Motoring

Ahead
SYNCHRONOUS MOTORS
CONTROLLED BY VARIABLE-SPEED DRIVES
ARE BRINGING HIGHER EFFICIENCIES
TO INDUSTRIAL APPLICATIONS
Heinz Lendenman, Reza R. Moghadam, Ari Tami and Lars-Erik Thand

Management Summary
Electric motors in industrial applications account for approximately 6065 percent of consumed
industrial electricity. Using energy effectively by increasing motor efficiency is at the center of con-
tinued motor optimization. Major energy savings are also gained through the use of variable speed
drive systems, and today this technology is adopted in as many as 3040 percent of all newly installed
motors. Sustainable use and investment also demand increased reliability and lifetime of a motor. The
streamlined rotor structure of ABBs synchronous reluctance motors eliminates rotor cage losses, thus
increasing efficiency and compactness. The possibility of achieving standard power and torque levels
at merely a low class-A temperature rise (60 K) improves the lifetime of the motor insulation and
lengthens the bearing lifetime or greasing intervals.

Electric motors are used in a wide range of industrial (SM). SMs with a 4-pole rotor operated at 50 Hz rotate in
applications. What most applications have in common is the synchronism with the supply at exactly 1,500 rpm. The cor-
need for their motor to be as efficient as possible and to have responding induction motor (IM), however, has slip losses
the longest possible lifetime without increasing maintenance and rotates only at 1,475 rpm for a chosen 30 kW example.
demands or failures. ABBs synchronous reluctance motors are In modern IMs with a short circuit rotor cage, the losses
physically smaller in size, helping machine builders to design associated with the rotor amount to 2035 percent of the
smaller, lighter and more efficient equipment. Additionally, total motor losses. Synchronous rotation eliminates most of
the possibility of high-speed operation helps to eliminate these associated losses.
mechanical power transmission elements such as gearboxes. The elimination of these slip losses leads to an efficiency
This eventually enables the integration of the motor and the increase of about ~0.6 percent (220 kW motor) to 8 percent
load equipmentnow an increasingly common request. (3 kW), as well as a 2040 percent increase in power and
To answer the need for a motor that is more efficient, torque density for the same insulation temperature class.
smaller and with a long lifetime and low maintenance needs, Synchronous motors come in different variantsfield-
and that could also be perfectly adapted to variable speed wound with brushless exciters; permanent-magnet (PM)
drive (VSD) operation, ABB radically re-thought all technol- motors; or as motors based on the principle of magnetic
ogy options. Starting a VSD motor is very different compared reluctance (often called a synchronous reluctance motor or
to a direct line connection start. This and other changes in SynRM). A SynRM rotor has neither a conducting short
boundary conditions highlighted potential opportunities to circuit cageas does the IMnor permanent magnets or
simplify the motor design and improve efficiency. One well field excitation winding. Rather, the magnetic principle of
known approach is the utilization of synchronous motors reluctance is utilized.
26 powertransmissionengineering august 2011 www.powertransmission.com
 Figure 1A motor-and-drive system undergoing highly accelerated stress testing
(HAST). (The above and all other pictures/images courtesy ABB).

The synchronous reluctance motor. Magnetic reluctance is

the magnetic equivalent of the resistance in electrical circuits.
The rotor consists of one direction of least-possible magnetic
resistance (d) and a perpendicular direction (q) with a high
magnetic reluctance or good magnetic insulation (Fig. 3).
Torque is produced as the rotor attempts to align the mag-
netically conducting direction to the stator field. The strength
of the produced torque is directly related to the saliency
ratioi.e., the inductance ratio between the two magnetic
directions of the rotor.
The invention of the SynRM concept dates back to 1923.
However, at that time the motor type was not adapted for
industrial use, due primarily to the lack of a direct online
starting capability. But nowwith the use of variable speed
controllersthis obstacle has been removed (Fig. 4).
In 1982, NdFeB-based, permanent-magnet materials
were discovered. The resulting new permanent-magnet (PM)
motor technology was adapted for servomotors and is now
emerging in many industrial specialty applications such as
gearless, low-speed torque motors (Ref. 1). But once again,
less attention was paid to the unpretentious SynRM.
In addition, not all earlier published work on the SynRM
succeeded in demonstrating superior torque performance or Figure 2The possibility of high-speed operation
reaching higher efficiency than the IM, as was expected from helps to eliminate mechanical power transmis-
the calculationsa fact cited by experts and academics as to sion elements, such as gearboxes.
why the SynRM is not used more often today. Presumably,
these early results were due to less-optimized converter con-
trol. Indeed, some publications show very promising results
continued

