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WRITTEN-POLE TECHNOLOGY

One fundamental problem with single-phase motors is the very high starting current required to get the motor up to speed. A typical single-phase motor may have starting currents that are six to ten times their normal running current. Newer motors with higher efficiency usually have even higher starting current inrush. This presents a major problem in areas with limited electric supply or in rural areas where only single-phase lines are available. Because of high starting currents, single-phase motors are not generally available in sizes over 15 hp. Many utilities restrict the use of single-phase motors to sizes under 10 hp for ordinary electric motors. High motor starting currents on singlephase lines can cause line voltage dips that can cause problems for other loads. The motor developed by Precise Power Corporation, known as the Written-Pole motor, uses an innovative approach of controlling the magnetic field of the motor to reduce the starting current requirements. The result is a motor that has starting current requirements of only about twice the normal running current and, as an added benefit, the motors have efficiencies of 90% or better compared to conventional motors, which have efficiencies of around 85%. The Written-Pole motor has been developed with inherently low per-unit starting current and they can be applied in single-phase service areas to ratings of over 100 hp without exceeding the starting current limits of many utility systems. Written-pole motors differ from conventional motors in the way the magnetic field is developed. In a conventional motor, the poles are in fixed positions. In a written-pole motor, a magnetic layer is written in different places on the motor's poles as the rotor turns The Story in Brief The award-winning Written-Pole technology, developed with EPRI support, overcomes some fundamental drawbacks of conventional motors and addresses critical needs of electric power customers big and small. With an innovative design that adds unique flexibility to a motor's magnetic characteristics, the technology drastically reduces the need for a high starting current and increases reliability. Thus it is particularly valuable for remote and rural applications, where single-phase power is the norm. Written-Pole technology is also being deployed in motor-generator sets that can serve as uninterruptible power supplies, offering high-tech power customers with sensitive loads an alternative to maintenance-intensive battery systems. Invented more than a century ago, electric motors pervade society today, running things as diverse as factory production lines and bedside alarm clocks. Collectively, these motors consume more than two-thirds of the electricity produced annually in the United States, with those over 5 hp (only 2% of all electric motors) accounting for more than 70% of the consumption. While these larger motors have certainly increased our nation's productivity in applications ranging from irrigation to steel manufacturing, their conventional design has presented some challenges. One fundamental problem is that the motors require a very

high current to start up - typically 6 to 10 times the current needed to maintain full-speed operation. For rural power customers with single-phase electric service, this means not being able to run motors over 16 hp without using expensive phase converters. For large industrial customers with three-phase service, it means the potential for power quality problems like voltage dips as large motors are brought on-line. In the early 1980s, Precise Power Corporation - with EPRI support - developed a breakthrough technology to address these issues. Called Written-Pole[TM] technology, this patented approach uses innovations in magnetism to reduce a motor's need for a high starting current. In fact, a Written-Pole motor (WPM) typically requires a starting current that's less than twice its running current. Additional advantages are the motor's very high efficiency - 92% in comparison with 85% for conventional motors - and its ability to ride through power interruptions of up to about 15 seconds.Also,WPMs can be combined with Written-Pole generators to offer an uninterruptible power source that's not dependent on maintenance-intensive batteries. Written-Pole technology is a revolutionary, yet fundamentally simple approach to enhancing the performance of electric motors and generators. The application of WrittenPole technology frees engineers from one of the most basic constraints faced by designers of conventional induction and synchronous machines. Unlike conventional designs, where the magnetic poles are fixed by the geometry of the rotor cage and stator windings, Written-Pole machines incorporate a proprietary concept that optimizes the magnetic geometry of the rotor for peak performance as the operating speed of the machine varies. Limitations of Conventional Technology: The speed of an electric motor is directly proportional to both frequency and number of poles. Conversely, the output frequency of a generator is directly proportional to its speed and number of poles.

The requirement for smooth balanced output dictates that conventional electric machines must have an even number of magnetic poles with an equal number of north and south orientations. As a result, conventional electric machines are typically classified as 2, 4, 6, or . pole machines, having either 1, 2, 3, or .. pairs of north and south poles respectively. Deviating from this principle will produce an electric machine that is magnetically unstable at its rated speed and unsuitable for steady-state operation. Written-Pole technology frees designers from this constraint without contradicting the fundamental rules that govern the operation of electric machines. The technology makes it possible to produce a pole pattern that correlates directly to the rotational speed of the machine enhancing performance through a considerable speed range.

