Rotary Screw Compressors

ASD.4 SFC Series Synchronous Reluctance Motor

SIGMA PROFILE + Innovative Drive Technology = Exceptional

Efficiency

NEW : Addition with ASD 35 SFC as of 2019

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LOGO for:
SFC machines with synchronous reluctance motor (SynRM)

• Initially for ASD.4 SFC

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ASD.4 SFC SynRM
Synchronous Reluctance Motor

• Synchronous reluctance motor + FC with a specially-

adapted control algorithm from Siemens

• Greater efficiency thanks to innovative drive system

• Significantly lower losses with partial load operation,

compared to asynchronous motors

• The DIN-EN 50598 (published since December 2014

and applicable since that time) demands a drive
system efficiency. We attained top classification with
IES2.

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ASD.4 SFC SynRM
Overview of the DIN-EN 50598

Energetic analysis ü Release date ü Obligation ü

Manufacturers of electrically-driven
machines can use standardised
load profiles to compute energetic
analyses
Transparency
Uniform frameworks allow the
comparison of drive systems (motor
and FC) for every type of
application
The standard was released on the 19th
of December, 2014
ü
Efficiency classes
Frequency converters are graded by
IE efficiency classes, while drive
systems are placed in IES efficiency
classes
Following its release, the EN 50598
standard is listed in the official EU
gazette
This creates an obligation for
converter manufacturers (presumption
of standard conformity)
EU regulation presumably in
2019
ü Key metrics ü
Losses for specified operating modes
are determining factors for this
standard

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ASD.4 SFC SynRM
Efficiency class is determined in the rated operating mode

p L , PDS
Power drive system / motor system losses ( 100 ; 100 )
20% higher
p L , RPDS IES 0
losses
Determination of efficiency ( 100 ; 100 )
IES 0
PDS relative
as reference value
torque / %
IES0 - IES2 classes
120%
p L,PDS (0;100) p L,PDS (50;100) p L,PDS (100;100)
100
Reference value 100% IES 1
IES 1 Reference value
(Reference system = ± 20%
Reference converter + 80%
p L,PDS (0;50) p L,PDS (50;50) p L,PDS (100;50)
50 Reference motor)
IES 2 20% lower losses
p L,PDS (0;25) p L,PDS (50;25) Reluctance system 50% IES 2 as reference value
25
ASD compressor
PDS relative
100 speed / %
50 0%

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ASD.4 SFC SynRM

• Energy efficiency will be a major focus

for future developments

• System optimisation of Sinamics FC and Kaeser-specific motors

ASD 35 SFC start of production approx. June 2019

1. ASD 40 / 50 / 60 SFC SynRM introduction 09/2017
2. BSD SFC SynRM SOP approx. August 2019
3. CSD.5 SFC/CSDX.5 SFC SynRM since 11/2018

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ASD.4 SFC SynRM

Synchronous
Reluctance
Motors

Technology

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 Comparison: Drive technology
Inge Atlas
rsol KAES
l Ran Copc ER
d o

Feature Switched reluctance Permanent magnet- Synchronous-

motor (SRM) Synchronous motor reluctance motor
Appearence (PMSM) (SynRM)

Principle Clocked magnetic field with DC voltage Three phase motor with permanent Three phase motor with special geometry
magnet sheet packages inside the rotor, causing a
defined field weakening

Used materials Rare earth Dependency on China, no Iron sheet packages as in standard
price stability Rare earth Dependency on China, no motors
price stability
Relacement Difficult & expensive Uncomplicated, as will be standard in the
purchase Special construction by AC no future (Siemens)
alternative, expensive www.kaeser.com / Page 9
ASD.4 SFC SynRM

Reluctance force Reluctance torque

Current
I I

FR MR

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ASD.4 SFC SynRM

Reluctance motor types

1. Synchronous reluctance
1. Synchronous reluctance motors (SynRM) have an equal number of stator and
rotor poles. The projections on the rotor are arranged to introduce internal flux
“barriers“, holes that direct the magnetic flux along the so-called direct axis.
Typical pole numbers are 4 and 6.
2. The rotor operates at synchronous speeds and there are no current-conducting
parts in the rotor. So, the rotors losses are minimal compared to those of an
induction motor.
3. Once started at synchronous speed, the motor can operate with sinusoidal
voltage. Speed control requires a variable-frequency drive. Source: Wikipedia

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ASD.4 SFC SynRM – not SRM

1. Switched reluctance or variable reluctance

2. The switched reluctance motor (SRM) is a form of stepper motor that uses fewer
poles. The SRM has the lowest construction cost of any industrial electric motor
because of its simple structure. Common uses for an SRM include applications
where the rotor must be held stationary for long periods, and in potentially
explosive environments such as mining because it does not have a mechanical
commutator.
3. The phase windings in a SRM are electrically isolated from each other, resulting
in higher fault tolerance than inverter-driven AC induction motors. The optimal
drive waveform is not a pure sinusoid, due to the non-linear torque relative to
rotor displacement, and the highly position-dependent inductance of the stator
phase windings. Source: Wikipedia

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ASD.4 SFC SynRM
Pole
Current
Force
Gap

Current
Force

Current
High
magnetic conductance

Low
magnetic conductance

High
reluctance torque
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ASD.4 SFC SynRM

