dmi outstanding performance (nxpowerlite)
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Presentation
DMI motors - innovations beyond the limits
DMI - DC motors for peak performance
Johan Swrd, Area Sales Manager DC Motors Vsters Sweden
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Agenda
Brief information about ABB DC Motors General information DMI Motor Technical requirements and how the DMI motor
fulfill these demands Typical applications for DC Motors
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Who is Johan Swrd?
Johan Swrd
Mechanical Engineer, Master Degree. University of Vsters Sweden
Married with Annika, Two Children Hampus 12 years old and Julia 11 years old
Lieutenant at Swedish Army
Started at ABB 1995
1995 1998 Sales Engineer at ABB Nuclear division within ABB Atom 1998 2005 Area Sales Manager for Robot Automation within ABB Robotics 2005 Area Sales Manager for DC Motors within ABB Machines
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ABB PRU DC Motors
Key figures Part of BU Machines Located in Vsters, Sweden
and Ostrava, Czech Republic Delivers ~1000 motors annually
>120 years of experience
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Steady growing DC business within ABB
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2001 20062005200420032002 2007
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+30
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Location Vsters, Sweden
Marketing & Sales Technical
development Assembly Testing
Ostrava, Czech rep.ABB Service Production of
complete rotors and stators
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Our offer
DMR-design (replaces DMP) Shaft height 112-180 mm Power output < 170 kW
DMI-design (replaces DMG, DMA) Shaft height 180-400 mm Power output < 1400 kW
LAN-design Shaft height 710mm Power output < 2200 kW
After sales Inspections Upgrade Spare Parts Replacement
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Small Stock Motors for a very short deliverytime We will have stockmotors available at a very short
deliverytime. (2 days) Standard motors also available at a short deliverytime (2
weeks)Cooling from N-end P nbas ntop IA P nbas ntop IA IF
DMI180M-BFA 125 1701 2720 339 148 2018 3228 339 8,0DMI180P-AXA 123 1421 2273 336 146 1688 2700 336 9,3DMI200P-DDA 160 1249 1998 435 189 1484 2374 433 13,0DMI200U-CMA 157 908 1452 433 185 1082 1731 429 13,5DMI225S-FDA 262 1318 2108 699 310 1561 2497 699 13,9DMI225U-EXA 262 1103 1764 703 310 1308 2092 702 15,2
Cooling from D-endDMI180M-BFA 106 1717 2720 286 126 2034 3228 287 8,0DMI180P-AXA 105 1436 2273 284 124 1703 2700 284 9,3DMI200P-DDA 136 1262 1998 367 161 1496 2374 367 13,0DMI200U-CMA 133 920 1452 363 157 1094 1731 361 13,5DMI225S-FDA 223 1328 2108 592 264 1571 2497 593 13,9DMI225U-EXA 223 1113 1764 595 264 1318 2092 595 15,2
UA = 400V UA = 470V
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General data
Armature voltage up to 810 V Field voltage 110-440 V Standards IEC, CE, CSA (up to 710 V) IM:
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General dataGeneral data
Degrees of protection and methods of cooling
IP 23IC 06Separatelycooled by maschinemounted fan unit,filter available
IP 23IC 17Separately cooledby ductedventilation
IP54, IP55IC 37Separatelycooled by ductedventilation
IP54, IP55IC 86WCooling by top or sidemounted air-water coolerwith filter for circulating air
IP54, IP55IC 666Cooling by top or sidemounted air-air cooler with filter for circulating air
IP54, IP55IC 410Totallyenclosed, framecooled withoutfan
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DC Theory
Base speed Field
weakeningnb nmax
UN
IN
IN
TN
PN
UA
IA
If
T
Pn
Armature voltage
Armature current
Field current
Torque
Output [kW]
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Market for DC Motors
DC is a stable market Global market size ~250
MUSD Consolidations of suppliers
Used where DC has its advantages a niche market
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Technical requirements and how the DMI motor fulfill these demands
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General requirements from the metals industry
High output and torque, but the space is limited The speed has to be able to variate over a wide range Requirements for high overloads High adaptability for replacement market How about the maintenance? Wide motorrange for several different applications Quality How can we together save the environment?
