Moja snimka 9

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S… Speaker 1 (Moja snimka 9)

Thank you very much.

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S… Speaker 1 (Moja snimka 9)

Yeah,

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S… Speaker 2 (Moja snimka 9)

the topic is indeed quite similar,

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but what I want to focus on is a more global view on the losses and

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the challenges that arise from these inverter -induced losses in our global

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phantasypeer server applications.

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So I will start with a quick introduction,

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motivation and then give you a shot overview of the mechanisms of

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these inverter and boost losses and show you the measurement methods

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we use for this paper and the results.

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So

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what we can see in the industry is

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increased demand for synchronous motors which comes on the one hand from

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S… Speaker 2 (Moja snimka 9)

the high efficiency as we heard a lot yesterday and today

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and also the power density and what we also

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see is an increased degree of automation so for example here on

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the right you see some types of robots which

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get more and more involved into automatic productions

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And the funny thing is we also see that customers use

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our servo motors for constant speed applications just because of their high

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efficiency and their really high power density.

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So the operation usually of servo motors

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requires high dynamics.

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We have rapid and frequent changes of speed and torque.

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And we also have high overload and also frequent operation

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depending on the application of course.

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So the requirements are quite high.

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So we need a compact and lightweight motor with a high efficiency,

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with low inertia and high output power.

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And all these are mainly restricted about

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thermal behavior.

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So let's elaborate a

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bit more on that.

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At first we have our environmental conditions that can already differ

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in many of these applications.

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So we have different ambient temperatures from,

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well...

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where the motor is installed.

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So the application can have even higher ambient temperatures than

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the usual ambient temperature in that region.

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We have some kind of airflow or we don't have that kind of airflow.

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And then the motor of course generates heat through

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its losses.

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So we usually speak about copper losses,

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iron losses,

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magnet losses and also refrigerant windage losses.

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S… Speaker 2 (Moja snimka 9)

So this already reduced our performance due to our thermal consequence.

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So we have thermal limits of winding insulation,

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and we also have decreased magnet performance,

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so the flux density of the magnet decreases with temperature,

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and we also have a risk of the magnetization.

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Now we have the inverter operation,

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as we've seen before,

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we have a non sinusoidal input voltage,

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and we have also high frequency harmonic components.

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added to the motor.

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So this now gives us an additional loss component that

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we cannot avoid.

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So this gives us additional,

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we call them virtual -induced losses.

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What are the principles behind them?

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Usually,

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in the industrial applications,

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we have our grid voltage,

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which is our input voltage for the inverter,

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which then uses some kind of modulation,

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falsewood modulation usually,

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which then is applied to the motor.

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If we look at this voltage in the frequency

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domain, we can see we,

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of course,

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don't have only the fundamental component,

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but also a lot of harmonic components.

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And these cause now additional high -frequency losses.

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So we have the copper losses due to the current ripple which remains.

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We have increased ion losses,

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so visperieses and eddy current losses.

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We have increased eddy current loss in our magnets.

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And we have additional losses in all other conducting parts

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of the world.

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So these harmonics are now,

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in first place,

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influenced by the advertent grid parameters.

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So before we look even at our motor,

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we see that the switching frequency,

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the modulation strategy,

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and the grid voltage itself determines these

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harmonics due to the C++ voltage.

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So if we want to apply this motor somewhere

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in the world,

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We see,

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for example, China and Brazil,

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we have 380 volts,

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we have 400 volts in Europe and Australia,

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for example.

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But if we then go to USA and Canada,

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we have 480 volts,

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but in Canada,

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usually also 575 volts.

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So this is also quite a big challenge for us.

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So what are the overall challenges?

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We have the dependence on many different parameters,

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so the inverter parameters we talked about,

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but then also the motor parameters.

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So we have the topology which decides that...

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how much losses will occur,

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we have frame size,

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we have the writing configuration,

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we have different materials,

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so all that comes into play when speaking about

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those authentic losses.

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The problem is,

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and that's why I talk about the industrial application,

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we usually don't know the application during

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development.

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If we see those many papers for electric vehicles,

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we have optimization of one system designated for

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one specific application.

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If we talk about industry applications,

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we usually don't know.

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We have light reference applications,

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but that's all.

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So we have different environmental conditions.

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We have many,

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many different load cycles and operating modes.

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As we have seen,

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different grid voltages.

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This is why we want to study the impact of these losses

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in those modular cell motor systems in our global applications.

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So we want to see or I want to show you the challenge

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that lies behind all that.

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So how do we measure these losses?

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It's a typical measurement setup.

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So we have our test motor and our load motor coupled by torque sensor and we

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have our power analyzer.

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And for today we use these

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quantities of the electrical input power and it's

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fundamental of the entire 4D analysis.

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We have the mechanical output power from the torque sensor and we

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also can calculate the fundamental current from the analysis

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which is done in this power analyzer.

