or 781-771-6988.
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• Linecurrentsformodellingthousandsofcurrentsources
• Easilydrawaconcept,thenanalyzefield,force,torque,fluxlinkageor
inductanceonaniterativebasis.Thedesigncanbeeasilymodified(i.e.
stretching,transformingandrotatingpartsofthegeometry)
• Easydirectimport/exportofgeometriesfrom/toCADtoolsandhaveafirst
resultwithinminutes
• Capableofsolvingproblemswithnonlinearpermeabilityandmagnetswith
nonlineardemagnetizationcurves
• EasygenerationofmodelusingBEMandFEM
• HealingtoolsforrepairingCADerrorssuchasoverlaps,intersectionsand
smallgapsinmodelgeometry
put our software to the test
Call for a 30-day FREE EVAluAtIOn and start improving produCtivity today.
a live demo is also available.
Call+1204.632.5636•[email protected]
or visit www.integratedsoft.com
magnets4_5x7_375.indd 1
25
YEARS
optimizing
designs
19
Winter 200927/07/09
2:01 PM
Industry News
Integrated Engineering Software
Launches Referral Program
Integrated Engineering Software, a developer of
hybrid simulation tools for electromagnetic, thermal
and structural design analysis, has launched a referral
program to celebrate its 25th anniversary. Integrated
customers who refer a new customer will have $150
donated to the charity of their choice.
“We wanted to reward our customers’ loyalty and mark
the occasion of our 25th anniversary by offering donations
to worthy causes,” said Bruce Klimpke, technical director
at Integrated Engineering Software. “We hope that in
doing so we can give something back to the communities
that our customers live in or feel strongly about.”
Klimpke sees the future as being bright, “Despite the
current economic climate, companies will continue to invest in software for design simulation because it offers cost
Palm Springs Convention Center m Palm Springs, CA
January 23–27, 2010 m labautomation.org/LA10
2010
Where Science, Technology and Industry Come Together
Premier Sponsor:
“The LabAutomation Conference and Exhibition is a
fascinating experience. It provides a wonderful venue
for sharing ideas with scientists and engineers around
the world. Laboratory automation is a critical component
of the high-throughput data measurements of modern
biology and medicine. The LabAutomation community
has a unique culture, is an integral component of the
high- throughput data measurements for genomics,
proteomics and phenotypes and thus provides a
crucial foundation for modern biology and medicine.”
– Leroy Hood, M.D., Ph.D., President,
Institute for Systems Biology
Register Now!
Register by December 14, 2009 for Maximum Savings.
Learn about the LabAutomation2010 Smart-Savers Program.
Visit labautomation.org/LA10
LabAutomation2010 Key Education Tracks:
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Detection and Separation
Micro- and Nanotechnologies
High-Throughput Technologies
Informatics
Evolving Applications of Laboratory Automation,
featuring Agriculture and Food
Exclusive Market Place Briefings
and development time reductions. As computers continue
to add processing power by parallelization and software
algorithms continue to shift the boundaries of what can be
simulated, design engineers can create better products for
less. We view the next 25 years at Integrated very positively indeed.”
GE’s New Power Technology Center in
Russia’s Kaluga Region
GE Energy has announced construction for GE’s
new Power Technology Center in the Kaluga Region of
Russia. The technology center further expands GE’s incountry capabilities to deliver its products and services
to customers across Russia and the Commonwealth of
Independent States (CIS) that are pushing to modernize
their energy assets.
GE signed the agreement in March 2009 with the
government of the Kaluga Region, the Kaluga Region Development Corp. and the administration of
Kaluga City.
GE’s initial investment in the Kaluga center is $30
million, but that figure is expected to grow to $50 million
by the time the facility is commissioned in late 2010.
Full-Service Consulting for Power and
Energy Industry
FullPower assists in the introduction and commercialization of a wide variety of new technologies including ultracapacitors, advanced batteries, hybrids and
nanomaterials. FullPower clients benefit from its access
to industry leading manufacturers, technology experts
and energy storage customers.
The firm identifies and provides advanced technical
support to suppliers of material, components and systems,
provides assistance for strategic planning, business development and manufacturing, establishes a sound business
plan to aid in obtaining government or private equity
funding and works with trade shows, industry groups and
consortiums to discuss industry trends and connect industry influencers and vendors to potential customers.