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General requirements from the metals industry
High output and torque, but the space is limited The speed has to be able to variate over a wide range Requirements for high overloads High adaptability for replacement market How about the maintenance? Wide motorrange for several different applications Quality How can we together save the environment?
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How does the DMI fulfill the demans
Power output and torque for DMI is above any competitor in the same size
How is it possible to get so much power from such a small motor
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How does the DMI fulfill the demansInsulation class
120145
165
10
101025
25
25
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200
250
Material class FTemp.utilization B
Material class HTemp.utilization F
Material class 200 DMI Temp.utilization
T
e
m
p
MarginHot spotAverage
Material Class FUtilazation B
Material Class HUtilazation F
Material Class 200Utilazation H
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Cooling Close Along the Rotor Windings
How does the DMI fulfill the demans
Safe Increase of Power Output
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How does the DMI fulfill the demans
Outstanding commutation
I will explain this later
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How does the DMI fulfill the demans
Power output and torque for DMI is above any competitor in the same size
How is it possible to get so much power from such a small motor In an application this gives smaller and lighter motors
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146%113%127%100%t %
0,840,650,730,58t (0-1000)SIEMENS 280SICME 280 KL6Ansaldo GH 280PKDMI 280V
Size 280
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100
200
300
400
500
600
700
0 500 1000 1500 2000 2500 3000n [rpm]
P
[
k
W
]
DMIANSALDOSICMESIEMENS*
How does the DMI fulfill the demans
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How does the DMI fulfill the demans
P=319, n=698, U=470
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0 500 1000 1500 2000 2500 3000n [rpm]
P
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DMI 280 TSiemens 355SICME 315
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How does the DMI fulfill the demans
New motor year 2007 DMI 400V
400mm shaft height intermediate plate 310mm 900 kW 800 - 1700 rpm equal shaft dimensions drop-in replacement
Example Customer: COMITAL, Sweden Application: Rolling Mill Existing DC-motor
brand ASEA LAD 710 710mm shaft height 900 kW 800 - 1700 rpm 420 Vdc Ducted air inlet and outlet
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How does the DMI fulfill the demans
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How does the DMI fulfill the demans
Power output and torque for DMI is above any competitor in the same size
How is it possible to get so much power from such a small motor In an application this gives smaller and lighter motors Low inertia gives fast accelleration
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High torque and small rotor size mean outstanding acceleration.
High top speed.Higher acceleration and top speed shorten process cycles Higher output
How does the DMI fulfill the demans
Process cycle (t)
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General requirements from the metals industry
High output and torque, but the space is limited The speed has to be able to variate over a wide range Requirements for high overloads High adaptability for replacement market How about the maintenance? Wide motorrange for several different applications Quality How can we together save the environment?
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How does the DMI fulfill the demans
Large speed range with constant power
The motor is more flexible and can be used in a large working area
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How does the DMI fulfill the demans
0
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600
800
1000
1200
1400
1600
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
rpm
k
W
DMI 400DMI 315DMI 280DMI 250DMI 225DMI 200DMI 180
DMI power and speed range
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How does the DMI fulfill the demans
Long motors => High TorqueShort motors => High speed
DMI 180 B. E, H, M, P, S, UDMI 200 B, E, H, M, P, S, UDMI 225 K, N, S, U, XDMI 250 L, P, T, V, YDMI 280 L, P, T, V, YDMI 315 N, R, T, V, Y, ZDMI 400 H, L, N, R, T, V, Y, Z
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DMI peaks performance after decades of DC evolution
DMI
How does the DMI fulfill the demans
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How does the DMI fulfill the demans
Large speed range with constant power
The motor is more flexible and can be used in a large working area The use of gearboxes might be unnecessary
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General requirements from the metals industry
High output and torque, but the space is limited The speed has to be able to variate over a wide range Requirements for high overloads High adaptability for replacement market How about the maintenance? Wide motorrange for several different applications Quality How can we together save the environment?
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How does the DMI fulfill the demans
Superior commutation performance Wide black band test
The electrical stress of the motor is down to one third of competitors
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How does the DMI fulfill the demans
Superior commutation performance Wide black band test
The electrical stress of the motor is down to one third of competitors
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How does the DMI fulfill the demans
Supports increased torque
Saturation is eliminated
Conventional DMI design
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How does the DMI fulfill the demans
Superior commutation performance Wide black band test
The electrical stress of the motor is down to one third of competitors The motor is less sensitive to external disturbances (polluted air, vibrations
etc.
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There are always commutation disturbances
Without margin Sparking occurs
How does the DMI fulfill the demans
Commutation Margin - Why?
load and supplydisturbances
Commutation margin
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DMI has an outstanding margin
How does the DMI fulfill the demans
DMI manages higher output power at higher speed than any other DC-motor.
load and supplydisturbances
Commutation margin
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How does the DMI fulfill the demans
Superior commutation performance Wide black band test
The electrical stress of the motor is down to one third of competitors The motor is less sensitive to external disturbances (polluted air, vibrations
etc. Less brushwear => longer lifetime for the brushes => less need for
maintenance
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General requirements from the metals industry
High output and torque, but the space is limited The speed has to be able to variate over a wide range Requirements for high overloads High adaptability for replacement market How about the maintenance? Wide motorrange for several different applications Quality How can we together save the environment?
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How does the DMI fulfill the demans
Large & old installed base of DC Motors ABB products very suitable
higher torque/power vs size always enough space
wider speed range reduced need of maintenance
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How does the DMI fulfill the demans
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How does the DMI fulfill the demans
Superior mechanical design
Very high maximum speedlimit
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DMI combines high speed and less maintenance
Same rpm
Small commutator diameter reduces
surface speed
How does the DMI fulfill the demansConventional design DMI
...allows higher rpm
Lower surface speed...
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Substantially reduced maintenance
Multiple spokes ensures cummutatorstability
Highest Commutator Quality available
How does the DMI fulfill the demans
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How does the DMI fulfill the demans
Superior mechanical design
Very high maximum speedlimit Small commutator => less brushwear
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Reduced brushwear
How does the DMI fulfill the demans
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How does the DMI fulfill the demans
1.Reduced peripheral Speed.
Reduced brushwear
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How does the DMI fulfill the demans
Superior mechanical design
Very high maximum speedlimit Small commutator => less brushwear New standard brushes and new design of brushgear
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How does the DMI fulfill the demans
2. DMI Uses Longer Brushes
Reduced maintenance
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How does the DMI fulfill the demans
Changing brushes can be done during normal service stop
3.DMI uses more of the brushes.
Reduced maintenance
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How does the DMI fulfill the demans
Stable pressure finger with time stable neutral position
Accurate repositioning Brush wear sensor indicates
when it is time to change brushes (option)
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How does the DMI fulfill the demans
Superior mechanical design
Very high maximum speedlimit Small commutator => less brushwear New brushgear and new brushes Easy to change brushes
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How does the DMI fulfill the demans
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How does the DMI fulfill the demans
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How does the DMI fulfill the demans
Superior mechanical design
Very high maximum speedlimit Small commutator => less brushwear New brushgear and new brushes Easy to change brushes Flexible solutions for positioning terminalbox and fan to user preferences
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How does the DMI fulfill the demans
Terminal box location and cable entrance
Option: Flying leads without terminal box
Cable entrance from all directions
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How does the DMI fulfill the demans
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6 Fan Locations...
There is always a way to mount the fan
How does the DMI fulfill the demans
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How does the DMI fulfill the demans
Superior mechanical design
Very high maximum speedlimit Small commutator => less brushwear New brushgear and new brushes Easy to change brushes Flexible solutions for positioning terminalbox and fan to user preferences Smooth running at low speed
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How does the DMI fulfill the demans
Low noise
Skewed Rotor Slots
Eliminates cogging at low speed
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How does the DMI fulfill the demans
This gives DMI an even torque at the lowest speeds
To eliminate Magnetic Polarization, every sheet is turned in the stacking process
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General requirements from the metals industry
High output and torque, but the space is limited The speed has to be able to variate over a wide range Requirements for high overloads High adaptability for replacement market How about the maintenance? Wide motorrange for several different applications Quality How can we together save the environment?
