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© MAGNETEC GmbH, Germany Hans‐Joachim Poess 1Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
MAGNETECMAGNET-TECHNOLOGIE
Presentation from Hans-Joachim Poess 2015 Motor & Drive Systems 2015
Manager EMC and Head of Development at www.magnetec.de
Variable Frequency Drives are driving Motors and control the applications. The high performance of the VFD helps to save Energy and save costs. To have a reliable application it is needed to careAbout the high frequency Common Mode Noise which can damage the Motors, Bearings, Sensors and other components. To eliminate this HF Common Mode Noise the most efficient and maintenance freeSolution is to Absorb it and change it to safe thermal energy. How to do this will be
described in the Presentation.
V 1.0 20141211
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 2Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
MAGNETECMAGNET-TECHNOLOGIE
Histrorical Grinding systemCurry Cinnamon, Kardamom, Marsala …
Without electroerosion of the bearings ;=)
Where we do not need Inductive Absorbers:
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 3Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
MAGNETECMAGNET-TECHNOLOGIE
All kind of electrical drive and converter systemsWhere we do we need Inductive Absorbers:
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 4Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Cool Blue Plus+
What are Cool Blue inductive Absorbers1Where they are used2What is the advantage3Which improvement4Outview (new Typeline)5Other new Products …6
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 5Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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1 What are Cool Blueinductive Absorbers
Nanocrystalline Ringcores made out of a ~ 20µm thickamorphous strip changed to nanocrystalline Structure by an annealing Process to a grain size of about 20 Nanometers.This gives about 1000 insulated areas only in the heightdirection of the tape.
The Power losses of Nanoperm is about 1000 times lowerthan from typical Silicon Iron.
The frequency range is fromsome Herz up to the 100 Mega Herz area.
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 6Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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melting furnace
inductionheating
liquid metal under pressure,T = 1200°C
ceramic nozzle
amorphous strip20-25 m thickness
Cu casting wheelT = 20°C
v = 100km/h
Laboratory fabricationAmorphous Tape
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 7Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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2 Where they are used
To avoidelectroerosionespecially in Motorbearings
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 8Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
MAGNETECMAGNET-TECHNOLOGIE
2 Where they are usedTo avoid electroerosion in industrial applications ,especiallyin Motorbearings, Gearboxes, Sensors a.s.o.
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 9Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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3 What is the advantageEasy to mount and to retrofit
Low cost compared to other sollutions like Hybrid Bearings
Easy to select
Working parallel against conducted and radiated emissions
Maintenance free
Workingtime over decades (when correct designed)
Effect is immediate seen (Sum Peak Current)
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 10Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Which improvement4
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 11Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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4 Improved Inductivity
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 12Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Which improvement
0,00E+00
2,00E‐01
4,00E‐01
6,00E‐01
8,00E‐01
1,00E+00
1,20E+00
1,40E+00
10 100 1000 10000 100000
|Z|/Ω
Frequenz [kHz]
|Z|(Cool Blue +)(f)/|Z|(Cool Blue)
Up to over 20 %
20 % 100 MHzestimated
Measured values
4
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 13Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
MAGNETECMAGNET-TECHNOLOGIE
Outview (new Typeline)5Possible mechanical Dimensions
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 14Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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NANOPERM®plate‐coresforwirelesspowertransmission
roundplate‐corePermeabilityµr~5kDimensionOD~300mmID~16mmH~9mm
rectangularplate‐corePermeabilityµr~30kDimensionofonebar:200x20x5
diamand‐core‐shapePermeabilityµr~30kDimensionofthebars:20‐100x10x5
Other new Products6
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 15Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Cool Blue Cores are increasing the reliabilityof Motors and complete Machines in the case of maintenance and avalability.
