electrical machines and

ELECTRICAL MACHINES ANDCONVERTERS EXPERIMENTAL LOSSDETERMINATION AND UNCERTAINTYANALYSIS

Adjunct Professor Lassi Aarniovuori, IEEE Senior MemberDr Hannu Kärkkäinen, IEEE MemberLaboratory of Electric Drives TechnologyLUT-University, Finland

23rd of August 2020 Aarniovuori & Kärkkäinen @ICEM'20

CONTENTS1. INRODUCTION

• MOTIVATION• MEASUREMENT THEORY

2. EFFICIENCY DETERMINATION METHODS• DIRECT• INDIRECT• SUMMATMION OF LOSSES• CALORIMETER

• CALORIMETER TYPES• BEST PRACTICE

3. INTERNATIONAL STANDARDS FOR LOSSDETERMINATION AND CLASSIFICATION (IEC & IEEE)

• DIRECT-ON-LINE MOTORS• CONVERTER DRIVEN MOTORS• CONVERTERS (COMPLETE DRIVE MODULES)• POWER DRIVE SYSTEMS

4. POWER MEASUREMENT• ACTIVE POWER• HARMONIC POWER

5. MEASUREMENT UNCERTAINTY ANALYSIS• TYPE A UNCERTAINTY (DATA)• TYPE B UNCERTAINTY (MEASUREMENT

INSTRUMENTS)• POWER ANALYZER• CURRENT TRANSDUCERS• TORQUE & SPEED MEASUREMENT

6. EXPERIENCES• CASE 1. CONVERTER DRIVEN INDUCTION MOTOR• CASE 2. DOL SYNRM• CASE 3. CONVERTER DRIVEN SYNRM• CASE 4. HIGH POWER SOLAR INVERTER

7. QUESTIONS AND DISCUSSION


MOTIVATION

23rd of August 2020 Aarniovuori & Kärkkäinen @ICEM'20 Source: http://zapatopi.net/kelvin/quotes/

"If you can not measure it,you can not improve it."

- Lord Kelvin

ELECTRIC CARS


Source:World Energy Outlook 2017IEA

BASICS OF MEASUREMENTS

• Measurement result is an estimate of the quantity.

• “Uncertainty” = incomplete knowledge of the quantity.• “Uncertainty” = doubt about the validity of a measurement.


P 56 W

“We are talking of uncertainty, when we don’t know whether weshould correct the measurement result by subtracting or adding agiven error to the result.”

MEASUREMENT METHODS


• Applicable to all motor technologies and converters.

• The two methods are totally independent of each other and can be usedsimultaneously.

CalorimetricInput-output

OutputInputLoss PPP fluidpmLoss TcqP

LOSS MEASUREMENT METHODS


STANDARDS IN MOTORS AND DRIVES


Classification

IEC 60034-30-1

Measurement

IEC 61800-9-2

IEC 60034-2-1

IEC(TS) 60034-2-3IEC(TS) 60034-30-2

IEC 61800-9-2

Rotating electrical machines - Part 30-1: Efficiencyclasses of line operated AC motors (IE code)

IEC 60034-30-1:2014


Super-Premium efficiency

Premium efficiency

High efficiency

Standard efficiency

IE4

IE3

IE2

IE1

Hig

here

ffici

ency

The rated powers from 0.12 kW to 1000 kW.All motor technologies as long as they are rated for direct-on-lineoperation.Single speed electric motors (single and three phase).50 Hz and 60 Hz.2, 4, 6 or 8 poles.Rated voltage from 50 V up to 1 kV.

IEC 60034-30-1:2014 - COVERAGE


IEC 60034-30-1:2014 - LIMITS


HOW IS THE EFFICIENCY DETERMINED?


DIRECT INDIRECT

The efficiency of an electric machine is defined as the ratio ofmechanical output power to electrical input power.

= mechelectric

Torque transducer

Power analyzer

= electric losselectric

IEC 60034-2-1 – SEGREGATION OF LOSSES


Stator Copper

Rotor Copper

Additional Load Iron Losses

Friction and windage

Technical specificationSpecifies efficiency classification for AC motors designed for variablespeed drives (VSD).Efficiency classification

Hyper efficiency IE5If motor is DOL capable IEC 60034-30-1 is usedTesting point 90% speed (45 Hz) and rated torque to allow full magneticflux.Nominal efficiency limits reduced compared to sinusoidal supply

Harmonics losses due to converter supply 15% / 25%Due to lower efficiency at 90% test speed