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How does the DMI fulfill the demans
Less need for and simplified mainenance
Maintenance is a considerable part of the lifetime cost of a DC motor
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How does the DMI fulfill the demans
Less need for and simplified mainenance
Maintenance is a considerable part of the lifetime cost of a DC motor
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General requirements from the metals industry
High output and torque, but the space is limited The speed has to be able to variate over a wide range Requirements for high overloads High adaptability for replacement market How about the maintenance? Wide motorrange for several different applications Quality How can we together save the environment?
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How does the DMI fulfill the demans
A large Speed/Output area means high productivity in applications
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How does the DMI fulfill the demans
Long motors => High TorqueShort motors => High speed
DMI 180 B. E, H, M, P, S, UDMI 200 B, E, H, M, P, S, UDMI 225 K, N, S, U, XDMI 250 L, P, T, V, YDMI 280 L, P, T, V, YDMI 315 N, R, T, V, Y, ZDMI 400 H, L, N, R, T, V, Y, Z
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General requirements from the metals industry
High output and torque, but the space is limited The speed has to be able to variate over a wide range Requirements for high overloads High adaptability for replacement market How about the maintenance? Wide motorrange for several different applications Quality How can we together save the environment?
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How does the DMI fulfill the demans
Quality
Long lifetime of the motor
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A dc drive with DMI gives a long lasting trouble free operation.
How does the DMI fulfill the demans
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How does the DMI fulfill the demans
Quality
Long lifetime High availability
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How does the DMI fulfill the demans
Quality
Long lifetime High availability All DMI motors are tested at full load
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How does the DMI fulfill the demans
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How does the DMI fulfill the demans
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How does the DMI fulfill the demans
Quality
Long lifetime High availability All DMI motors are tested at full load Safe deliveries at right time
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How does the DMI fulfill the demans
Quality
Long lifetime High availability All DMI motors are tested at full load Safe deliveries at right time Long term customer co-operation, Close to service shops world wide
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How does the DMI fulfill the demans
Logistic center has a world wide coverage for spare parts. Spare Parts On-Line => Short deliverytimes
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General requirements from the metals industry
High output and torque, but the space is limited The speed has to be able to variate over a wide range Requirements for high overloads High adaptability for replacement market How about the maintenance? Wide motorrange for several different applications Quality How can we together save the environment?
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How does the DMI fulfill the demans
Low environmental impact
The workshops has implemented ISO 14001.
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How does the DMI fulfill the demans
Low environmental impact
The workshops has implemented ISO 14001. Low noice
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How does the DMI fulfill the demans
Low environmental impact
The workshops has implemented ISO 14001. Low noice Less use of copper in motors
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How does the DMI fulfill the demans
Low environmental impact
The workshops has implemented ISO 14001. Low noice Less use of copper in motors Less brushwear => cleaner environment at customer site.
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Typical applications for DC Motors
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METALS
Mill stand High starting torque Load variations Wide speed range with high
maximum speed
Coiler/ Uncoiler High Base to top speed ratio Constant power for uncoiler Quick response to step load
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METALS
Shear Short, repetitive duty cycle High overload for short time Fast acceleration, decelearation
Press machine Compact installation DC is a cost efficient solution Overload capacity
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Pulp & Paper, Cement
Re-winder Current sharing between forward &
reverse drums High overload Wide speed range
Kiln High Starting torque for long time (1 min) 2 motor configuration for redundant
operation Master/ Follower Cost effective solution
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Cranes & Mines
Harbor cranes Overloads during long time Fast acceleration, smooth start &
stop Compact installations Reliability
Mine hoists Very low base speed Smooth start & stop High starting torque High reliability
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Rubber and Plastics
Rubber mixer High starting torque Cyclic load patterns High reliability to avoid batch loss 2 motor configuration
(Master/Follower)
Extruder Running at low speed for long time High starting torque Variation in speed leads to product
rejection Compact installations
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Rope ways & Lifts, Marine
Ski lifts High reliability for safety standards High staring torque Smooth start & stop Low noise Compact installation
Marine applications High torque (300%) Limitation in space/ small footprint
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Food & Feed
Sugar centrifuge Cyclic load & speed changes Precise speed holding accuracy
due to high inertia of load High start / stopping torque for
acceleration & stopping
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johan.sward@se.abb.com+46 21 32 94 27
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