Other Applications:EMC Filters, Common Mode Chokes, Transformers, Automotive EMC components against Radio disturbance, inductive Heating,
With the new Cool Blue Plus + the performance is over 20 % higher
Cool Blue Cores are absorbing the dangerous electrical noise andchange it to save thermical energy
No expensive insulated (Hybrid) Motorbearings are needed in many cases
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 16Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
MAGNETECMAGNET-TECHNOLOGIE
Special Electro Erosion800kV Discharge
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 17Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Adding NANOPERM Line Aborbers NaLA type M-381
option for effect demonstration :deactivate cores by a shortcut
2 x M-113
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 18Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Reducing Ipeak from ~ 40 A down to ~ 6 A by combination ofCOOL BLUE Cores and NANOPERM Line Absorbers NaLA
and smoothening the High Frequency away
without cores
with combined cores
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 19Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
MAGNETECMAGNET-TECHNOLOGIE
Solution: Combine the COOL BLUE Cores and NaLA coresto absorb the Common Mode Noise to save thermal Energy
2 x M-112 COOL BLUE Cores
6 x M-381 (NaLA)
UVW
L1L2L3
shield
Common Mode
Differential Mode
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 20Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Solution: Combine the COOL BLUE Cores and NaLA coresto absorb the Common Mode Noise to save thermal Energy
2 x M-367 COOL BLUE Cores
3 x M-053 (NaLA)
UVW
L1L2L3
shield
Common Mode
Differential ModeN=2
7,5 KW 50 m
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 21Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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1. Common Mode Noise suppression for Inverter driveswith NANOPERM Cores
Table: selection and amount of Cool Blue Cores depending on rated power and cable length Hans‐Joachim Poess
All data are for information and not guaranteed values.
Inverter power range up to
Kilowatt 0,7 7,5 30 75 315 1.200 > 1.200
horse power 1 10 40 102 428 1.631 > 1.631
p/n oval n/a M‐049 M‐049 M‐283 M‐302 M‐111 M‐248
p/n round M‐923 M‐367 M‐367 M‐113 M‐116 M‐117 n /a
Cable length
[m]
50/164 ft 2 2 4 4 4 4 4
Amountofcores
[pcs.]
100/328 ft 4 4 4 4 4 4 4
150/492 ft 4 4 6 6 6 6 6
300/984 ft 4 4 6 6 6 6 6
Low power range (up to 10 kw) need some times 2 turns on the Nanoperm cores
N=1N=2
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 22Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Table : selection and amount of NaLA Cores depending on rated power and cable length Hans‐Joachim Poess
All data are for information and not guaranteed values.
Inverter power range up to
Kilowatt 0,7 7,5 30 75 315 1.200 > 1.200
horse power 1 10 40 102 428 1631 > 1.200
p/n M‐606 M‐053 M‐102 M‐381 M‐613 M‐614 M‐616
core sizeDa Di h [mm]
16x11x5 25x20x10 30x20x10 40x32x15 80x63x30 100x80x30 160x130x30
Cable length
[m]
50/164 ft 2 1 1 1 1 1 1
Amountofcores
[pcs.]
100/328 ft 4 2 2 2 2 2 2
150/492 ft 6 3 3 3 3 3 3
300/984 ft 8 4 4 4 4 4 4
2. Differential Mode Noise suppression for Inverter driveswith NANOPERM Line Absorbers NaLA
If the NaLA cores getting too warm, use the double amount each line
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 23Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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MR – Typelines (µr > 8000)Cool Blue Cores for Power Applications
Mechanical shape like the R-series from Power Ferrites
Higher Inductivity
Higher Impedance
Higher Saturation Induction
Higher using Temperature
More Robust
1:1 Substitution to Power Ferrites but better Performance.
No change of Capacitors needed
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 24Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
MAGNETECMAGNET-TECHNOLOGIE
Ln-Inductivity at 100 kHz; Isat – Saturation current DC, all values are for information only. Details are in the dataheets.
Our Ring cores are based on Nanocrystalline soft magnetic tape material NANOPERM. Compared to ferrite cores, the following advantages on the same core size are achieved: higher Inductivity higher Saturation current optimised Power losses mechanicaly extremely robust higher continuous component temp (120°C) higher Frequency bandwidth from Hz up to 100 MHz
Cores are available for the nominal current range from 1 – 1000 Amps and higher, designed acc. to EN60938-1 for UN = 500V. Operating temperature range: -40...+120°C. The casing material is UL listed and fulfils UL-94 V0.
