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a r t i c l e i n f o a b s t r a c t
Article history: Future energy challenges, likewise the environmental crises such as fossil fuel emissions and global
Received 27 March 2008 warming urge the world to focus on energy saving programs more than ever. An effective way to face
Received in revised form these challenges is to improve electric motors efficiency as one of the greatest energy consumption
2 April 2009
apparatuses in the world. Induction motors constitute, by far, the largest portion of electric motors both
Accepted 20 April 2009
Available online 4 June 2009
in terms of quantity and total power ratings among all electric motors. However, more efficient motor
types gradually appear as alternatives. In this paper, line start permanent magnet motors as a powerful
candidate with growing market are investigated in some details. The motor opportunities like high
Keywords:
Line start motors efficiency, high power factor and high power density are explored against the challenges associated with
Permanent magnet this motor including higher cost, extra manufacturing burden and transient and synchronization
Energy saving behaviors. Finally, some concluding comments and remarks are drawn for future research and
Efficiency manufacturing of line start permanent magnet motors.
Synchronous motors Ó 2009 Elsevier Ltd. All rights reserved.
Induction motors
1. Introduction On the other hand, practical attempts are being made to increase
the efficiency of electric motors and drives such as motor chal-
The global annual energy consumption has been increasing for lenges programs in the U.S. and the EU [6,7].
decades, reaching a record high of 11,741 Mtoe in 2006 [1]. Most of The efficiency improvement of induction motors, among all
this energy comes from fossil fuels with 81% provided by oil, natural types of electric motors, is the most effective practice since this
gas and coal [1]. Excessive consumption of these primary energy type of motors consumes a huge portion of the total energy going to
resources has caused severe shrinking of the resources besides the electric motors which is 96% in the U.S. [3]. This is usually achieved
air pollution and global warming. Therefore, energy saving in through design optimization of induction motors resulting in
general is a vital concern for the mankind today. limited degrees of success. An alternative solution is to replace the
A large amount of the primary energy resources are converted to induction motors with high efficiency permanent magnet (PM)
electric energy of which more than 50% is utilized to supply electric motors which are gaining ground due to a substantial reduction in
motors [1–3]. As so, the electric motors are responsible for a huge permanent magnet prices in recent years. However, PM motors
share of emission which is 97 million Ton of CO2 for three phase need inverters for starting which is not economical for many single
induction motors only in the UK alone. This is 17% of the total speed applications such as most fans, pumps and compressors
annual CO2 emissions of the country [4]. Therefore, optimizing forming more than 70% of electric motor applications [3]. To
electric motor efficiency is crucial for energy saving and emission overcome this problem, the cage equipped PM motors, so-called
reduction [5]. Some regulations have set minimum efficiencies for line start permanent magnet synchronous (LS-PMS) motors have
electric motors in the United States, Canada, the European Union been developed since 1955 [8]. However, a lack of high energy
and other countries. Also associations like NEMA and Institute of permanent magnets in the past and their high prices later on,
Electrical and Electronics Engineers (IEEE) have proceeded to plan prevented a widespread use of LS-PMS motors. In recent years, the
new standards for electric motors demanding higher efficiencies. introduction of high energy permanent magnet materials with
reasonable prices has paved the path for LS-PMS motors.
In this paper, having a statistical glance on the world energy status
* Corresponding author. Tel.: þ98 21 6111 4422; fax: þ98 21 8877 8690. in recent years, the potential of LS-PMS motors as a candidate to
E-mail addresses: ahassanpour@ut.ac.ir (A. Hassanpour Isfahani), vaezs@ut.ac.ir
(S. Vaez-Zadeh).
replace induction motors in single speed applications is investigated.
URL: http://.eng.ut.ac.ir/ece/vaez-zadeh The challenges of these motors are then described. Finally, the most
1
Tel.: þ98 21 6111 4916; fax: þ98 21 8877 8690. critical issues are addressed for future investigations.
0360-5442/$ – see front matter Ó 2009 Elsevier Ltd. All rights reserved.
doi:10.1016/j.energy.2009.04.022
1756 A. Hassanpour Isfahani, S. Vaez-Zadeh / Energy 34 (2009) 1755–1763
Fig. 1. Global energy development in the world Organisation for Economic Co-oper-
ation and Development (Organisation for Economic Co-operation and Development
(ÓOECD)/International Energy Agency (IEA), 2008, derived from Key World Energy Fig. 3. The share of different fuels in CO2 emission in the world (ÓOECD/IEA, 2008,
Statistics). derived from Key World Energy Statistics).
A. Hassanpour Isfahani, S. Vaez-Zadeh / Energy 34 (2009) 1755–1763 1757
Table 1
Different efficiency standards.
