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A Global Update on the Market for Electric Motors and Drives
Ivan Campos, Research Analyst - Manufacturing Technology Group, OMDIA

This presentation will highlight the recent trends and economic factors that affect the industrial market for motors and drives, with an added focus on the effects of recent macroeconomic factors and emerging technologies. This presentation will define the market in terms of revenues and units with supporting qualitative analysis. Much of the focus will be on how governmental legislation for motors and drives are less of a factor, and how emerging technologies are shaping the direction that suppliers of this equipment will take in the near and distant future.
 

 

The Market for Predictive Maintenance in Motor Driven Systems

Blake Griffin, Market Research Analyst, Interact Analysis

The presentation will provide an overview of the predictive maintenance trend and the emerging technologies enabling its rapid growth in motor driven systems. There will be a particular focus around market drivers/barriers, new business models associated with the technology, as well as smart sensing and its implications for the market going forward.

 

 

 

 

A Summary of Transverse Flux Motors in Both Design and Applications

Lowell Christensen, Permanent Magnet Motor Design Consultant, Lowell Christensen LLC

This presentation will give a brief discussion of Transverse Flux Motors designs and the usage of these motors in several applications types. It will also show the advantages of the Transverse Flux Motor 3D magnetic circuit design over the 2D designs used in Radial Flux motors. This presentation will also show the output performance characteristics when changing the Transverse Flux Motor size and other design parameters on the of these motors. It will show the advantages and disadvantages of using these motors in various types of applications.

 

 

Hairpin Motor Production Technologies

Alexander Kuehl, Research Director Electormechanical Engineering, Friedrich-Alexander-University Erlangen-Nuremberg (FAU)

The electrification of the drive train of passenger cars is currently undergoing an evolution from windings previously drawn in, which are known from industrially used electrical machines, to windings specially tailored to the requirements of mobile electric traction. A main trend is the use of pluggable shape windings, so-called hairpins. In order to fully exploit the economic advantages of this winding, elaborated production concepts and strategies are required. Due to the novelty and the currently ongoing innovation of these type of windings, the differentiated manufacturing possibilities per process step have not yet been fully defined. In view of the economic efficiency, high process speeds with increasing process reliability play a major role. The aim of this presentation is to show a process chain of hairpin technology that is as universally valid as possible, to name the different alternatives for each process step and to explain their characteristics.

 

Inverter Built-In Motor and System Diagnosis Reduces Field Returns and Creates Market Value
Cristian Ionescu-Catrina, Senior Marketing Manager, Power Integrations

We are analyzing the benefits of integrating smart diagnosis in the motor driver stage rather than adding extra components (sensors) and processing power. This reduces number of field returns and creates more market value. Particularly monitoring and reporting of following faults will be addressed in the presentation: over-current, over-temperature, over and under-voltage and motor vibration detection with minimum external components and microprocessor interaction. Lack of fault diagnosis or misdiagnosis of the motor and motor drive operation increases field returns. Relative high share (30 percent) of compressor returns come with no-fault-found that leads to unnecessary returns, inefficient resource allocation and unhappy customers. Ability to diagnose operation, take action and log faults in real time reduce the number of returns and service cost.

 

Effects of Deteriorated Magnetic Properties of Stators on Performance of Electric Motors
Lukasz Mierczak, Ph.D, R&D Engineer, Dr. Brockhaus Messtechnik GmbH & Co.

Accurate design and prediction of electric motor performance is not a trivial task. Motor design engineers make use of advanced numerical and analytical methods for electromagnetic and thermal analysis, and still find considerable differences in efficiency of modelled and manufactured machines. One of the primary sources for this mismatch is the inaccuracy in stator lamination magnetic properties, such as BH curve and power loss, which are used as input data for calculating flux linkages of the coils and heat dissipation, and consequently determining the main motor parameters including torque and operating temperature. In this presentation the results from Brockhaus case studies on the detrimental impact of manufacturing processes on magnetic properties of stators will be presented. Moreover, the effect of deteriorated magnetic properties of stators on final performance of electric motors will be analyzed.
 