Types (Extract)
dout x dinner x height [mm]
LN @ 100kHz
[µH]
Isat [A]
MR-055 55x32x18 11 13 MR-063 63x38x25 14 15 MR-080 80x40x15 11 18 MR-102 102x66x15 8 25 MR-140 140x103x25 8 38 MR-202 202x153x25 8 55
Even bigger available
MR – Typelines (µr > 8000)Cool Blue Cores for Power Applications
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 25Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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How to measure
Common Mode Noise and
how to absorb it withCool Blue Cores (Inductive Absorbers)
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 26Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Inverter with a standard motor and a DC-load-motor
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 27Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Measuring Voltages and Common Mode Currents
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 28Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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What is the source of the Problem: Common Mode Currents in high frequencies
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 29Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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High frequencies in the MHz range
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 30Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Why Mhz and not kHz ?
Because of the impedance of the Motor, especially the bearings:
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 31Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Where does this currents come from ?
IGBT is the source of theNoise and the current loops back
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 32Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Where are the vagabonding currents running ?
Runs over groundingpathes like brushes
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 33Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
MAGNETECMAGNET-TECHNOLOGIE
How can we avoid these vagabonding currents ?
Absorb the currents
And change it
Into
Thermal energy
By using
Inductive Absorbers
Cool Blue
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 34Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
MAGNETECMAGNET-TECHNOLOGIE
What is the effect of the Inductive Absorbers ?
Without inductive Absorbers With inductive Absorbers
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 35Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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How to check ?
Shortcut open the loop
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 36Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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How is the Common Mode Current changing with theamount of Cool Blue Cores ?
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 37Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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What happens on more turns ?
It helps !
The Cool Blue Cores should not go into saturationThe parasitic capacity should be low enough
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 38Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Theoretical Background: SimulationVoltage
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 39Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Theoretical Background: Simulation no Saturation
Voltage
Current
Current
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 40Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
MAGNETECMAGNET-TECHNOLOGIE
Theoretical Background: Simulation with SaturationVoltage
Current
Current
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 41Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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To avoid saturation:
New material parameters ofNanoperm
Low mySaturation current up to
Factor 80
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 42Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Diagram L(f) low my 1000 - 8000
0
0,000002
0,000004
0,000006
0,000008
0,00001
10 100 1000 10000
L [H
]
frequency [kHz]
Nanoperm low my 63x50x30 different permeabilities
µ 1000
µ 2000
µ 4000
µ 8000
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 43Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Low my diagramm L(I)
0,00
1,00
2,00
3,00
4,00
5,00
6,00
7,00
10 30 50 70 90 110 130 150 170 190
indu
ctiv
ity (µ
H)
current (A)
Nanoperm low my 63x50x30 different permeabilities
Inductivity ( current) turn no =1
µ8000
µ4000
µ2000
µ1000
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 44Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Calculation Imax Nanoperm of µr
H= I*N/lfe magnetic field (A/m)
B=µ0*µr*Imax*N/lfe magnetic induction (Vs/Am)
B=µ0*µr*H
Imax= (B*lfe)/(µ0*µr*N)
B= 1 Vs/Am material constant Nanoperm (1,2T) 20 % savetymargin
µ0= 4*pi*10^‐7 Vs/m² constant
µr – relative Permeability; N=turn no.Lfe – middle pathlength)
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 45Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Dimensioning Imax calculation
Imax= (B*lfe)/(µ0*µr*N)
Examples on one core dimension
63x50x30 mmImax (µr=30000) = 4,8 AImax (µr=1000) = 143AImax (µr=500) = 286 A
