Development of Ulta-Efficient Electric Motors
- Baldor Comp.
Electric motors utilize a large amount of electrical energy in utility and industrial applications. Electric motors constructed with high temperature superconducting (HTS) materials have the potential to dramatically reduce electric motor size and losses. HTS motors are best suited for large motor applications at ratings above 1000 horsepower (hp), where the energy savings from the efficiency improvement can overcome the additional power required to keep the superconductors on the rotor cooled. Large HTS based motors are expected to be half the volume and have half the losses of conventional induction motors of the same rating. For a 5000 hp industrial motor, this energy savings can result in $50,000 in operating cost savings over the course of a single year of operation. Since large horsepower motors utilize (or convert) about 30% of the electrical power generated in the United States and about 70% of large motors are candidates for replacement by HTS motors, the annual energy savings potential through the utilization of HTS motors can be up to $1 Billion in the United States alone. Research in the application of HTS materials to electric motors has lead to a number of HTS motor prototypes yet no industrial HTS motor product has yet been introduced. These motor demonstrations have been synchronous motors with HTS field windings, on the rotor. Figure 1-1 shows a solid model rendering of this type of motor. The rotor winding is made with HTS coils that are held at cryogenic temperature by introducing cooling fluid from the cryocooler to the rotor through a transfer coupling. The stator winding is made of copper wire. The HTS winding is thermally isolated from the warm armature and motor shafts by a vacuum insulation space and through the use of composite torque tubes. The stator in Figure 1-1 is an air core stator in that the stator teeth and a small part of the yoke is made up of nonmagnetic material so the magnetic fields distribute themselves as if in air. Between the HTS field winding and the physical air gap is a series of concentric cylinders that act as vacuum insulation space walls as well as conducting paths for induced currents to flow in order to shield the HTS winding and the rotor cold space from time dependent fields. These time dependent fields may be caused by rotor hunting, during a change in motor load, or by non-fundamental component voltages and currents applied by the inverter. These motors are variable speed controlled by the inverter. Common large motor utility and industrial applications are pump and fan drives that are best suited by a variable speed motor. Inverter control of the HTS motor eliminates the need to design the rotor for line starting, which would dump a large amount of heat into the rotor that would then heavily tax the cryogenic cooling system. The field winding is fed by a brushless exciter that provides DC current to the HTS rotor winding. The stator winding is air or water cooled. Technical and commercial hurdles to industrial HTS motor product introduction and customer acceptance include (1) the high cost of HTS wire and the cryogenic cooling system components, (2) customer concerns about reliability of HTS motors, and (3) the ability to attain the loss reduction potential of large HTS motors. Reliance Electric has demonstrated a number of HTS based electric motors up to a 1000 hp, variable speed synchronous motor with an HTS field winding in the year 2000. In 2001 this motor was tested to 1600 hp with a sinusoidal (constant frequency) supply. Figure 1-2 shows the HTS motor on the dynamometer test stand in the Reliance Electric test lab. The extensive test program of the 1000 hp motor successfully demonstrated the technical feasibility of large HTS motors and the basic technologies involved, however the test results did indicate the need for design refinements. In addition, test results served to identify other more fundamental critical technology issues, and revealed the need to continue research efforts in order to improve future HTS motor first cost, reliability, and performance. The lessons learned from the development and testing of the 1000 hp motor were the basis for the tasks proposed for the project that is being described in this final report. These eight tasks and the technology and commercial issues they address are listed in Table 1-1.
- Research Organization:
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Sponsoring Organization:
- USDOE Office of Vehicle Technology Program (EE-2G)
- DOE Contract Number:
- DE-AC05-00OR22725
- OSTI ID:
- 973932
- Report Number(s):
- ORNL/C-05/0709; TRN: US201007%%295
- Country of Publication:
- United States
- Language:
- English
Similar Records
Steady-state cooling of a high-temperature superconducting motor
Steady-state cooling of a high-temperature superconducting motor