II. Written Pole Motor Design


As we saw in the previous section, conventional induction motors have a fixed, even number of discrete field pole structures, and therefore have a fixed relationship between shaft speed and the frequency of the electrical input. In contrast, the written-pole motor operates as if it has a variable number of poles. The keys to the operation of a writtenpole motor consist of a special magnetic layer on the rotor and a special exciter winding. The written-pole motor has a continuous layer of permanent magnetic material on the surface of the rotor. The main windings of the stator are similar to those of conventional motors, with an additional concentrated winding around an exciter pole. The magnetic layer can be magnetized, or written, into any desired magnetic pole pattern by the exciter pole while the motor is operating Construction : The main elements of a written-pole motor are illustrated in Figure below. Written Pole motors use similar construction techniques found in conventional motors.

The rotor of a written-pole motor is a combination of induction hysteresis and permanent magnet technology. The basic platform consists of a conventional steel shaft inserted into a lamination stack containing a high resistance rotor cage. The high resistance cage is a

key factor in limiting the starting current of written-pole motors and provides considerable induction torque during the initial stage of starting. The total cross sectional area and resistivity of the rotor cage is selected to provide high slip, high power factor starting characteristics. While this configuration would be detrimental to the operating efficiency of a conventional induction motor, the synchronous mode of operation used in written-pole motor eliminates induced currents in the rotor bars and the resulting electrical losses. A continuous layer of permanent magnetic ferrite material covers the rotor lamination stack and its exact makeup is proprietary to Precise Power Corporation. The ferrite material used in the rotor is similar to the magnetic material used in conventional permanent magnet synchronous motors, enabling it to maintain its magnetization throughout the normal range of operation. However, the unique properties of this proprietary material reduce the strength of the magnetic field required to magnetize or re-orient the material to a level low enough that it becomes practical to remagnetize the rotor while it is rotating. This can be accomplished without losing the properties required for normal operation and has the added benefit of increasing the amount of hysteresis torque available during starting. The stator of a written-pole motor is very similar to a typical induction motor. The stator lamination stack is constructed using low loss electrical steel laminations. The windings are similar in design and function to those used in a conventional induction or synchronous motor. When connected to input utility power, the currents in the windings produce a rotating magnetic field, which interacts with the rotor to apply rotational force to the shaft. A unique feature of a written-pole motor is the use of a concentrated excitation winding located at one or two points on the stator. The excitation windings are contained within the stator structure and are located between the main stator windings. The excitation winding is designed to produce a magnetic field powerful enough to fully magnetize the portion of the rotors' magnetic layer that is immediately across the air gap from it. This winding is used to maintain the correct pole geometry in the rotor. Energy required for operation of the excitation windings is magnetically coupled through the stator from the adjacent stator windings. As previously mentioned, the speed of an electric motor is directly proportional to both input frequency and number of poles. Conversely, the output frequency of a generator is directly proportional to its speed and number of poles. The requirement for smooth balanced output dictates that conventional electric machines must have an even number of magnetic poles with an equal number of north and south orientations. For instance, a 4-pole machine will have 2-pairs of North-South poles; a 6-pole machine will have 3pairs of North-South poles, etc. Deviating from this principle will produce an electric machine that is magnetically unstable at its rated speed and unsuitable for steady-state operation. Written-pole motors overcome this technical barrier and make it possible to produce a pole pattern that correlates directly to the rotational speed of the machine enhancing performance through a considerable speed range The continuous layer of magnetic material on the surface of the rotor which can be magnetized into any desired pole configuration using the exciter winding contained within the stator windings. As the magnet material passes beneath this excitation winding, it is subjected to an alternating magnetic field produced by AC current flowing

in the winding. The strength and orientation of this magnetic field controls the geometry of the magnetic poles induced on the rotor. If the polarity of the magnet material passing beneath the excitation winding does not match the polarity of the magnetic field produced by the winding, the polarity of the magnet is reversed to match the field produced by the excitation winding.

Advantages of Written-Pole motors include, Low starting current High operating efficiency Excellent torque characteristics Unity power factor operation Ability to start high-inertia loads Ability to re-synchronous under load after pull-out Because a written-pole motor has much lower starting current than a traditional electric motor, it takes longer to reach full speed. A conventional motor generally reaches full speed in a matter of seconds - it must to prevent overheating whereas, a writtenpole motor may take several minutes to reach full speed. The slow start up speed is beneficial in some applications such as water pumps; since the slow speed can prevent water hammering that are prevalent in water pumping applications with fast ramp up speeds of conventional motors. Written-Pole Advantage: Written-Pole motors and generators incorporate a continuous layer of magnetic material on the surface of the rotor which can be magnetized into any desired pole configuration using a high density winding contained within the stator windings. As the magnet material passes beneath this excitation winding, it is subjected to an alternating magnetic field produced by AC current flowing in the winding. The strength and orientation of this magnetic field controls the geometry of the magnetic poles induced on the rotor. If the polarity of the magnet material passing beneath the excitation winding does not match the

polarity of the magnetic field produced by the winding, the polarity of the magnet is reversed to match the field produced by the excitation winding. Since the power supplied to the excitation winding is a constant frequency 60 Hz, AC sinusoidal supply, the actual size and quantity of poles generated on the surface of the rotor are dependent on the rotational speed of the machine. Lower speeds result in a larger number of smaller poles with shorter spans, while higher speeds result in a smaller number of larger poles with longer spans. The concept is similar in principle to the idea of a continuous magnetic tape looping through a recording head.

