Motors and the Current State of Motion Technology

Motors and the Current State of Motion Technology

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Q&A at the end of the presentation

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Before We Start

Moderator

Miles Budimir Design World

Presenter

Dan Jones Incremotion Associates

Motors and the Current

State of Motion Technology

Dan Jones

Incremotion Associates

Combination of:

New Motors

New Power Devices

New Software Tools

New Controller IC’s

New Feedback Devices

Newly Emerging Technology

“Motion Control”

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Most motor technologies were developed as theoretical

types at least 20 years before they began to move into

production.

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Some motor technologies awaited the need of new

applications and/or new drive and control developments.

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The emergence of new needs and new applications drives

the development of new motor technologies.

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Energy savings (higher motor efficiencies)

Electric replacing pneumatic and hydraulic applications

Weight savings

More torque (torque-weight density)

More power (power density)

New Needs

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Aircraft pumps and actuators (electric)

Hybrid and electric vehicles

Handheld portable electric tools

Battlefield and household robots

Medical diagnostic machines (MRI, PET, CAT, etc.)

Medical powered prosthetics (arms, wrists, ankles, knees, etc.)

New Applications

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There are 3 major classes of controlled motion:

1. Constant speed

2. Variable speed

3. Variable position

Motors in Controlled Motion

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Various Motor Types – CD-adapco (SPEED)

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Radial air gap (induction, PM brushless & SR)

Axial air gap or axial flux

Transverse flux

Basic Motor Configurations

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Axial Air Gap Motor

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Synchronous Reluctance Motor

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Yasa Axial Flux – High Power Density Motor

Winner of the Drayson Racing FIA World Land Speed

Record at 204 mph

Axial Flux Motors – Version 1

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Axial Flux Motor

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In hub motors for electric bikes, electric scooters

PM generators (direct drive)

Rotary industrial tables

Robots (waist and elbow)

Automotive starter/generators

Applications (Axial Flux)

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Advantages o High power density

o Very high power efficiency

o Can be fluid cooled

Disadvantages o Very high rotor inertia

o Complex lamination structure

o High RE magnet weight

Axial Flux Motors

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Controlling the PM Motor’s Magnetic field by using

magnetic flux from an Exciter.

Focusing on the motors speed to achieve the widest speed

range possible.

The i-Motor Technology – Japan (Ver. 2)

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Field changeable magnet excitation motor

Changes in magnetization results in variable field strength

that leads to a wide range of motor shaft speeds

Smart control techniques can lead to higher power

efficiencies over a wide speed range

i-Motor Performance Features

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A wide range of variable speed applications are achievable that include:

Electric vehicles

Pumps

Fans

Compressors

Textile machines

Spindles in machine tools

Food equipment (bottling, labeling, handling)

Oil, chemical and gas processing

Pulp and paper processing

Many others

i-Motor Application Opportunities

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Advantages o Use ferrite magnets

o Widest speed range

o Lowest cost

o Lower inertia with gearbox decouple

Disadvantages o Needs gearbox

o Pancake shape limits drop in replacements

i-Motor Axial Flux Motor

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ABB IE4 Efficiency Synchronous Reluctance Motor

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Advantages o No magnets

o Uses conventional inverter drives

o Higher torque density than induction motors

o Higher power factor

o Wide constant power vs. speed range

o Brushless

Disadvantages o Complicated rotor construction

o Non-linear torque vs. current

o Complicated control algorithm

Synchronous Reluctance Motor

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First paper by Professor Weh in 1988.

Only academia with very large computers could simulate the magnetic action of this motor.

PC based motor simulation programs did not become available until the mid-1990’s and they were not initially very friendly.

It is a 3 phase brushless PM motor type.

Transverse Flux Motor History

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Advantages o Highest torque – weight density

o Highest continuous torque per volume

o Low internal losses

o Simplest winding (coil)

Disadvantages o Limited speed (< 1000 rpm)

o Complicated construction

Transverse Flux Motors

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New motor developments continue

Development driven by new applications and needs

Higher power density motors now appearing

New motors in development for ever higher power efficiencies

More new motor developments to come

Conclusions

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Questions?

Design World Miles Budimir [email protected] Phone: 440.234.4531 Twitter: @DW_Motion

Incremotion Associates Dan Jones [email protected] Phone: 805.496.2621

Thank You

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