www.powertransmission.com august 2011 powertransmissionengineering 27

and have addressed the electromagnetic design aspects in tional to the inverse of power factor and efficiency 1/
great depth (Refs. 23). It is important to note the contrast of (h*cos[r]) is actually lower than that of a small-size induc-
the SynRM to the switched reluctanceor stepper motor tion machine at the same torque and speed. This is primarily
with an entirely different stator, winding concept and non- due to the significant gain in efficiency. Only for large motors
sinusoidal current waves; a motor often considered unsuitable
for industrial use due to high noise. A cited disadvantage of
the SynRM is a higher current need for the same torque com- For small motors at 3 or 4 kW level,
pared to the PM motor, since the rotor must be magnetized
through the stator. However, the power factor as seen from
as much as 60 percent more power
the network is determined by the power converter and is in can be obtained for the same tem-
unity with all operating modeseven for the SynRM. perature rise.
The industrial motor for VSD systems. In ABBs SynRM
rotor designs and drive control, the motor current, propor-
is the converter current higher than with an IM at the same
torque. In general, the ABB SynRM operates with the same
T d
frame size for the drive (e.g., ACS850) as the IM at the same

q power and torque level, albeit at the increased power den-

sity and higher efficiency than the IM. The motor efficiency
increase translates to a nearly identical energy savings at the
drive system level.
T One other key advantage of ABBs SynRM is the plain

rotor structure. Without magnets or cage, the rotor construc-
tion is more robust than either IM or PM machines. In addi-
T = 3 Pp 1 - 1 2 sin(2 )
2 Lq Ld
tion, no risk of permanent loss of performance exists due to
potential de-magnetization in case of failure or overheating
Pp = Pole pairs of the motor
situations. The motor is inherently safe in operation since,
without magnets, no back-EMF voltage is induced and the
Figure 3Synchronous reluctance rotor and need for over-voltage protection of the converter becomes
torque principle. superfluous. Finally, rare earth materials for permanent
2 Innovation timeline in LV motors magnets are relatively expensive and have currently been in
limited supply for some markets due to the geographic con-
size
Induction
SynRM
Out- centration of the common raw materials suppliers, among
motor put
140 other reasons.
4 kW induction motors (kg)

3.3kW 4.3kW +30-

Weight of standard 4-pole,

Introduction of
120
IEC standard
100
=83% =90% 45% Elimination of most of the rotor losses and the stream-
100
Introduction 160 22kW 29kW +32% lined rotor structure result in a number of benefits for this
80
of SynRM
280 90kW 110kW +22%
motor and its connected load equipment (Fig. 5). A motor
60
5 hp = 3.7 kW
40
with this technology can be operated at the IEC standard-
Technology comparison
20 measured ratings ized power level for the given frame size. In this case, the
0
1900 1950 2000
VSD efficiency gain ranges from more than 5 percent units
year for single kW machines to about 0.5 percent for the largest
Induction motor motors (frame 315). Consequently, where an IM would have
ABB Synchronous reluctance Motor run at class-F temperature rise (105 K), the ABB SynRM
operates merely at class-A temperature rise (60 K) (Fig. 6).
Figure 4 Innovation timeline in LV motors.
3 Loss distribution and efficiency

Induction Synchronous 98
motor reluctance
Loss origin
Efficiency (%) due to loss reduction

motor 96
Rotor iron

Rotor 94
conductor

Windage 92
Bearings
90
Stator iron

88
SynRM
Stator
conductor 86
IM

84
1 10 100 1000
Loss reduction: 10 30%
(Example: 15 kW @1500 rpm) Rated power (kW)

Figure 5Loss distribution and efficiency.

28 powertransmissionengineering august 2011 www.powertransmission.com
 Temperature Classes
C
180
15

155
10
130
Hotspot temperature margin 10
120
105
5

Permissible temperature rise

60 80 105 125

40
Maximum ambient temperature 40 40 40 40

0
Insulation class A B F H
Maximum winding temperature 105 130 155 180

Ambient temperature is the temperature of the air sur- at the hottest spot. This is known as the hot spot allowance.
rounding the motor. This is the threshold point or temperature Insulation classes group insulations by their resistance to
the motor assumes when shut off and completely cool. thermal aging and failure. The four common insulation classes
Temperature rise is the change within a motor when oper- are designated as A, B, F or H. The temperature capability of
ating at full load. The difference between the motors starting each class is the maximum temperature at which the insulation
temperature and its final elevated temperature is the motors can operate to give an average life of 20,000 hr.
temperature rise. Operating a motor at a lower temperature rise than
The standard method of measuring temperature rise allowed by the insulation class can change the motors thermal
involves taking the difference between the cold and hot ohmic capacity, allowing it to handle higher than normal ambient
resistance of the winding. This averages the temperature temperatures. In doing so, the motors life is extended.
change of the whole windingincluding the motor leads, end The above graph shows the temperature ratings, tem-
turns, and wire deep inside the stator slots. Since some of these perature rise allowances and hot spot allowances for various
spots are hotter than others, an allowance factor uses the aver- enclosures of standard motors.
age temperature to indicate what the temperature probably is

