A Technical Paper on

Improved Efficiency in Induction Motors

With

DCR Technology
Submitted to

ANUSODHANA 2K12
BY
P. Chandini III B.Tech,EEE 17chandini@gmail.com Ph.no:9494534390 S. Kavya III B.Tech,EEE smilykavyass@gmail.com Ph.no:9441611015

RK COLLEGE OF ENGINEERING VIJAYAWADA

Abstract: In todays power production and utilization scenario, various types of problems are faced such as depletion of fossil fuel sources, increase in fuel cost, deterioration of ecological balance due to carbon and emission, distribution transmission

encouraging efficiency. Introduction:

electrical

energy

Electric Motor systems are the largest industrial loads, on an average accounting for more than 70% of all electricity consumption. In the agricultural and commercial sectors also, power consumption by ac motors is quite substantial. On an average, the energy consumed by a motor during its life cycle is 60-100 times the initial cost of the motor. Therefore efficiency of the motor is of paramount importance both during selection and operation. Even small increase in

losses, higher energy consumption due to poor efficiency drives and increased demand due to development taking place in many areas of world. Many of these problems can be addressed by adopting suitable technology resulting in energy saving. Energy conservation

efficiency improvement can make a big difference in energy savings with accompanying contamination. High electrical conductivity of copper in the rotor structure of a squirrel cage induction motor can achieve a reduction in overall energy losses of around 11% 19 % and a consequent increase in energy efficiency. This paper reviews the implementation of Die-Cast Copper Rotor (DCR) Motor, Efficiency improvement, Energy saving potential, adoption of DCR Technology in India and the comparisons of various decrease in air

through energy efficiency is the need of the hour and attempting to achieve this by developing higher efficiency motors with Die-cast Copper details Rotor about case Motor energy energy studies [DCR] efficiency saving in the Technology. This paper provides improvements, potential,

existing Die-cast Aluminium Rotor Motor [DAR] with the proposed DCR motor, especially in the industrial and agricultural sectors. This paper also includes some of the general policy approaches for

efficiency standards besides the application of DCR motor in agricultural pump sets. The needs and tasks regarding the technology are also discussed.

with Die-cast Copper Rotor Motor [DCR]. As Electrical conductivity of copper is 60% higher than Aluminum, therefore efficiency of electric motor with copper bar rotors is higher than with Aluminum Die cast rotors by at least- one percentage point. This is due to around 15 to 20% reduction in overall energy losses (rotor resistance and windage/friction losses) achievable with copper bar rotors. Hence, for the same required energy cost with die-cast copper rotors would be significantly less. Based on copper rotors, super

Die-cast Copper Rotor Motor

This paper is organized into the 3 sections:

1. Describes DCR technology,

efficiency or ultra efficiency motors can be produced, especially in the area of small size motors. Motors can reach a higher level of efficiency in the same size by using copper rotors. Advantages:
Higher efficiency improvement

its advantages and drawbacks.

2. Describes the efficiency

improvement in industrial sectors.

3. Presents a brief study about

especially in small size motors.

Reduced temperature rise

the general policy approaches for encouraging energy efficiency.

1. DCR Technology:

during operation (Cooler running motor means longer motor life).

Improving motor efficiency

Many technology saving.

problems resulting is in

can

be

addressed by adopting suitable energy by This achieved

brings significant energy savings.

developing higher efficiency motors

 Low maintenance cost (Improved conductor bar and end rings). Motors can reach a higher level of efficiency in the same size by using copper rotors. DCR Motors has long life span. Reduction of manufacturing cost. Technical Features: Starting torque The DCR motor has the advantage of high torque at running speed and its starting torque is lower than in aluminum rotor motors (85 Nm instead of 90 Nm in a 5.5 kW motor), which is beneficial for gearbox life. In applications where lower starting torque is a problem, a modified design of the rotor slot offers a solution. It is found that the measured inter-bar resistance is lower reduced in DCR pull-out than in cast and

continuous rated motor this cannot be a problem. However, this effect is offset by efficiency increases due to the other factors contribute the substantial efficiency increases. Higher start-up current: The higher conductivity of copper, i.e. its lower electrical resistance, will result in a slightly higher start- up current since the slot area remains the same. (7.0 times the nominal current for a 7.5 Kw copper rotor motor, instead of 6.0 times for its Al rotor) starter can be used to avoid that this higher current aspects the electricity system. Also, since motors are increasingly being driven by inverters, inrush and starting currents become less of an issue. Rotor inertia: The higher rotor weight increases rotor inertia. This improves the motors efficiency, but can be a problem in certain applications for example motors that frequently switch direction at high speed. A survey among manufacturers, users, researchers, engineers and members of associations, reveals that the copper rotor motor has now become an accepted technology (82 %). The main application domain

aluminum rotors. This leads to a torque increased stray-load losses. For a

is

for

industrial

low

voltage

DCR

induction motors of 1 up to 100 KW, but the technology also has potential motors. Comparison between DCR and DAR:
Reduction in slip by 2%

for

fractional

KW

Drawbacks And Solution: The melting point for aluminum alloys is in the 676C (1250 F) range. Copper melts at 1083C (1982F). This high melting temperature results in failure of conventional die steels by thermal fatigue of the surface. The die-cast as a state-of-the-art technology makes an increase of rotor size each year due to the manufacturing advancements The challenges of die casting copper, which are higher temperatures and pressures compared with die casting aluminum, have been solved with the development of a die casting process using nickel-base alloy die inserts operated at elevated temperature.
2. Efficiency Improvement in