Speed = 1600 rpm Poles = 4.5 Pole Span = 85 deg An 1800-rpm, or 4-pole, electric motor operating at 1600-rpm requires 4.5 poles to maintain synchronous operation on constant frequency, 60 Hz input. Conversely, for an 1800-rpm generator to maintain its rated 60 Hz output at 1600 rpm also requires 4.5 poles. The ability to optimize the pole geometry while in motion allows Written-Pole machines to accommodate significant variances in speed without compromising performance. Upon attaining its rated speed, power to the excitation winding is removed allowing the machine to operate as a synchronous machine. Variation from the machine's rated speed restores power to the excitation winding thereby ensuring that the pole geometry on the rotor remains matched to the rotating electromotive fields produced by the stator winding. A truly revolutionary development, Written-Pole technology allows designers of electric machines to attain new levels of performance for the first time in the history of electric machine design.

Written-Pole Applications:

The application of Written-Pole technology to electric motors yields many desirable characteristics including very low starting current requirements, high operating efficiency, unity power factor operation, instantaneous restart capability, the ability to synchronize under load, and the capability to start very high inertia loads without oversizing. When applied to electric generators, Written-Pole technology allows for the regulation of output voltage and frequency over a considerable speed range without relying on external regulators or power electronics. Combining Written-Pole motors and generators with an integral flywheel allows Precise Power Corporation to create a simple, rugged power protection unit that is ideally suited for rugged industrial and commercial environments where space and infrastructure costs are key considerations. Written-Pole technology is used in a family of single and three-phase motive power and power protection systems used by many customers including the US Weather Service, NASA, Federal Aviation Authority, US Air Force and many commercial and industrial customers.

Award Winning Technology : A recipient of the R&D 100 Award in 1994, Written-Pole technology was recognized by R&D Magazine as one of that year's most technologically significant innovations. The technology has also been recognized by numerous technical organizations including the Professional Society of Engineers in the United States. Developed by Precise Power Corporation, a Bradenton, Florida based motor and generator manufacturer, with support from the Electric Power Research Institute and numerous electric utilities including Manitoba Hydro, this innovative concept is protected by numerous US and International patents. Written-Pole coil writes and erases the magnetic pole 60 times per second (i.e., at a frequency of 60 Hz) during a motor's startup. And these poles alternate: first a north pole is written; then that pole is erased, and a south pole is written in its place. The alternating magnetic poles serve to pull the rotor forward much as a high current would, increasing the rotor's speed during each rotation until the motor reaches its full design speed. (A synchronous motor, the WPM is designed for an operational speed that is in sync with power line frequency.) When the full speed is achieved, the pole-writing procedure ceases and the poles remain as last written. Written-Pole technology does not work on its own to start the motor. In fact, the technology is not even activated until the motor is brought up to 80% of its design speed by more-conventional startup technologies. One of these is the so-called squirrel cage

(which, if named today, might be more aptly called the hamster's wheel). An essential part of many ordinary motors, the squirrel cage is typically made of a low-resistance material so that it does not lose energy at full speed. The WPM employs a squirrel cage made of high-resistance material, which allows it to be activated by a much lower starting current. In the meantime, an effect called hysteresis (a phenomenon that some small synchronous motors, such as those in household clocks, also make use of) helps increase the torque required to get the motor up to 80% of its design speed. At this point, the Written-Pole technology is activated to complete the startup. Because the WPM involves a lower starting current and lower torque than conventional motors, it takes longer to come to full speed. Whereas the high current and high torque of conventional motor technology would have a heavy load up and running within seconds, a WPM may take i to 5 minutes to start the same load. A brisk startup is actually mandatory for conventional motors, since the high internal temperatures generated by the elevated current and torque could very well burn out a motor that fails to start a heavy load within about 20 seconds. In contrast, the lower starting current of the Written-Pole technology means that less heat is generated and a longer startup time is possible. As a result, the WPM can start loads more than 10 times as heavy as those that can be started by conventional induction motors of the same size. The gentler effect of the lower current and longer startup enhances the WPM's reliability and can extend its life to just about double the life of conventional motors. Another advantage of smoother operation is the mitigation of water hammer, a damaging phenomenon that can occur in pumping applications. In addition, a WPM's big, heavy rotor has great inertia, which makes the motor as difficult to slow down as to start up and thus helps it ride through power disturbances as long as 15 seconds. In contrast, a conventional motor will grind to a halt if an interruption lasts more than a second.

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