Figure 6.
In comparison, for a specific compressor at 4,500 rpm, the compared to stator lossestheir near elimination has a par-
associated ABB SynRM features still lower bearing tem- ticularly high impact on the torque performance. For small
peratures when run at true class-H rise (125 K) than the motors at 3 or 4 kW level, as much as 60 percent more power
larger IM run at class-F rise (105 K). The motor was thus can be obtained for the same temperature rise. For a 60 kW
also called a CoolMotor (Fig. 7). This low-temperature motor the gain is in the 40 percent range and for a 220 kW
operation improves the lifetime of the motor insulation and motor in the 20 percent range, compared to an IM. In most
lengthens the bearing lifetime or greasing intervals. Motor cases, the same power can be obtained from a motor by one
bearings in particular require regular servicing and, according or sometimes two frame sizes smaller than an IM. The reduc-
tion of the footprint is appreciable for all applications that can
utilize lower frame heights and smaller motors. An additional
The low-temperature operation im- gain is the reduced heat load on nearby parts, particularly in
proves the lifetime of the motor insula- closed cabinets. Even at this vastly increased power density, a
further important advantage results from the removal of the
tion and extends the bearing lifetime or losses on the rotor side; since much of the heat conduction
greasing intervals. through the shaft is eliminated, the bearing temperature,
particularly on the drive-end, is reduced. Comparing an ABB
SynRM with an IM at 6 kW, this can be as much as a 30 K
to some studies, bearing failure is the root cause of approxi- reduction, with an approximately 15 to 20 K reduction typical
mately 70 percent of all unplanned motor outages. The lower over the entire range. This effect is particularly pronounced at
bearing temperature directly translates into longer greasing higher speeds, as well as for operation at higher temperature
intervals, reduced maintenance and higher reliability. Even classes. The generally high efficiency is maintained even at
if a bearing eventually needs replacing, having no magnetic this high output. Furthermore, the ABB SynRM retains the
forcesunlike a PM motorthe bearing change is as easy excellent partial load efficiency curve typical of synchronous
as for an IM. machines in that the efficiency remains higheven at partial
The technology enables good torque utilization at higher load; a feature particularly appreciated in VSD drives for fans
speeds. In another utilization of this technology, the opera- and pumps.
tion is maintained at the conventional temperatureoften Finally, these rotors feature about 3050 percent reduced
B- or F-class. Since losses on the rotor are difficult to cool continued

www.powertransmission.com august 2011 powertransmissionengineering 29

higher-speed ramp rates. torque during rotation, thus keeping the motor noise as low
Rotor construction and reliability. Most technical aspects as with conventional motors. One result of this complex
of drive systems with ABBs SynRMs are directly based optimization using FEM, along with analytical and genetic
on existing technology. The housing, connection box, sta- algorithms, was that a 4-pole configuration is most suitable
tor, winding design and technology and bearing options are for the entire speed range up to 6,000 rpm.
identical to IMs. As the 3-phase currents are sinusoidal, the
same drive products can control this motor type, provided the
firmware is optimized and includes this motor type. Only the
rotor is different.
Drive conditions of pumps, fans,
The rotor is less complex than in both IM and PM, as compressors, and mining and
laminated electrical steel sheets are fitted to the shaft. The crane applications were emulated
complexity is in the design. Extensive finite element simula-
tions (FEM) were used to design the cross-section carefully
using methods for highly acceler-
in terms of electrical and mechanical properties. Important ated stress testing (HAST).
design choices made include the number of magnetic seg-
ments and the exact shape of the air barriers. This determines
the torque production and the magnetization current of the To verify the reliability of this new rotor, extensive motor
motor. Minimizing this reactive current was crucial in main- and drive system testing was conducted throughout devel-
taining a favorable drive rating. The exact placement of the opment. Drive conditions of pumps, fans, compressors and
segments along the periphery is essential to create smooth mining and crane applications were emulated using methods

5 Temperature scans from a thermal imaging camera

C
50

45

40

35

30

25
Induction rotor Synchronous reluctance rotor

Figure 7Temperature scans from a thermal-imaging camera.

The performances of the new motor drive system are given for three IEC motor frame sizes.