Advertiser Index
Allied Motion Technologies, Inc. . . . . . . .20
www.alliedmotion.com
Applied Power . . . . . . . . . . . . . . . . . . .4
www.appliedps.com
CGI Motion . . . . . . . . . . . . . . . . . . . . 3
www.cgimotion.com
CUI . . . . . . . . . . . . . . . . . . . . . . . . . . 9
www.cui.com
Discovery Technology International . . 8, 10
www.discovtech.com
Grid Connect . . . . . . . . . . . . . . . . . . . . .22
www.gridconnect.com
Infineon . . . . . . . . . . . . . . . . . . . . . . . 2
www.infineon.com
Infolytica Corporation . . . . . . . . . . . . . . 20
www.infolytica.com
Integrated Engineering Software . .4, 19,21
www.integratedsoft.com
MicroMo . . . . . . . . . . . . . . . . . . . . . . . . . 6
www.micromo.com
Midwest Motion Products . . . . . . . . . . . .22
www.midwestmotion.com
PEI . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
www.peipittsburgh.com
Powerex . . . . . . . . . . . . . . . . . . . .5, 17
www.pwrx.com
Sanrex . . . . . . . . . . . . . . . . . . . . . . .21
www.sanrex.com
Semikron . . . . . . . . . . . . . . . . . . . . . .7
www.semikron.com
Suhner Manufacturing Inc. . . . . . . . .10
www.suhner.com
Trio Motion Technology . . . . . . . . . . .24
www.triomotion.com
US Digital . . . . . . . . . . . . . . . . . . . . .10
The right design solution for
http://usdigital.com
any type of electric machine
Varflex Corp . . . . . . . . . . . . . . . . . . . .8
www.varflex.com
Yokogawa
Corp
of
America
. . . . . . . . 23
MotorSolve supports BLDC, SRM and IM types of
www.yokogawa.com/us/
motors and generators. Design machines rapidly.
MotorSolve & MagNet 2D/3D
• Preliminary Results for 2009 North American
Laboratory Purchasing Trends Report
• India’s Emerging Pharmaceutical Market
• The SiLA Consortium for Standardization
in Laboratory Automation
• Pioneering Commercialization from Academia
to Market Through the MF3 Center
MagNet’s electromechanical simulations account
for the effects of rotary or linear motion,
heating, core losses and more: it is the essential tool
for any type of machine design.
A Diversity of Industries Including:
•
•
•
•
•
Drug Discovery and Development
Forensics and Security
Energy Generation and Petrochemicals
Agriculture and Food
Clinical Diagnostics
ALA is a non-profit association committed to driving progress
in laboratory technologies through high-quality education that
benefits the global scientific community, including its membership
of scientists, engineers, academicians, and thought leaders.
20
Winter 2009
Free trial versions available
at www.infolytica.com
Your fastest solution
to a better design
Get Ready for 2010!
For more information about
advertising in e-Drive magazine,
please contact Sue Hannebrink at
[email protected].
Contact Sue, and learn more about
online advertising opportunities, too.
Industry News
Small Motor Market During
Economic Downturn
The global economic downturn is forecast to create a
23 percent contraction of unit shipments in the world market for small motors in 2009, according to the new IMS
Research report the “World Market for Small Motors.”
However, because of the growing importance of the medical sector, which currently accounts for 19 percent of the
market, IMS Research expects a recovery to pre-recession
levels of activity by early 2012.
The previous downturn took place toward the end of
2001, when the market was believed to have dropped by
around 6 percent in Europe. This resulted in a number of
company acquisitions in the following years, so that acquiring companies could gain access to regional markets
and complimentary motor technologies, as well as boost
market shares.
Historically, the companies most active in acquisitions
have been the American and Japanese multi-nationals.
The current downturn may well provide additional
opportunities for further consolidation of this market.
Companies that have suffered badly in 2009 and require
investment may be most vulnerable to take over. Regional
suppliers, particularly those with more innovative technologies, such as brushless DC motors, may be especially
attractive targets to multinationals with money to invest.
Tutorial on Linear Position Sensors
(LVDTs) Featured on Web Site
Macro Sensors offers a tutorial on Linear Variable Differential Transformers or LVDT linear position sensors on
its Web site. The tutorial covers everything about LVDTs
including construction, significant features, operation and
industrial applications. It also answers questions on where
to use an LVDT and what types of electronics work best
for specific applications.
LVDTs can measure movements as small as a few
millionths of an inch up to several inches as well as
positions up to ±20 inches (±0.5 m). Features such as
friction-free operation, infinite resolution and unlimited mechanical life make LVDTs well suited in a wide
variety of applications such as industrial automation
manufacturing, power generation, civil engineering as
well as industrial and subsea environments.
FedEx Expands Hybrid-Electric Fleet
of the conversion program is that it not only reduces
pollution but also extends the life of the vehicles,
helping to eliminate waste production and creating a
reduce-and-reuse program.