4.1. Efficiency
Fig. 5. A d-q reference frame equivalent circuit of LS-PMS motors. Fig. 6. Distribution of average losses in different parts of induction motors.
1758 A. Hassanpour Isfahani, S. Vaez-Zadeh / Energy 34 (2009) 1755–1763
Table 2
Comparison of LS-PM motors and Induction motors.
Induction motors, due to their inductive behavior, suffer from Fig. 8. Comparison of induction motors and PM motors weight [16].
a low power factor, resulting in a reduction in the capacity of
electricity distribution systems by increasing current flow and
4.4. Rotor temperature
voltage drops. This may lead to an increase in the losses of trans-
mission lines and overheating and premature failure of motors and
Rotor temperature is influenced by its losses as well as motor
other inductive equipments. A low power factor also causes extra
speed. In induction motors, rotor losses include two components
losses in stator windings of induction motors. Besides, many utili-
i.e. iron loss and cage loss. In LS-PMS motors, thanks to synchro-
ties charge customers by an additional fee if their power factor is
nous speed, the cage loss vanishes to negligible eddy current loss
less than a minimum, say 0.95 [14].
caused by air gap space harmonics. Therefore, the rotor tempera-
LS-PMS motors can work with substantially higher power factor
ture of these motors is about 30% less than that of induction motors
than induction motors. They even work in exact or close to unity
with the same output power [17]. This advantage may protect
power factor in many applications and working conditions. Table 2
permanent magnets from temperature demagnetization. However,
compares some LS-PMS motors with induction motors of the same
since the starting state of LS-PMS motors may be slower than that
power rating and frame size in terms of their power factors. The
of induction motors, the overheating of rotor should be checked
variations of efficiency, power factor and the product of these two
during the design of LS-PMS motors.
characteristics of a three phase LS-PMS motor is compared with
those of an induction motor of the same power rating in Fig. 7 [15].
The figure shows the absolute superiority of the LS-PMS motor over
5. LS-PMS motor challenges
the induction motor.
5.1. Cost
4.3. Torque and power density
The cost of a motor consists of a material cost and
It is well known that PM motors in general are superior to other a manufacturing cost. In this section the material cost is considered
motors in terms of torque production and power density capabil- and the manufacturing one will be discussed afterwards. The use of
ities due to the usage of permanent magnets. A comparison of permanent magnets in LS-PM motors is the main cause of their
weight versus power for PM motors and induction motors of higher prices with respect to induction motors. However, in the last
a specific manufacturer is presented in Fig. 8 [16]. It shows the decade the magnet price has decreased substantially due to high
superiority of the PM motors. The LS-PMS motors as a kind of PM volume magnet production, particularly in China. As an example,
motors enjoy this advantage too. Therefore, the LS-PMS motors are the average price of sintered NdFeB has dropped by 40% from 1998
more compact and thus more suitable for integrated systems. to 2003 [18].
It is shown that the materials of permanent magnet motors cost
approximately 4.5 V/kW more than that of induction motors for
a power rating around 5.5 kW [12]. In another case, it was stated
that the materials price used in a 1 hp LS-PMS motor is about 20%
higher than that of a comparable induction motor [19].
Fig. 7. Efficiency and power factor versus shaft torque for a LS-PMS motor and an
induction motor [15]. Fig. 9. Cash flow diagram for energy saving assessment of the LS-PMS motor.
A. Hassanpour Isfahani, S. Vaez-Zadeh / Energy 34 (2009) 1755–1763 1759
Fig. 11. Payback period of additional cost of LS-PMS motor with different interest rate
and energy inflation rate.
Fig. 10. Average lifetime of induction motors [21].
where i and j are the interest rate, and the inflation rate of energy
cost respectively. The notation n stands for the number of years of
the interest period which is equal to a lifetime of the motor.
If the present worth of savings (P) is greater than the extra cost
of the LS-PMS motor with respect to an induction motor (I), the
substitution of the induction motor with the LS-PMS motor is
Table 3
Annual cost saving of a one-point efficiency gain for different energy prices and duty
times.
Motor size Annual saving Annual saving Annual saving Annual saving
0.04 $/kwh, 0.04 $/kwh, 0.10 $/kwh, 0.10 $/kwh,
8000 h/year 4000 h/year 8000 h/year 4000 h/year
5 hp $17 $8.5 $42.5 $21.5
10 hp $32 $16 $80 $40
20 hp $61 $30.5 $152.5 $76.25
50 hp $142 $71 $177.5 $88.75
100 hp $278 $139 $695 $347.5
200 hp $537 $268.5 $1342.5 $671.25
Fig. 12. Different torques applied to the rotor of LS-PMS motors [22].