Motor, temperature rise class F Drive, 400 V

Size PN nN PN nmax Eff TN MM Type code IN Noise Frame MD
mm kW r/min kW r/min %(1/1) Nm kg ACS-850-04 A dBA size kg
100 4 1,500 4 2,250 84.3 25 22 010A-5 10.5 39 B 5
100 7.5 3,000 7.5 4,500 88.7 23 22 018A-5 18 39 B 5
100 13 4,500 13 6,000 90.5 27 22 030A-5 30 63 C 16
100 17.5 6,000 17.5 6,000 91.3 27 22 044A-5 44 71 C 16
160 26 1,500 26 2,250 91.7 165 180 061A-5 61 70 D 23
160 50 3,000 50 4,500 94.0 159 180 144A-5 144 65 E0 35
160 70 4,500 70 5,300 94.6 148 180 166A-5 166 65 E 67
280 110 1,500 110 1,800 96.0 700 640 260A-5 260 65 E 67
280 130 1,800 130 2,200 95.9 689 640 290A-5 290 65 E 67

For full specifications check ABB web pages at www.abb.com/motors&generators

Figure 8Performance of motor drive system for piloting.

30 powertransmissionengineering august 2011 www.powertransmission.com

for highly accelerated stress testing (HAST). HAST cycles Heinz Lendenmann, Reza Rajabi Moghaddam
were developed specifically for this motor to ensure robust ABB Corporate Research
lifetime performance, such as successfully conducting high- Vsters, Sweden
repetition-rate motor starts and stops at speeds above catalog- [email protected]
permitted values. The cycle count and overload conditions [email protected]
were dimensioned to correspond to a more than 20-year
lifetime of rated operation. Ari Tammi
Drive converter and control. Conventional ABB drive ABB Discrete Automation and Motion
technology used for IM and PM motors, with standard direct Motors & Generators
torque control (DTC), was adapted to include the SynRM Vaasa, Finland
as a new motor type. Despite sharing many similarities with [email protected]
the PM motor, except for zero rotor flux, strong develop-
ment focus was given to optimizing the torque production Lars-Erik Thand
through maximum-torque-per-Ampere (MTPA) control. ABB Discrete Automation and Motion
This ensures that the drive current is kept minimal in each Motors & Generators
operating point. The control also includes capabilities for Vsters, Sweden
the field-weakening range; i.e., the speed range above the [email protected]
nominal rated speed. A maximal rated speed of as much as 1.5
times nominal can be reached for much of the motor range. References
This drive control is a particularly important ABB result 1. Haikola, M. No Gears Required: ABBs Direct Drive
that enables this SynRM to reach appreciably higher torque Solution Meets the Challenges of the Worlds Most
densities than IMs. Demanding Processes. ABB Review, April, 2009, pp. 1215.
The installation and operation of the power electronic 2. Boglietti, A., A. Cavagnino, M. Pastorelli and A. Vagati.
drive for this motor is indistinguishable from driving VSDs Experimental Comparison of Induction and Synchronous
with IM or PM motors. Standard features include automatic Reluctance Motors Performance, IEEE/IAS Annual Meeting,
parameter identification based on nameplate values and sen- Oct., 2005, Vol. 1, pp. 474479.
sorless operation. The motor does not need any speed sensors 3. Germishuizen, J. J., F.S. Van der Merwe, K. Van der
but nevertheless can maintain perfect speed accuracy as well Westhuizen and M.J. Kamper. Performance Comparison of
as a high torque dynamic. The drive can even be dimensioned Reluctance Synchronous and Induction Traction Drives for
for specially requested overload and cycle load capability. Electrical Multiple Units, IEEE/IAS Annual Meeting, Oct.
Performance preview. Since this motor, like the PM 812, 2000, Vol. 1, pp. 316323.
motor, always requires a VSD drive, matched pairs of motor
and ACS drives are given as the standard recommendation

An additional gain is the reduced

heat load on nearby partsparticu-
larly in closed cabinets.

for a range of power and speed levels (Fig. 8).

As a response to the key market trends of higher output,
higher efficiency, longer service intervals and footprint reduc-
tion, a radical new motor uniquely suited for VSD systems
is now available. The result is that increased power density
of 2040 percent when compared to an IM; a rotor con-
struction without short circuit cage or permanent magnets;
smaller motors; less heat generation and the highest possible
efficiency for VSD systems is now a reality. A standard IM
fitted with a new rotorcombined with a standard drive with
new softwareresults in a high- output, high-efficiency VSD
system. The output and efficiency performance is comparable
to a PM motor drive, while technologies associated with the
robust induction motor deliver the best of both worlds to
usersall with value-added benefits as a bonus.

www.powertransmission.com august 2011 powertransmissionengineering 31