In at this time’s world, motors are ubiquitous, powering the whole lot from family home equipment to industrial equipment. The significance of optimizing motor management for power effectivity can’t be overstated, provided that motors account for a good portion of world power consumption. This text delves into the construction of motors, the usage of variable frequency drives (VFDs), and the options for motor management purposes, together with {hardware} help and superior algorithms.

The prevalence of motors

Motors are integral to our every day lives, present in family home equipment like washers, dryers, dishwashers, and pool pumps. They’re additionally important in automotive purposes, with fashionable automobiles containing anyplace from 40 to 100 motors, relying on the mannequin and trim stage. Industrial environments are closely reliant on motors, significantly in robotics and manufacturing facility automation. Determine 1 reveals the vary of motor purposes from family home equipment to automotive and industrial.

Determine 1 The vary of purposes involving motors highlights the prevalence of this know-how and thus the significance of contemplating their power consumption and effectivity. Supply: Microchip

In accordance with the Power Data Administration, roughly 50% of world power consumption is attributed to motors. In industrial purposes, this determine can exceed 80%. As an example, in the USA, the overall power consumption in 2022 was 4.07 trillion kilowatt-hours, equating to a every day consumption of 11.2 billion kilowatt-hours. Bettering motor effectivity by simply 1% may save 56 million kilowatt-hours of power every day.

Key tendencies in motor effectivity

Determine 2 reveals the 4 avenues to enhance motor effectivity: power effectivity motors, the usage of drives and higher electronics, superior algorithms, and the combination of IoT. This part will contact upon these 4 subjects and go into extra element.

Determine 2 The 4 avenues to enhance motor effectivity: power effectivity motors, the usage of drives and higher electronics, the combination of IoT, and superior algorithms. Supply: Microchip

Power environment friendly motors

One of many main tendencies in motor effectivity is the transition from conventional motors, comparable to AC induction motors, to extra environment friendly varieties like brushless DC (BLDC) motors, everlasting magnet synchronous motors (PMSM) and inside everlasting magnet (IPM) motors. These motors supply increased effectivity and improved efficiency. Moreover, developments in supplies, comparable to the usage of amorphous metals and uncommon earth magnets, have additional enhanced motor effectivity.

Materials developments

Within the realm of motor know-how, developments in supplies and design have considerably enhanced the effectivity and efficiency of motors over the previous century. As proven in Determine 3, a motor usually consists of finish bells, a rotor, bearings, and a stator with windings.

Determine 3 The essential construction of a motor the place rotor and stator coils supplies have shifted from aluminum to copper. Supply: Microchip

Over time, the supplies utilized in these elements have developed. As an example, the transition from aluminum to copper within the rotor and stator coils has improved conductivity and effectivity. Moreover, developments in manufacturing tolerances have lowered noise and additional elevated effectivity.

One notable pattern in motor know-how is the usage of amorphous supplies in rotors and stators. Historically, silicon steels have been used, however they’d excessive eddy present and hysteresis losses. These are actually being changed by amorphous supplies like metallic glasses, which have decrease losses and thus increased effectivity.

For everlasting magnet motors, stronger magnets, comparable to these produced from uncommon earth supplies like neodymium, iron and boron, present extra torque and effectivity. Nonetheless, because of sustainability issues, options like aluminum, nickel, chromium, and ferrite-based magnets are being explored for his or her good properties over a spread of temperatures and powerful magnetic fields.

Motor construction

The transition from journal bearings to ball bearings has performed a major function in lowering friction and enhancing tolerances, thereby enhancing motor effectivity. Over the previous century, motors have change into significantly smaller whereas sustaining the identical energy output. As proven in Determine 4, a contemporary 5-horsepower, squirrel-cage rotor, three-phase induction electrical motor (SCIM) is considerably smaller and weighs roughly 20% of what a motor with the identical energy score did in 1910. This discount in dimension may be attributed to the usage of lighter and extra environment friendly supplies, in addition to developments in thermal and electrical insulation.

Determine 4 A timeline of the discount in mass for a 3.7 kW SCIM motor from 1910 to 2020. Supply: Hitachi

Lighter motors are significantly useful for automotive purposes, the place lowering weight can result in elevated effectivity and the flexibility to combine motors into extra compact areas. As we proceed to discover new supplies and designs, the potential for even higher effectivity and efficiency in motor programs stays promising.

Variable frequency drives

Variable frequency drives (VFDs) have change into more and more widespread for controlling motor velocity and enhancing effectivity. VFDs modify the motor’s velocity to match the load necessities, lowering power consumption. The transition from insulated gate bipolar transistors (IGBTs) to silicon carbide (SiC) and gallium nitride (GaN) know-how in VFDs has additionally contributed to increased effectivity and quicker switching.