Force

Current

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ASD.4 SFC SynRM

Force

Current

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ASD.4 SFC SynRM
Synchronous Reluctance Motor – Torque Generation

Step 1 Step 2 Step 3

Stator flow exclusively through the iron, except for Stator flow has changed, takes long paths through • Rotor turns into position of Step 1
the air gap the air gaps
• In a rotating stator field, the rotor
• • High magnetic resistance must turn continually
Low magnetic resistance
• • Increased system energy • The rotor frequency matches the
Lowest “system energy”
Resulting in a torque acting in the direction of stator frequency, however, rotor
system energy minimisation and stator are “phase-shifted”

q
d

• Comparable to two magnets “adhering to each

• Comparable to two magnets flying towards each
other”
other

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ASD.4 SFC SynRM
Synchronous Reluctance Motor – Function

Synchronous Permanent magnet-excited synchronous motor

reluctance motor without permanent magnets with special rotor design

General rules for synchronous motors 3p

Ti   p iq  Ld  Lq  id  iq 
2
• id: responsible for magnetic field
In standard operation, a magnetic field is generated by
magnets Torque generated by Torque generated by reluctance
id=0 (except in field-weakening) permanent magnets effects
• iq: responsible for torque
• Reluctance effects are undesired in servo motors, in particular High
magnetic conductance

Low
magnetic conductance

High
reluctance torque

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ASD.4 SFC SynRM

Synchronous Reluctance Motors

Efficiency Benefits

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ASD.4 SFC SynRM
System properties – Energy efficiency at nominal point and partial load

1. Realisation of energy efficiency classes higher than IE3 is complex with standard
asynchronous motors

Efficiency

System with ASD.4 SFC

reluctance motor
kW 5.5 7.5 11.0 15.0 18.5 22.0 30.0

Reluctance 91.9 92.6 93.5 93.9 94.2 94.5 94.9

*

IE4* 90.7 91.5 92.3 93.0 93.3 93.7 94.1

1
System with IE3* 88.0 89.0 90.1 90.9 91.5 92.0 92.6
asynchronous motor IE2* 85.9 87.0 88.4 89.2 89.9 90.3 91.1
2
*) Minimum efficiency to IEC 60034-30-1. Converted to
converter operation according to DIN EN 50598-2
(chapter 5.3.2.6: Harmonic-dependent additional losses)

2. Synchronous reluctance motors have a higher efficiency in partial load, compared to standard
asynchronous motors

0.5 · Prated Prated Power

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ASD.4 SFC SynRM
Synchronous Reluctance Motor in ASD.4

• Combines the advantages of asynchronous and synchronous motors

within one drive system
• The best from both synchronous and asynchronous motors
- The rotor contains neither aluminium, copper or expensive rare-earth
magnets
- The drive is therefore durable and service-friendly
• Design principle means virtually no thermal losses, resulting in
significantly lower bearing temperature
- Positive effects on service life
• Control characteristics similar to synchronous motors
• Combined with a precisely-adjusted FC, lower losses - particularly in
partial load range

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ASD.4 SFC SynRM
Increased Efficiency

 Increased efficiency
compared to ASD.3 SFC / 100 Hz motor
and ASK.3 SFC

 Compared to
VSD+

 Efficiency advantage
ASD.4 SFC SynRM vs VSD+

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ASD 35 SFC SynRM Comparison
FAD range
Pressure (Vmax - Vmin)
Model Speed range [rpm]
[bar(g)]
    m³/min
        1000 1500 2300 3000 3585  
ASK 34   FAD m³/min 0,94 1,38 2,21 2,89 3,50 2,56
SFC 8 total power input kW 7,8 10,4 15,5 19,9 24,4  
asynchron
motor   specific power kW/(m³/min) 8,31 7,54 7,02 6,89 6,97  
    delta vs. reluctance motor % 0,0% 8,9% 9,0% 9,3% 11,0%  
                   
        1000 1500 2300 3000 3595  
ASK 40   FAD m³/min 0,94 1,66 2,61 3,42 4,08 3,14
SFC 8 total power input kW 8,0 12,2 18,2 23,8 29,1  
asynchron
motor   specific power kW/(m³/min) 8,51 7,35 6,97 6,96 7,13  
    delta vs. reluctance motor % 2,4% 6,1% 8,3% 10,5% 13,5%  
                   
        783 1300 1800 2400 2967  
ASD 35   FAD m³/min 0,89 1,61 2,32 3,15 3,90 3,01
SFC Syn 8 total power input kW 7,40 11,1 14,9 19,9 24,5  
reluctance
motor   specific power kW/(m³/min) 8,31 6,93 6,44 6,30 6,28  
                   
  FAD m³/min 0,93 1,85 2,28 3,12 3,50 2,57
GA 18
8 total power input kW 7,9 13,0 15,3 20,6 23,3  
VSD+
  specific power kW/(m³/min) 8,49 7,03 6,71 6,60 6,66  
    delta vs. reluctance motor % 2,2% 1,4% 4,3% 4,8% 6,0%  
                   

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ASD 35 SFC SynRM Comparison

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ASD.4 SFC SynRM
Energy Efficiency - Summary

The combination of optimised products does not necessarily mean

an optimised complete system

System optimisation with SINAMICS and SIMOTICS Kaeser-

motors in combination with highly efficient SIGMA airends

Exceptional efficiency!
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