In converting the standard delivery vehicles, the
power-train equipment including the engine, transmission, fuel tank and drive shaft, were replaced with a
2007 Cummins ISB 200 hp engine and Eaton hybridelectric system. Costs were reduced by utilizing the
existing chassis and body.
The vehicles feature a diesel engine coupled with an
electric motor/generator and lithium-ion batteries. These
batteries capture and store energy during the regenerative
braking phase of vehicle operation, eliminating the need
to plug into an electrical source. The sophisticated hybrid
controller selects the most efficient mode of operation,
diesel or electric depending upon current operating conditions and driver demand.
FedEx Corp. has added 92 hybrid-electric trucks
to its delivery fleet, the first standard FedEx delivery
trucks converted to hybrid-electric systems.
The addition of the 92 trucks increases the FedEx
fleet of hybrid-electric vehicles by more than 50 percent,
from 172 to 264. The FedEx hybrid-electric fleet has
Opal-RT Technologies Announces
logged more than four million miles of revenue service
Major European Expansion
since being introduced in 2004, reducing fuel use by
Opal-RT Technologies, Inc., a developer of open, PC150,000 gallons and carbon dioxide emissions by 1,521
based Real-Time Simulators for electrical, mechanical
metric tons, which is equivalent to removing 279 cars
and power electronic systems has reached an agreement
from the road annually.
in principle with Viveris Technologies of Paris, France to
The hybrid conversions were produced in Charlotte,
jointly establish a European subsidiary. Opal-RT Europe
N.C., during the past six months and created 50 new,
will serve the needs of Opal-RT customers and distributemporary green jobs in the area. The converted hytors from the Atlantic Ocean to Russia.
brids were developed with Freightliner Custom Chassis
Corp. (FCCC) and Eaton Corp., which provided the
hybrid-electric systems. The standard FedEx trucks
Sanrex_Edrive_05.qxd
PMyour
Page
1
Please3:25
send
industry
news to Joanna Larez
used in the retrofit program were
2000 or 2001 models 7/13/07
at
[email protected].
with 300,000 to 500,000 miles driven. An added benefit
Magnet analysis
software
Analyze & Model:
• Forces and torques in motors, magnetic bearings & magnetic couplings,
among others
• Forces and torques on current-carrying coils for loudspeakers and voice
coil actuators
• Field values vs. position for Hall Effect sensors
• Flux linkage and induced voltage for Variable Reluctance sensors
• Particle trajectory analysis with steering and focusing magnets
• Optimized shapes of coils and pole pieces for electromagnets such as those
used in MRI machines and magnetizing fixtures
Fast. Accurate. Easy-to-use.
• Veryshortlearningcurve;noscriptingrequired
• Designoptimizationbyparametricsolvers
• Parallelprocessing
• Highestlevelofsupportintheindustry
Best Features:
• Linecurrentsformodellingthousandsofcurrentsources
• Easilydrawaconcept,thenanalyzefield,force,torque,fluxlinkageor
inductanceonaniterativebasis.Thedesigncanbeeasilymodified(i.e.
stretching,transformingandrotatingpartsofthegeometry)
• Easydirectimport/exportofgeometriesfrom/toCADtoolsandhaveafirst
resultwithinminutes
• Capableofsolvingproblemswithnonlinearpermeabilityandmagnetswith
nonlineardemagnetizationcurves
• EasygenerationofmodelusingBEMandFEM
• HealingtoolsforrepairingCADerrorssuchasoverlaps,intersectionsand
smallgapsinmodelgeometry
put our software to the test
Call for a 30-day FREE EVAluAtIOn and start improving produCtivity today.
a live demo is also available.
Call+1204.632.5636•[email protected]
or visit www.integratedsoft.com
magnets4_5x7_375.indd 1
25
YEARS
optimizing
designs
27/07/09 2:01 PM
Winter 2009
21
Web Guide
www.sanrex.com
SanRex helps companies
around the world develop
smarter solutions for their
power semiconductors
needs. SanRex's line of
Diodes, Thyristors, Tricas,
Transistors and IPMs will
help maximize efficiency
and improve the performance on your products.
www.infolytica.com
Infolytica specializes in
software tools for motor designers: MagNet
2D/3D for accurate
electromagnetic-field
simulations and MotorSolve for electric motor
design. Visit us for free
trial downloads or sign up for an information webinar.
www.triomotion.com
Trio is an engineering
technology company
that designs high-performance servo and stepper
motion controls from 1
to 24 axes of coordinated
control, using a variety
of drive interfaces. The
compact stand-alone
design utilizes a unique software feature code or flexible
daughter board approach to mix and match axis functionality.