IEC 60034-30-2:2016


Technical specification1st Edition November / 2013Test methods for determining losses and efficiencies of converter-fed AC-machines.1st Edition Standard May /2020.Test methods for determining losses and efficiencies of converter-fed motors(IEC 60034-30-2)Input – Output - method

IEC 60034-2-3


Adjustable speed electrical power drive systems - Part 9-2: Ecodesign forpower drive systems, motor starters, power electronics and their drivenapplications - Energy efficiency indicators for power drive systems andmotor starters.Specifies energy efficiency indicators of power electronics (complete drivemodules, CDM), power drive systems (PDS) and motor starters, all used formotor driven equipment.Specifies the methodology for the determination of losses of the completedrive module (CDM) and the power drive systems (PDS).Defines IE and IES-classes, their limit values and provides test proceduresfor the classification of the overall losses of the motor system.

IEC 61800-9-2:2017


Classification based on reference losses instead of efficiency.Reference class IE1.25% margin for CDMs and 20% for systems.

IEC 61800-9-2:2017


Specifies threelossdeterminationmethods forfrequencyconverters

CalculationInput –outputCalorimetric

IEC 61800-9-2:2017


Converter and motor package design based on application demand.More degrees of freedom

Motor technology.Number of pole pairs vs. excitation frequency.Rated speed vs. field weakening operation.Maximum efficiency at rated point or with the partial loads.Multiple different combinations that fulfills the application’s needs.

Optimization criteriaEnergy efficiency.Dynamic performance.Lifetime system cost.Reliability.Torque quality.

VARIABLE SPEED DRIVE SYSTEM


MOTOR TECHNOLOGIES IN VSDS


INDUCTIONMACHINES

SYNCHRNOUSRELUCTANCEMACHINES

PERMANENT MAGNETSYNHRONOUSMACHINES

SynRM PMaSynRM* PMSMwithsaliency

PMSMNon-salient

> 1 = 1

= 0>

> 1

>>= 0

*PMs in q-axis

VARIABLE SPEED DRIVE SYSTEM


Superior energy efficiency due to PM-material self-excitation.The difference in the energy-efficiency compared with IM andSynRM is amplified when used with partial loads.The highest torque density.Near unity power factor can be achieved.Lower converter losses, because rotor exciation current needed

PERMANENT MAGNET SYNCHRONOUSMACHINE


Expensive.Limited field-weakening capability.Demagnetization of permanent magnets.

PRO

SC

ON

S

SYNCHRONUS RELUCTANCE MOTOR


Similar stator than IM.No winding in the rotor.Low power factor.Cheap.Simple and ruggedconstruction.Higher efficiency alsowith partial loads.Higher reliability dueto lower winding andbearing temperatures

IM VS. SYNRM


H. Kärkkäinen, L. Aarniovuori, M. Niemelä, J. Pyrhönen. “Technology Comparison of Induction Motor and Synchronous Reluctance Motor”,43rd Annu. Conf. IEEE Industrial Electronics Society (IECON), Peking, China, November 2017.

15 kW SynRM vs. IE3 IM


15 kW SynRM vs. IE3 IM

IM VS SYNRM DRIVE SYSTEM


MEASUREMENT POINTS

17.10.2019 IECON 2019

The same cycle for all converters.Thermal equilibrium in point (1)f=100%, T=100%.Rest the points in descendingorder.30 minutes in the diagonal points(11,16, 21 and 26).5 minutes in other points.

17.10.2019 IECON 2019

,

Lineconverter

200 kW IM 75 kW IM

,PC

T12

WT1600 , ,

VSC

,,

INPUT-OUTPUT MEASUREMENT


Mot

orlo

sses

Con

verte

rlos

ses

EFFICIENCY AND LOSS VALUESC

onve

rtere

ffici

ency

Mot

oref

ficie

ncy

Isolines presenting theconverter and motorlosses and efficienciesare given in the paper asa function of thefrequency and torque.

75 kW CONVERTER FED IMHARMONIC LOSSES


Isolines are presentingthe relative harmoniclosses as a function of thefrequency and torque.

LOSS ANALYSIS15 kW induction motor loss components withfrequency converter supply and sinusoidalsupply (400 V, 50 Hz fundamental voltage)


UNCERTAINTY IN MEASUREMENTS- 37 kW induction motor, electrical power, mechanical power, and input-output loss

uncertainty in Watts

Electric power uncertainty(total electric power = 39.7 kW)

Mechanical power uncertainty(total mech. power = 37.0 kW)

Loss uncertainty(total losses = 2.7 kW)


REFERENCES1. L. Aarniovuori, H. Kärkkäinen, A. Anuchin, J. