The Future Energy Challenge Energy Challenge in the Home

1
The Future Energy Challenge Energy Challenge in
the Home
Single-Phase Powered Induction Machine Drive for
Residential Applications
April 29, 2004 Power Affiliates
Program Presented by Brett Nee Jonathan
Kimball

• Sponsored by
• Grainger Center for Electric Machinery and
  Electromechanics
• National Science Foundation
• California Energy Commission
• In kind support from
• Emerson Motor Company

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Overview

• Future Energy Challenges Motivation
• Design Specifications
• UIUCs solution the iDRIVE
• Competition Results
• 2005 Future Energy Challenge

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Motivation

• Motors account for approximately 64 of the U.S.
  electrical use
• Approximately 1 billion motors in the U.S. use
  over 1700 billion kWh/yr
• 90 of the motors are less than 1 hp in size, and
  account for approximately 10 of the electricity
  consumed by the motor population
• This translates to 170 billion kWh/yr

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Motivation

• Each 1 improvement in motor and drive efficiency
  results in
• 1.7 billion kWh/yr of energy saved
• An equivalent of 6 10 million tons of displaced
  coal/yr
• 15 20 million tons less CO2 released into
  atmosphere/year
• Over 1 billion energy cost saved/yr

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2003 FEC Requirements

• Create a Motor and Drive System
• Motor System Specifications
• Output power range 50W - 500W (lt1HP)
• Motor Speed ranges from 150RPM - 5000RPM
• Efficiency gt 70
• Power Factor gt 0.8
• Operate from a single phase 120 Vac source

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The iDRIVE
PFC Boost Rectifier Hex-bridge Inverter
Induction Motor
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iDRIVE PFC Boost

• Specifications
• 200 V dc bus with /- 10 V ripple
• gt95 Efficiency
• Power Factor1
• Output Power 80W - 800W

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iDRIVE - Inverter

• Characteristics
• dc to ac conversion (three-phase)
• Transfers power from PFC stage to the induction
  motor
• gt95 Efficiency
• Volts per Hertz motor control strategy using
  Harmonic Elimination

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Hamonic Elimination
3rd 13th harmonics eliminated
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iDRIVE Induction Motor

• Why a new design?
• Low efficiency of standard machines.
• Machines are not designed specifically for high
  efficiency with drives.
• Need a different approach to meet the
  specifications.
• Different performance criteria can be applied
• No line-starts.
• Motors operate only in low slip regime.

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System efficiency
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2003 FEC Competition Results

• Competition in Raleigh, NC. (May 2003 )
• 4 finalist teams, 1 semi-finalist
• Testing facilities provided by Advanced Energy
• University of Illinois
• 2nd place overall (7500)
• Best Technical Presentation (2500)

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2003 FEC Team
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2005 FEC Team
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How do we build a winning system?

• Everything must work
• Should have plenty of time for system integration
• Must achieve higher efficiency
• Must maintain low cost
• Must innovate
• Potentially follow multiple paths

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Motor Concepts

• PMSM? Investigate
• Cost issues
• Induction Motor
• Needs to be a lower slip design
• Investigating exterior rotor for higher inertia

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Topology Concepts

• Boost PFC
• Well-known industrial solution
• Ideal for unity power factor
• Buck PFC
• Relatively untried
• Possibly more passives?
• Lower voltage stresses on semiconductors
• Block diagram doesnt change

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Control Issues

• Use inertia of motor
• Free energy storage element
• May displace capacitive energy storage
• Need to address stability and instantaneous power
  flow
• Otherwise shape current
• Meet letter of specification, 0.8 PF
• May be able to meet spec at a lower cost

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Example WaveformsUnity PF vs. 0.8 PF
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2005 Future Energy Challenge

• Course offering ENG 491 fall and spring
• 18 students currently involved
• Mechanical Engineering
• Electrical Engineering
• Grad students will drop off as undergrads come up
  to speed
• Students will be organized into sub-teams
• Replaces senior design requirement for EEs

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Summary

• Competed effectively in 2003 Future Energy
  Challenge
• Have several good ideas to build on, several
  lessons learned
• Assembled a strong team to develop these ideas
  into a winning entry in 2005 Future Energy
  Challenge