Increase in starting current by 10%

Decrease in starting torque by 17%

Improvement in E ciency by 2.8%

Decrease in Temperature by 7.50C

Decrease in Full load Current by 4%

Chance in Full load p.f Negligible

Industrial Sector Industries use squirrel cage

DAR Motor

induction motor as the driving element in majority of the motive loads. By merely replacing the DAR by DCR (without changing the other parameters), the efficiency of the motor were proven to improve by 1.6% in 37.0kw motor and 9.4% in 0.75kw motor. Improved efficiencies obtained

by using DCR in the exiting designs are given in table for the certain popular ratings used in the

0.75 1.50 2.2 3.7 7.5 11.0 18.5 37.0

71.0 76.0 79.3 83.0 85.0 85.5 87.0 88.5

82.6 85.0 86.5 88.3 90.2 91.0 92.2 93.6

industrial sector in 3phase test conditions. Most of the motors used in industry are oversized and even when proper sized motors are used they are not loaded to their full capacities. This results in poor efficiency which leads to more energy consumption and energy cost. Replacement of a standard with a DCR motor is not likely to have much influence on motor power factor (on an average pf improvement is less than 1%). The higher power factor reduces the currents in cables supplying power to motor and this reduces cable loss, improving the system efficiency even by 2%. This even allows a lower cable size saving tremendously capital costs. Saving is also made by reducing capacitors required to power factor. Efficiency between standard efficient motors Motor rating (KW) Standard Efficient Motor (DAR) Energy Efficient Motor (DCR) comparison and energy

This table shows efficiency comparisons of standard and DCR motors by simply changing the standard efficiency motor with energy efficient (DCR) motor, the efficiency improvement is found by 11.6% in 0.75kw motor and nearly 5% in 37.0kw motor. 3. GENERAL POLICY APPROACHES FOR ENCOURAGING ENERGY EFFICIENCY Energy efficiency is a fundamental element in progress towards a sustainable energy future. As global energy demand continues to grow to meet the needs and aspirations of people across the globe, actions to increase electrical energy efficiency will be essential. Some of the policy approaches for encouraging electrical energy efficiency are given below:

Promoting energy efficient technologies: Number of technologies show of great promise use. for For costeach the effectively improving the efficiency electricity we technology, efficiency. Tax incentives and rebates: Government should consider supporting policies energy that in high promote support efficient technologies directly by implementing encourage Government energy investments should and describe

If the rating of the machine is high, the incremental difference in efficiency of DCR motor is narrowed down. In todays rising power shortage, it is one of the solutions of energy efficiency initiative and energy conservation of induction motor by using DCR technology. Apart from energy savings, the DCR motor also reduces the production of greenhouse gases and push down the total environmental cost of electricity generation. Therefore the adoption of these motors can give immense benefits to the user as well as the country and the global environment. Finally some of the general policy approaches for encouraging electrical energy efficiency are also presented. References [1] BOGLIETTI, A.CAVAGNINO, A.LAZZARI, M.PASTORELLI, M. : Induction Motor Efficiency Measurements in Accordance to IEEE 112-B, IEC 34-2 and JEC 37 International standards, in Conf. Rec. IEEEIEMDC03, Madison, WI, 2003, pp. 1599-1605. [2] FUCHSLOCH. J. F.FINLEY, W. R.WALTER, R. W. The Next Generation Motor-Designing a New Approach to Improve the Energy Efficiency of NEMA Premium Motors, IEEE Ind. Appl. Magazine (Jan/Feb 2008). [3] NEMA Standards Publication No. MG1, National Electrical Manufacturers Association (NEMA), Washington, D.C., 1993. [4] MANOHARAN, S. DEIVASAHAYAM, M. RANGANAT-

potential benefits of improving

efficiency products and equipment. efficiency

energy efficient technologies like DCR technology through their own purchasing policies. CONCLUSION: This paper describes DCR technology, its advantages, drawbacks and their remedies, enhancement of energy efficiency in induction motor using DCR technology, especially in industrial sector. The results shows for the same output power, by merely replacing the existing motor (without changing the other parameters), the efficiency of the motor is increased by nearly 9% points in the lower capacity motors.

[5] LIE, S.Di PIETRO, C. Copper Die Cast Efficiency Improvement and Economic Consideration : IEEE Transaction on Energy Conversion 10 No. 3 (Sep 1995), 419424. 6] PARASILITI, F.VILLANI, M.PARIS, C.WALTI, O. SONGINI, G.NOVELLO, A. ROSSI, T. : Three-Phase Induction Motor Efficiency Improvements with Die-Cast Copper Rotor Cage and Premium Steel, SPEEDAM 2004, Capri, June 1618, pp. 34. [7] BRUNNER, C. U. : International Harmonization of Motor Standards Saves Energy, APEC Workshop, Beijing, 3 December 2007. [8] BONNETT, A. H.YUNG, C. : Increased Efficiency versus Increased Reliability, IEEE Industrial Applications Magazine (Jan/Feb 2008). [9] HSU, J. S.FRANCOFERREIRA, E. A. : Method of Manufacturing Squirrel Cage Rotors, U.S. Patent NO. 6,088,906, July 18, 2000. [10] FINLEYW. R. HODOWANEC, M. M. : Selection of Copper versus Aluminum Rotors for Induction Motors, IEEE Transactions on Industry Applications 37 No. 6 (Nov/Dec 2001),
1563-1573.