In at this time’s world, motors are ubiquitous, powering every part from family home equipment to industrial equipment. The significance of optimizing motor management for vitality effectivity can’t be overstated, on condition that motors account for a good portion of world vitality consumption. This text delves into the construction of motors, using variable frequency drives (VFDs), and the options for motor management functions, together with {hardware} assist and superior algorithms.

The prevalence of motors

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

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

In line with the Vitality Info Administration, roughly 50% of world vitality consumption is attributed to motors. In industrial functions, this determine can exceed 80%. As an example, in the USA, the overall vitality consumption in 2022 was 4.07 trillion kilowatt-hours, equating to a each day consumption of 11.2 billion kilowatt-hours. Bettering motor effectivity by simply 1% might save 56 million kilowatt-hours of vitality each day.

Key tendencies in motor effectivity

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

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

Vitality environment friendly motors

One of many main tendencies in motor effectivity is the transition from conventional motors, similar to AC induction motors, to extra environment friendly sorts like brushless DC (BLDC) motors, everlasting magnet synchronous motors (PMSM) and inside everlasting magnet (IPM) motors. These motors supply larger effectivity and improved efficiency. Moreover, developments in supplies, similar to using 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 fundamental 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 advanced. 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 diminished noise and additional elevated effectivity.

One notable development in motor know-how is using amorphous supplies in rotors and stators. Historically, silicon steels had been used, however they’d excessive eddy present and hysteresis losses. These at the moment are being changed by amorphous supplies like metallic glasses, which have decrease losses and thus larger effectivity.

For everlasting magnet motors, stronger magnets, similar to these made out of uncommon earth supplies like neodymium, iron and boron, present extra torque and effectivity. Nonetheless, because of sustainability considerations, options like aluminum, nickel, chromium, and ferrite-based magnets are being explored for his or her good properties over a variety of temperatures and robust magnetic fields.

Motor construction

The transition from journal bearings to ball bearings has performed a big position in decreasing friction and bettering 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 might be attributed to using 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 functions, the place decreasing weight can result in elevated effectivity and the power to combine motors into extra compact areas. As we proceed to discover new supplies and designs, the potential for even better effectivity and efficiency in motor methods stays promising.

Variable frequency drives

Variable frequency drives (VFDs) have change into more and more common for controlling motor pace and bettering effectivity. VFDs modify the motor’s pace to match the load necessities, decreasing vitality 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 larger effectivity and sooner switching.

VFD affect

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

As an example, conventional motor methods typically function at full energy, with movement charges managed by throttling valves, resulting in substantial vitality losses. In distinction, VFDs get rid of the necessity for throttling by adjusting the motor pace to match the required movement price, thereby decreasing vitality consumption and growing total 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 variety of energy administration units are essential to successfully profit from VFDs.

Determine 6 Primary block diagram of supporting energy administration units 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), might 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, similar to V/F management for AC induction motors, are cost-effective and easy however could not supply the best effectivity. Extra superior algorithms, similar to six-step commutation for BLDC and PMSM motors, can supply sensor or sensor-less precision torque management. Subject-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 prime efficiency pace, 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 pc (CORDIC) with sine-cosine required for FOC of motors. Supply: Microchip

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

Integration with IoT and AI/ML

The mixing of IoT and AI applied sciences has revolutionized motor management. Sensors are used to detect present, torque, and rotor place, amongst different parameters, info that’s then fed to MCUs for processing. With the mixing of ML, these methods 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, decreasing the chance of surprising breakdowns. By constantly analyzing parameters similar to present, torque and vibration, predictive upkeep ensures environment friendly motor operation and minimizes downtime. Methods can, for 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 similar to an unbalanced load or a damaged bearing, by monitoring the quiescent present of the motor.

Optimizing motor management

Optimizing motor management for vitality effectivity is essential for decreasing international vitality consumption and bettering the efficiency of varied functions. By transitioning to environment friendly motors, using VFDs, implementing superior management algorithms and integrating IoT and AI applied sciences, vital vitality financial savings might be achieved. Because the demand for energy-efficient options continues to develop, developments in motor management know-how will play an important position in assembly these wants.

Pramit Nandy is a product advertising and marketing supervisor at Microchip Know-how Inc., targeted on motor management functions. 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

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

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• Anatomy of MCUs for motor management
• MCUs specializing in motor management, energy conversion

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