A Historical Overview and Current Trends on Magnets, Electric Machines, and Drives
Dal Ohm, Ph.D., President, Drivetech, Inc.

Ever since Magnetism was first discovered by a shepherd named Magnes in Greece, applications of magnetic properties were slowly spread and evolved world-wide. With the invention of battery and discoveries on electricity and magnetic field, various types of electric motors/generators were invented during 1800s-1900s, and used for electrical power systems and high-power motors. After development of power semiconductors and electronic circuit, motor-generator control and drive technology has been advanced to high efficiency and precise control.  This presentation will summarize past historical events and current technologies, then discuss on near-future advancement and applications of motor-generators with drives.
 

 

VFD Cable, Essential or Overkill
Steve Wetzel, Principal Engineer, Southwire Company

Variable frequency drive (VFD) systems can have issues with both radiated and non-radiated electromagnetic interference (EMI) which decreases system productivity.  If EMI is left uncontrolled; motors, drives and other electrical devices in the facility may have operational issues or even be damaged.  We will explore how VFD cable can mitigate many of these issues.  We will identify three critical components to a VFD cable and explore how each component works to control the adverse effects of the drives high frequency pulse width modulated waveforms.
 

 

 

Operating Electro-Magnets with Current or Voltage Control Algorithms from Standard Industrial Drives
Carl Lee Tolbert, Vice President of Engineering, B&D Industrial

With the popularity of thyristor-based industrial DC drives being used in plants for extruders, winders, and other applications, does it not make sense to utilize the same drive without special firmware modifications also to run other applications? These alternative applications include lifting magnets, magnetic chucks, and magnetic separators. From a maintenance perspective, standard firmware equates to lest investment in training and spare parts inventory. To answer this, B&D has built custom electro-magnets, a test stand, and acquired an off-the-shelf thyristor-based DC drive to test two specific operational modes. The first operating mode test uses a single magnet with the DC drive in current control mode. The second running test uses two magnets in series with the DC drive in voltage control mode. The presentation will review the testing, findings, as well as a call to future research.

New Trends in the High Efficiency Motors Market Utilizing Amorphous and Nanocrystalline Soft Magnetic Materials

Eric Theisen, Director of Research & Development, Metglas, Inc.

Here we update the status of the advances in Fe-based amorphous and nanocrystalline soft magnetic alloys currently used in the market and highlight their primary industrial applications.  Emerging trends with electric motors utilize these advancements fabrication methods.  There are many approaches to incorporate amorphous ribbon into the motor components and we will discuss the methods that have been industrially adopted.  FeCo based amorphous alloys further enhance the induction levels (1.8T) and can be viable in these applications.  There are also new FeCo and FeNi nanocrystalline alloys being developed specifically suited towards motor applications that will be discussed.  

 

 

New Trends in Magnetic Absolute Position Measurement

Torsten Becker, CEO, BOGEN Electronic GmbH

Absolute encoders are getting into the mainstream of motor and automation applications. While this has been an important area for resolvers and end of shaft encoders, the advantages of magnetic encoders have convinced many designers to switch to magnetic technology: high resolution, small required space and dirt immunity. While existing magnetic absolute encoders have a lot of advantage and some drawbacks, there are several exciting new developments for new magnetic solutions, e.g. for better integration into products. Increased accuracy, resolution and design freedom are some of the main improvement areas. Looking at the state of the art and identifying key trends provides CTOSs and lead engineers with a better understanding of possible improvement areas for their next generation projects. Comparing the requirement of different application types with actual performance of magnetic encoders will highlight new paths for improving performance. e.g. for more energy efficiency.


 

High-Tech Adhesives: Solutions for e-Mobility and Additive Balancing Processes
Timothy Froning, Regional Sales Engineer, DELO Industrial Adhesives

Bonding technology is a key to improve the performance of e-motors. When it comes to harsh requirements with high temperatures and stress due to rotational forces, high tech adhesives can protect and reliably bond parts like magnets. DELO provides tailor-made adhesive solutions and helps its customers to achieve fast and efficient production processes, e.g. with the light fixation for 2C epoxies. Process improvements can also be achieved with DELOs new balancing method. Using special balancing compounds based on adhesives, especially small e-motors in large volume can be balanced very fast and accurate.