1760 A. Hassanpour Isfahani, S. Vaez-Zadeh / Energy 34 (2009) 1755–1763
Fig. 15. Effect of input voltage on starting process (Ó[1984] IEEE) [24].
Fig. 13. Failure in starting and synchronization [22].
to $5560 for a 100 hp motor. These energy cost savings can Possibly the main deterrent factor in LS-PMS motors is the braking
compensate for the extra cost of LS-PMS motors. torque produced by magnet poles. This torque is developed during
A 5.5 kW LS-PMS motor is approximately $30 more expensive starting period up to synchronous speed and reaches its maximum
than an induction motor with the same power rating but has value at a low speed as seen in Fig. 12. The value of braking torque
approximately 20% lower losses. While a 5.5 kW premium efficient can be expressed as [22]:
induction motor has an efficiency of 91.7%, the efficiency of the
LS-PMS motor with the same power rating expects to be almost 2 ð1 sÞ2
rs2 þ Xsq
3Prs ð1 sÞE02
93.3% or 1.6% more than the efficiency of the induction motor. As so, Tb ¼ $ 2 (14)
2 us
the payback period for the extra cost of the LS-PMS motor with rs2 þ Xsd Xsq ð1 sÞ2
different combinations of interest and inflation rates of energy and
with an energy cost of $0.04/kWh and an operating time of 4000 hr where E0, Xsd, Xsq, us and s are magnet back-EMF, d-axis stator
a year at 0.75 load factor is shown in Fig. 11. This period, with reactance, q-axis stator reactance, synchronous angular frequency
a simple payback method, is around 2.43 years. and slip respectively. This torque resists against cage torque and
In general, it should be mentioned that when the total invest- may cause a failing in starting or synchronization of the motor as
ment and operating cost of an LS-PMS motor are considered, it shown in Fig. 13. It is seen that in the case 1 the magnet braking
looks like an opportunity rather than a challenge. Of course, torque deteriorates the normal operation in low speed in compar-
a detailed cost–benefit analysis is needed for every actual case ison to an induction machine and results in a slow starting and an
before a final conclusion can be drawn. overshoot in the speed curve even when the motor can normally
Fig. 14. Slow starting and overshooting (Ó[2004] IEEE) [23]. Fig. 16. Effect of rotor resistance on starting process (Ó[1984] IEEE) [24].
A. Hassanpour Isfahani, S. Vaez-Zadeh / Energy 34 (2009) 1755–1763 1761
Fig. 17. Effect of inertia momentum on starting process (Ó[2004] IEEE) [23].
start and synchronize as shown in Fig. 14. In this figure the rise time
of motor speed is about 2.5 s which is relatively long.
Magnet braking torque is not the only deficiency of LS-PMS
motors starting. The motors also suffer from a sensitive depen-
dency of starting process on input voltage, shaft inertia momentum
and cages resistance. The effect of input voltage on the starting
process is shown in Fig. 15. It is seen that with a reduced input
voltage, the motor starts more slowly and even may fail in
synchronization. The settling time of speed curve also increases
Fig. 19. Comparison of maximum tolerable torque of LS-PMS motors for constant and
with falling of input voltage. The effect of cage resistance on the moving fluid load torques.
starting of an LS-PMS motor is shown in Fig. 16. It is seen that there
is an optimal value for this resistance out of which the motor does
not start properly.
Finally, the effect of load inertia on starting process is depicted in TL ¼ ku2 (15)
Fig. 17. It is seen that by increasing the load inertia, the motor starting
Therefore, the load torque is relatively small in low speed range,
deteriorates. This may lead to high torque pulsations in induction helping the motor to start easily. However, the motor may not start
mode, not reaching the synchronous operation at all. easily under a constant load. The starting of an LS-PMS motor under
Another problem associated with LS-PMS motors as well as these two types of loads is compared [17]. As seen in Fig. 19 the
induction motors is the production of torque dips due to spatial motor can start under a maximum constant load torque of about
harmonics as shown in Fig. 18 [38–42]. This problem, deteriorated 1.55 Nm; while, it can operate under a load torque of 7 Nm if the
by braking torque, may reduce the resultant torque significantly in torque is defined by (15). Therefore, LS-PMS motors are more
low speeds and cause failure of motor starting under a load. For suitable to run applications such as fans, pumps and compressors.
most applications such as fans, compressors and pumps which
move a fluid, the load torque is proportional to square of speed i.e.
5.3. Manufacturing and sizing
Fig. 18. Effects of spatial harmonics on torque-speed characteristic of induction motors Fig. 20. Distribution of induction motor ratings in Germany in terms of energy
(derived from [43]). consumption [16].
1762 A. Hassanpour Isfahani, S. Vaez-Zadeh / Energy 34 (2009) 1755–1763
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