Controllers can be easily upgraded and expanded in the field.
PCI and 3U board level controllers offer low cost in a very
compact format. Control interface options include stepper,
servo, SERCOS, and CAN drive command generation, with
more on the way. All multi-tasking controllers program using
the easy Trio Basic language and have cams, gearing, linear,
circular, and helical interpolation functionality. Communication options include DeviceNET, ProfiBUS, ModBus RTU,
RS232/485 ASCII, Ethernet TCP/IP, Modbus/TCP, Ethernet
IP, and fiber optic. The standard high-speed CANbus interface
can expand I/O using Trio modules, or other machine mounted
industrial I/O systems, with direct pneumatic interfacing.
22
Winter 2009
www.peipittsburgh.com
PEI manufactures BStage banding tapes,
edging and surge rope for
large AC and DC motors.
PEI is also a full line
distributor for insulating
products, specializing
in polyimide films and
laminates, polyester, adhesive tapes, glass and cotton tapes,
and papers.
www.dti-piezotech.com
DTI s piezoelectric technology consists of novel
rotary and linear ultrasonic
piezomotors. The scalability of DTI s technology gives rise to a unique
range of cutting-edge
piezomotor devices having
broad application in the industrial and scientific markets.
www.pwrx.com
Powerex turns ideas into
cost-effective products
and is a leading supplier
of discrete, modular and
integrated high power
semiconductor solutions,
supporting many markets.
www.discovtech.com
DTI s piezoelectric technology consists of novel rotary
and linear ultrasonic piezomotors. The scalability of
DTI s technology gives rise
to a unique range of cuttingedge piezomotor devices
having broad application in
the industrial and scientific
markets.
www.suhner-transmission-expert.com
Manufacturer of custom & standard flexible
shafts(drive cables)with diameters ranging from .028"
to .750". Flexible shafts for
rotary transmission or helix
cables for linear motion.
www.integratedsoft.com
Integrated Engineering
Software (IES) develops
software for design engineers in the Automotive,
Medical, Telecommunications, Power & Aerospace
markets. Speed, performance and ease-of-use
allow quick and accurate
modeling of Electric & Magnetic Fields, Eddy Currents, Power
Electronics and Electrical Drives.
www.semikron.com
SEMIKRON with its global
network of 45 companies is
one of the worlds leading
independent manufacturers
of power electronics, intelligent power modules and
thyristor/diode modules.
TOTAL SOLUTION FOR YOUR
MOTOR AND DRIVE MEASUREMENTS
T
he Yokogawa WT300 Power Analyzer delivers the measurement performance required for
demanding applications such as testing Electric Motors, Inverters, PWM Motor Drives and
system efficiency.
Key Benefits:
• 0.02% Basic Power Accuracy
• Wide Bandwidth - DC to 1 MHz
• Harmonic Analysis to 100 Orders
• Accurate PWM Measurements
• Speed & Torque Measurements
• Mechanical Power Measurements
• V/Hz Analysis for VFD’s
• Synchronous Speed & Slip
• Efficiency Calculations
• 3-Year Warranty
T
he DL750 Digital Oscilloscope features high
vertical resolution, long acquisition memory
and isolated inputs.
Ty p i c a l M o t o r Te s t S y s t e m
Inverter
Motor
Load
• 2 to 16 analog channel input
• 12 and 16-bit high resolution
• Isolated input modules
• High-Voltage, 850 V RMS
• 0.25% accuracy
ADB907
• Seven different Plug-in input modules
http://tmi.yokogawa.com
WHAT’S CONTROLLING YOUR MACHINE?
Trio’s new MC464 Motion Coordinator
provides the machine builder with
unprecedented exibility, options
and performance for total machine
control in a very cost effective,
modular package.
TM
WHAT YOU WANT...
The MC464 can control up to 64 axes and
hundreds of I/O points. Interface to drives using
EtherCAT, Ethernet-RTX, analog servos, step &
direction, CANbus, or SERCOS.
WHAT YOU NEED...
Industry standard buses including EthernetIP,
Modus TCP, Probus, CANopen, and CClink let you
connect with many common PLC platforms.
WHAT YOU LIKE...
Run up to 30 programs simultaneously in the powerful 64-bit multi-tasking
environment using simple Trio BASIC, IEC-61131 languages, or g-codes.
Give us call and we’ll show you.
It’s time to rethink your machine control.
NS
IO
AT
IC
UN
M
M
ES
CO
AC
Y
RF
OR
TE
CT
IN
FA
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OF
ES
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YO
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www.triomotion.com

Winter - Service Wire

Transcription

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