 

High Speed/ High Power Density Electric Power Generation and Motor Drive
Jay Vaidya, Founding President, Electrodynamics Associates, Inc.

This presentation mainly covers the electric power generation using high speed generators driven directly by high speed turbines. The result is 100 kW to 5 MW electric power generation with 10 percent to 15 percent of the currently available  power systems. Applications are in aerospace as well as commercial applications needing compact power systems. The same technology is also available for high speed motor drives. Discussion will includes many mechanical and electrical innovations that allow and enhance the operation at high speed.

 

 

Experimental Approach for Solving Side Band Noise of Miniature Planetary Gearbox
Pradeep Deshmane, Principal Engineer – Gearbox, Portescap India Pvt. Ltd.

Vibration and noise spectra from miniature planetary transmissions commonly exhibit components at distinct frequencies around the gear mesh (tooth passing) frequency and its higher harmonics, called modulation sidebands. They constitute a significant portion of the vibration and noise generated by the transmission. Sidebands have influence on noise quality measures as well as having great potential to provide valuable clues regarding gear tooth combinations, phasing of planets, manufacturing errors like eccentricity, run out present in the gear set, planet pin position error, etc. The first critical step in designing and controlling the sideband activity of a planetary transmission is to develop a compressive approach to analyze modulation sidebands as well as describing the mechanisms causing sidebands. This session describes the investigation of side bands, correlation with test results and solution to minimize the noise. Practical examples will be provided. Benefits for a variety of aerospace and commercial applications will be highlighted to conclude the discussion.

Fast Magnetic Angle Sensor For High-End Robot Control Applications

Dr. Dragana Popovic Renella, SENIS AG Switzerland

Lennart Nachtigall, Robotics Systems Lab, ETH Switzerland

A Fast Magnetic Angle Sensor has been successfully applied in high-end robot control applications to precisely measure angle for very high resolution and accurate position control of fast robot actuators. At the Robotics Systems Lab, ETH Switzerland, various self-developed motor drives for robot arms and walking robots are developed. In these applications, the FAMAS absolute angle sensor can satisfy some requirements, which could not be reached with previously applied magnet-based absolute encoders. The requirements for use in the motor drive robot applications are: 10kHz update rate; a high magnetic resolution, i.e. a low-noise measured value (this requirement could not be satisfied with previously applied magnet-based absolute encoders); a high tolerance to electromagnetic interference for use in a motor; robust to allow using lower cost structural parts. The patented algorithm implemented in this sensor includes an innovative servo loop control system. It allows angle sensing at practically unlimited rotary speeds, with extremely low latency independent of angle. This sensor provides the digital value of the angle without additional hardware, significantly reducing total implementation cost.

Introducing Industry 4.5 in Coil Manufacturing
Dr. Justin Goldston, Assistant Professor of Project and Supply Chain Management, Penn State University

As the pandemic of 2020 moved digital transformation projects higher on strategic agendas of around the world, leaders began to reach out to researchers and industry experts to further understand technologies such as Artificial Intelligence (AI), Machine Learning (ML), and edge computing for industrial application. With the inclusion of these technologies that are growing in adoption within various industries, the coil manufacturing sector will see an emergence of Integrated Intelligent Automation (IIA). With both scholars and practitioners identifying cybersecurity as a primary concern with Industry 4.0, this discussion will touch on how organizations can successfully implement IIA to safely architect the smart factory we envisioned back in 2010.

 

Materials, Automation & Simulation in Electric Machine Design & Production - Radial Magnetic Orientation Technology and its Application in Motors

Brian Coleman, Vice President of Business Development, International Magnaproducts, Inc.

Proper application of magnetic materials requires attention to several factors including benchmarking, material considerations, manufacturing methods and design optimization.  Using neodymium iron boron rings for permanent magnet motors is not new.  In this presentation will focus on a new production method for those rings using patented rotating orientation technology along with the benefits of this novel material. This presentation will review assembly, magnetization and magnetic wave form testing that allows correlation with motor testing. 

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