VFD affect

Variable Frequency Drives (VFDs) have revolutionized motor management by permitting exact management over motor velocity and torque. This know-how optimizes motor efficiency and considerably improves system effectivity. A VFD adjusts the frequency and voltage provided to the motor, enabling it to function on the most effective level for a given load.

As an example, conventional motor programs typically function at full energy, with stream charges managed by throttling valves, resulting in substantial power losses. In distinction, VFDs eradicate the necessity for throttling by adjusting the motor velocity to match the required stream charge, thereby lowering power consumption and rising general system effectivity. As proven in Determine 5, research have proven that switching to a VFD can greater than double the effectivity of a motor system, from round 31% to 72%.

Determine 5 Switching to a VFD can greater than double the effectivity of a motor system, from round 31% to 72%. Supply: [1]

Motor management {hardware}

As proven in Determine 6 a spread of energy administration gadgets are essential to successfully profit from VFDs.

Determine 6 Fundamental block diagram of supporting energy administration gadgets for motor management. Supply: Microchip

AC-DC converters using SiC in tandem with gate drivers allow precision switching for environment friendly energy conversion. MCUs with motor-specific peripherals and specialised algorithms, e.g. dsPIC33 digital sign controllers (DSCs), may be optimized to transform DC to variable AC. Lastly, built-in sensors supply real-time suggestions on present, voltage and temperature, enhancing system reliability.

Superior management algorithms

Conventional strategies, comparable to V/F management for AC induction motors, are cost-effective and simple however could not supply the very best effectivity. Extra superior algorithms, comparable to six-step commutation for BLDC and PMSM motors, can supply sensor or sensor-less precision torque management. Discipline-oriented management (FOC), for instance, makes use of a single-cycle MAC with information saturation as properly a zero overhead looping and barrel shifting for top efficiency velocity, place, and torque management. Determine 7 reveals a pattern block diagram for FOC of a motor utilizing the least FPGA sources to execute a full motor management algorithm.

Determine 7 The block diagram for modular sensorless BLDC motor management algorithm utilizing coordinate rotation digital laptop (CORDIC) with sine-cosine required for FOC of motors. Supply: Microchip

The Zero-Pace/Most-Torque (ZS/MT) management algorithm is a brand new variation of the sensorless FOC algorithm that permits the adoption of sensorless management strategies in high-torque or low-speed motor management purposes. ZS/MT eliminates the necessity for Corridor impact sensors through the use of a dependable preliminary place detection (IPD) technique primarily based on high-frequency injection (HFI) to find out the precise rotor place at zero and low speeds, making it excellent for purposes like drilling machines, storage door openers, automotive starters and e-bikes.

Integration with IoT and AI/ML

The combination of IoT and AI applied sciences has revolutionized motor management. Sensors are used to detect present, torque, and rotor place, amongst different parameters, data that’s then fed to MCUs for processing. With the combination of ML, these programs can carry out predictive upkeep by analyzing sensor information to foretell potential motor failures or upkeep wants.

Predictive upkeep ensures that motors function at peak effectivity and efficiency, lowering the probability of sudden breakdowns. By constantly analyzing parameters comparable to present, torque and vibration, predictive upkeep ensures environment friendly motor operation and minimizes downtime. Techniques can, as an example, make use of a classification mannequin to find out the operational state of a motor, figuring out whether or not it’s functioning usually or experiencing anomalies comparable to an unbalanced load or a damaged bearing, by monitoring the quiescent present of the motor.

Optimizing motor management

Optimizing motor management for power effectivity is essential for lowering world power consumption and enhancing the efficiency of assorted purposes. By transitioning to environment friendly motors, using VFDs, implementing superior management algorithms and integrating IoT and AI applied sciences, vital power financial savings may be achieved. Because the demand for energy-efficient options continues to develop, developments in motor management know-how will play an important function in assembly these wants.

Pramit Nandy is a product advertising supervisor at Microchip Expertise Inc., targeted on motor management purposes. Nandy has been with Microchip since 2021 and his earlier expertise features a product marking manger place with Onsemi. He holds a grasp’s diploma in electrical engineering from Arizona State College.

Reference

T. de Almeida, F. J. T. E. Ferreira and D. Each, “Technical and economical concerns within the utility of variable-speed drives with electrical motor programs,” in IEEE Transactions on Trade Purposes, vol. 41, no. 1, pp. 188-199, Jan.-Feb. 2005, doi: 10.1109/TIA.2004.841022.

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