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We have the state of winding losses,

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we have the high -frequency losses,

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which is just the subtraction of the electrical liquid power

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and fundamental component.

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And the rest for today,

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we just say these are our speed -dependent losses,

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so iron losses,

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friction and windage losses.

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Of course,

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this is not 100 % accurate,

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but it's a good measure just to say how much of

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these high -frequency losses occur in these

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motors.

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So what we will see later is some kind of relative loss distribution between

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these three components.

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For the procedures we use,

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we can start with simple measurements like our S1 curve.

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So this usually determines our permissive

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continuous torque in our applications.

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So when you design a servo motor for a specific road cycle,

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you usually have an equivalent point,

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which has to lie under this curve.

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So we know the motor is firmly stable.

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So usually,

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of course, determined by winding temperature and magnetic temperature and so on.

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Then,

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if we want to study the whole operating range,

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my colleague has developed a procedure that allows

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us to

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measure the whole range.

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So if we just have this S1 curve,

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we don't get a lot of information because,

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as I said,

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the applications for the load cycles are very dynamic.

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We have operating points everywhere around this operating range.

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And so we need to measure the whole range.

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So what we do is we have controlled thermal state

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by...

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keeping the temperature at rated load point and we

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do that by not only driving

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the motor in these load point map but also

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with some compensation points which compensates the losses and

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then keeps the temperature almost constant over the whole measurement.

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So what we can do then is,

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for example, draw this harmonic loss map for the solar

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operating range.

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And we can also draw this versus

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the modulation index to see just how these losses

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play. So this is what we are going to see as well in the result.

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So which motors are we going to measure?

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These are three of our servo motors from one of our servo

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motor series.

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We use them because the effect will be the worst in these motors.

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Of course,

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we have surface mounted magnets,

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so they see all the harmonics in the air gap field.

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And they are usually not really designed

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to have the least possible harmonic losses,

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but they are designed for highest continuous torque and maximum

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as one curve with some limitations.

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and of course not that non -ventilated because that's also the

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worst case here.

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So at first we are going to look at these three

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different motors in three sizes and we see the S1 curves with the relative

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torque versus speed and what we can see here is that the

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smallest motor has

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already a slight decrease because of course the losses increase versus

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the speed.

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So speed dependent losses,

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iron losses increase and as the motor is not ventilated

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the continuous torque decreases.

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But what we can see as well that it gets even worse

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for the large motors.

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And if we look now at the loss components,

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we can see here the three different components that we talked about.

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We see that,

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of course,

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if we decrease the torque,

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we also decrease the proper losses.

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But what we can see as well,

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the speed -dependent loss and losses rise.

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really significant high frequency losses.

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So these are even those small and medium motors but we can see in

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the medium motor we almost have half of the losses which come

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from just the inverter operation.

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Or we assume that because as I said the measurement is just a

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qualitative measure for this.

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So what is our key message here?

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Well, they account for a significant portion of the total losses,

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so it's an important factor.

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We have to take that into account during development,

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which is quite obvious.

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The same goes for different lengths of the motor.

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So we usually have different shaft tails and different lengths just

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to have a wide range which we can use for different applications and

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different needs.

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And here we see the same results basically.

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So for the smallest motor they are about one quarter and

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for the longest motor they are already

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again about half the losses.

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Next thing is what we have seen before as well,

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the importance of switching frequency.

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Of course,

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if we have lower frequencies,

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we see higher losses overall.

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And if we increase the switching frequency

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to 8 GHz,

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we have lower losses in all our operation points.

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But this has been...

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talking about yesterday as well,

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we have to look at our system.

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So what we see at first is our motor efficiency,

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which is then higher than 8 kHz.

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But if we now add the inverter losses to this equation,

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we see that the total system losses here are higher than

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8 kHz.

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So the system efficiency is lower.

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This is then our message where we have

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a switching frequency which might be specified by standards if we

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are measuring according to them because there's not really an applicable

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standard for server motors yet but it's work in progress and

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in practice this means we have to optimize the system

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which is sometimes difficult but because sometimes we

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sell the whole system

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So we have the motor and inverter of our company which is sold.

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Sometimes only the motor,

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sometimes only the inverter.

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So sometimes we don't really have the opportunity

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to just look at the whole system.

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And of course there are also,

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apart from the losses,

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there are also other parameters that are important.

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For example, acoustics which usually are improved at high

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frequencies and some different motor and inverter choices as

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I said.

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And now,

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what I think is the most interesting

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and difficult one is the

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grid voltage.

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So,

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in our measurement center we have three different

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S… Speaker 1 (Moja snimka 9)

voltage levels that we could measure.

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S… Speaker 1 (Moja snimka 9)

360 volts,

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S… Speaker 1 (Moja snimka 9)

400 volts and 500 volts of input voltage.