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 46Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Imax (dimensions and µ)
H= I*N/lfe B=µ0*µr*Imax*N/lfeB=µ0*µr*H Imax= (B*lfe)/(µ0*µr*N)B 1Vs/Amµ0 4*pi*10^‐7 Vs/m²
lfe (m) 0,18 0,225 0,28 0,36 0,45 0,58 1,49coredim 63x50x30 80x63x30 100x80x30 130x100x30 160x130x30 200x175x30 500x450x30µr Imax Imax Imax Imax Imax Imax Imax
100 1432,4 1790,5 2228,2 2864,8 3581,0 4615,5 11857,0500 286,5 358,1 445,6 573,0 716,2 923,1 2371,4
1000 143,2 179,0 222,8 286,5 358,1 461,5 1185,72000 71,6 89,5 111,4 143,2 179,0 230,8 592,94000 35,8 44,8 55,7 71,6 89,5 115,4 296,48000 17,9 22,4 27,9 35,8 44,8 57,7 148,2
30000 4,8 6,0 7,4 9,5 11,9 15,4 39,560000 2,4 3,0 3,7 4,8 6,0 7,7 19,880000 1,8 2,2 2,8 3,6 4,5 5,8 14,8
You can online calculate: http://www.magnetec.de/dimensioning/abacus/abacus.php
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 47Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Different succesful applications
Wind turbines
Solar converter
And other Industrial Inverter – Applications
From Water pumps (some hundred Watt) up to
Stone grinding (Inverter steered up to 5 MW)
Power Distribution via GIS (Gas Insulates Switches in th 800 kV range)
Chillers
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 48Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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How did it start? proof‐of‐principle experiment in 2006
without filter cores ICM = up to 60A
with Cool Blue cores ICM ~ 10A –ok!
EMC measurements were carried out in the nacelle (height 80m)
Basic working Principle of Cool Blue
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 49Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Professional airconditioners, ‘chillers’ up to 500kW
contains:M‐116M‐117Realisation: now
Professional airconditioning systems used in industrialenvironment, airports, office buildings etc. Function: EMC compliance, motor bearing protection
Cool Blue – application examples
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 50Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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typical configuration of Cool Blue cores in Photo Voltaic central inverter with P = 500kWFunction: EMC filter
Realisation: now
S500kW Solar Central Inverter for Power Plants
Cool Blue – application examples
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 51Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Photovoltaic Inverters Application Example
Photovoltaic : residential string Inverters: 3‐12 kW
our EMC chokes may partly replace Ferrit chokes
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 52Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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On the cables
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 53Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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Picture of cores with thermocouple
Thermocouples for checking overtemperature
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 54Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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eMobility: electrical Cars and Infrastructure
EMC products for on‐board and off‐board systems
On‐Board:
DC/DC converters for battery chargers and power supply in a range from 3,0 … 6 kW
DC/AC converters for motor drive in the range from 50 … 100 kW
electrical steering systems
Off‐Board:
Stationary Charging Stations 5 ‐25kW private and public
Option: ‘Witricity’
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 55Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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high voltage gas‐insulated switchgear, ‘GIS’
Cool Blue cores in a 800kV switchgear for a modern energy distribution system over long ranges
Function: absorption of destructive high current transient pulses
Cool Blue – application examples
© MAGNETEC GmbH, Germany Hans‐Joachim Poess 56Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers
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100 Ohm
140 Ohm
The Problem of the motor bearings are the resonances in the area of 100 kHz and in the area of some MHz.The low impedance drives high common mode currents up to 100 A through the motor and over the motor bearings.The living time of the bearings is dramatically reduced if the common mode current is working in this frequency range.To avoid this fast damaging, the impedance against common mode currents have to be increased.The working solution for this is a Cool Blue core which is made from Nano crystalline material (Nanoperm) which is put over the motor cables. This Cool Blue Cores have a high impedanceFor example: M-160 (160x130x30 mm³) µ~30000L~ 20 µH at 100 kHz (per turn)Z=2*pi*f*LZ~ 2*3,14*100000 Hz* 0,00002 H ~12 Ohms For each coreTypical numbers for the amount of the Cool Blue Cores are 4 – 8 Pc8*12 Ohm ~ 100 Ohms for 100 kHzFor 3 MHzZ~ 2*3,14*300000 Hz* 0,000001 H ~18 Ohms 8*18 Ohms ~ 140 Ohms for 3 MHzThis impedances are added to the common mode path and can reduceSignificant the common mode current down to the 10th part.This will increase the living time of the motor bearings up to factors.
This diagram shows the impedance of a Motor against Common mode noise
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