Available online at www.sciencedirect.com
ScienceDirect Procedia Engineering 174 (2017) 1221 – 1228
13th Global Congress on Manufacturing and Management, GCMM 2016
Development of a super high efficiency motor with boron aluminum alloy rotor Hui Su a, Hui Wen b, Xinhua Zheng b, Jianxin Su c* a
Changsha Nanfang Professional College, Hunan 410208,China b Hunan Tianneng Motor Manufacturing Co Ltd 410105, China C College of information engineering, Xiangtan University, Hunan 411105,China
Abstract Ultra-efficient motor is a national energy-saving projects to promote the new products, in accordance with the traditional design ideas, we must increase the consumption of effective materials in exchange for the improvement of motor efficiency. In this paper, starting from the analysis of motor loss, to explore the design and production of ultra-efficient motor method. Based on the idea of reducing the rotor resistance to improve the motor efficiency and improve the motor load performance, a new method of reducing the resistivity of cast aluminum by boron-aluminum alloy is proposed,The test data of ordinary cast aluminum and boron aluminum alloy spline resistance are given,and the comparison of the main technical parameters and the load efficiency curves of the super-efficient motors produced by different rotor casting processes.The results show that the ultra efficient motors by boron-aluminum alloy rotor production, the main technical performance is far better than the common cast aluminum rotor ultra-efficient motors, some better than the cast copper rotor motor. It is an ultra- efficient motor production process with high performance price ratio. ©©2017 Authors. Published by Elsevier Ltd. This 2016The The Authors. Published by Elsevier Ltd. is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of the organizing committee of the 13th Global Congress on Manufacturing and Management. Peer-review under responsibility of the organizing committee of the 13th Global Congress on Manufacturing and Management
Keywords: Boron-aluminum alloy, motor rotor, ultra-efficient motor;
* Corresponding author. Tel.:13467904481. E-mail address:
[email protected]
1877-7058 © 2017 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of the organizing committee of the 13th Global Congress on Manufacturing and Management
doi:10.1016/j.proeng.2017.01.288
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1. Introduction Asynchronous motor is the most widely used power equipment in the national economy. It consumes more than 50% of the total power [1], and the motors widely used in our country are Y, Y2 and YE2 series, among which Y series motors the average efficiency of only 87.3%, a few years ago to promote the efficient motor YX3, its average efficiency is only 90.3%, nearly 10% of the energy is wasted, improve the efficiency of the motor for energy conservation, reduce production costs and protect the environment is very important The meaning. National energy-saving projects to promote the benefits of ultra-efficient YE3 series motor,is currently able to produce in only some of the domestic manufacturers, and analyze the basic reason is difficult to achieve the improvement of motor efficiency depends mainly on materials and process breakthroughs, in order to break the ultra-efficient motor production of the technical bottlenecks, Yunnan Copper, Nanyang explosion-proof, the International Copper Association, the Shanghai Electric Research Institute to invest 55 million, developed a cast copper rotor manufacturing process, the production of cast copper rotor motor, the first ultra efficient motor international awards, with the cast copper rotor production of ultra efficient motor prototype, reached the national level two energy efficiency standards,although the cast copper rotor motor to YE3 series of national standards, but the cast copper rotor casting process is extremely demanding, casting costs are expensive, the average cast copper rotor of the process cost than the cast aluminum rotor increased 88 yuan, and limited to 37KW the following motor [2], 37KW above the cast copper rotor has not been a technical breakthrough, so cast copper rotor motor has been successfully developed, but difficult scope and a full range of access to promotion. In order to solve the urgency and technical difficulty of producing super-efficient motor, it is necessary to develop a kind of rotor manufacturing method which can satisfy the requirement of super-efficient motor performance and not increase the difficulty of manufacturing technology, so that YE3 series motor can be popularized in large scale. 2. Ways to improve motor efficiency Table 1. The proportion of the loss of the motor. Pcu1
Pcu2
Pfe
Pm
Ps
25~35%
15~25%
15~30%
5~15%
3~15%
As the number of poles of the motor is different, the power is different, the materials used are different, the groove type is different, the production process is different, the proportion of the loss will be different[3], but to improve the efficiency of the motor, Only from the reduction of these five losses to proceed, the following brief description of the technical measures to reduce the loss and the cost: 2.1 Reduce the stator copper consumption: Motor stator copper loss PCU1:
PCU1
I 12 R1
(1)
I1 - motor stator current, R1 - stator winding resistance, to reduce the stator copper consumption, must reduce the stator winding resistance, is bound to reduce the number of winding turns, but must also increase the length of the iron core,which is bound to bring with the increase in the amount of iron and copper. 2.2 Reduce the rotor aluminum loss: Motor rotor aluminum loss PCU2:
PCU 2
I 22 R2
PM S
(2)
I2 - motor rotor current, R2 - motor rotor equivalent resistance, PM - electromagnetic power, S - slip, as the stator and rotor length requirements are the same,in order to reduce the stator copper loss, increased the length of the stator, will inevitably increase the length of the rotor, If the groove type is not changed, the rotor resistance
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must be increased. If the rotor bar can be made with the material with lower resistivity, the rotor resistance can be reduced, thus reducing the rotor loss and improving the motor efficiency. According to the electromagnetic torque and the relationship between the circuit parameters: (3) T KT )I 2COS