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S… Speaker 1 (Moja snimka 9)

And so,

13:48

S… Speaker 1 (Moja snimka 9)

not really the voltage levels that I showed before,

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S… Speaker 1 (Moja snimka 9)

but they go in the same direction.

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S… Speaker 1 (Moja snimka 9)

And what we see here is if we measure at 500 volts our whole

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S… Speaker 1 (Moja snimka 9)

efficiency map,

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S… Speaker 1 (Moja snimka 9)

the high frequency losses here in the main

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S… Speaker 1 (Moja snimka 9)

field operation make up almost half of the losses,

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S… Speaker 1 (Moja snimka 9)

sometimes even more.

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S… Speaker 1 (Moja snimka 9)

And the overall operation,

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S… Speaker 1 (Moja snimka 9)

which is not quite common or not as

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S… Speaker 1 (Moja snimka 9)

long as the operation in these areas,

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S… Speaker 1 (Moja snimka 9)

then they decrease.

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S… Speaker 1 (Moja snimka 9)

So if we look at this for different voltages,

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S… Speaker 1 (Moja snimka 9)

we see that the highest voltage already has the highest high frequency process.

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S… Speaker 1 (Moja snimka 9)

But what does that mean?

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S… Speaker 1 (Moja snimka 9)

If we look at one and the same operating point for these

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S… Speaker 1 (Moja snimka 9)

three different voltages,

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S… Speaker 1 (Moja snimka 9)

and we look at the efficiencies,

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S… Speaker 1 (Moja snimka 9)

we see that just depending on the input voltage,

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S… Speaker 1 (Moja snimka 9)

even though it's inverter operated,

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S… Speaker 1 (Moja snimka 9)

our efficiency decreases because our inverter abuse losses

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S… Speaker 1 (Moja snimka 9)

increase with voltage.

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S… Speaker 1 (Moja snimka 9)

For us,

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S… Speaker 1 (Moja snimka 9)

this means the same motor,

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S… Speaker 1 (Moja snimka 9)

which we developed for,

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S… Speaker 1 (Moja snimka 9)

in the best case,

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S… Speaker 1 (Moja snimka 9)

global application,

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S… Speaker 1 (Moja snimka 9)

has different efficiencies,

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S… Speaker 1 (Moja snimka 9)

and also then further behavior in different countries.

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S… Speaker 1 (Moja snimka 9)

So if we sell the motor in China,

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S… Speaker 1 (Moja snimka 9)

everything might be good,

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S… Speaker 1 (Moja snimka 9)

and the efficiency is good.

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S… Speaker 1 (Moja snimka 9)

If we sell the motor in USA with the same winding,

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S… Speaker 1 (Moja snimka 9)

we have low efficiency,

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S… Speaker 1 (Moja snimka 9)

and we have a high temperature rise.

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S… Speaker 1 (Moja snimka 9)

So, despite inverter operation,

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S… Speaker 1 (Moja snimka 9)

we always have to think about,

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S… Speaker 1 (Moja snimka 9)

well, do we need to adapt our winding to counteract

15:24

S… Speaker 1 (Moja snimka 9)

this problem or do we want to keep the variation of

15:28

S… Speaker 1 (Moja snimka 9)

the motor in production as low as possible just to keep our cost

15:32

S… Speaker 1 (Moja snimka 9)

as low as possible.

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S… Speaker 1 (Moja snimka 9)

So,

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S… Speaker 1 (Moja snimka 9)

what did we see?

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S… Speaker 1 (Moja snimka 9)

We saw that the inversion is supposed to depend on the size on

15:42

S… Speaker 1 (Moja snimka 9)

one end and become significant for large motors.

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S… Speaker 1 (Moja snimka 9)

So the larger the cell motors get,

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S… Speaker 1 (Moja snimka 9)

the more important these losses are.

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S… Speaker 1 (Moja snimka 9)

It can be significantly influenced by

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S… Speaker 1 (Moja snimka 9)

the inverter power parameters.

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S… Speaker 1 (Moja snimka 9)

So we only look at the pushing frequency,

15:57

S… Speaker 1 (Moja snimka 9)

but of course the other inverter parameters are important as well.

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S… Speaker 1 (Moja snimka 9)

The global usage leads to different efficiencies or system

16:05

S… Speaker 1 (Moja snimka 9)

efficiencies despite the inverter operation and still

16:10

S… Speaker 1 (Moja snimka 9)

the key message is the system optimization is important.

16:16

S… Speaker 1 (Moja snimka 9)

development and an application so we try our best even though we

16:20

S… Speaker 1 (Moja snimka 9)

don't know all the applications which are going to be going to be used

16:24

S… Speaker 1 (Moja snimka 9)

but we try our best to say well we want to reduce these losses and

16:29

S… Speaker 1 (Moja snimka 9)

try to account for all the effects that we have seen so

16:34

S… Speaker 1 (Moja snimka 9)

thank you very much and i'm open

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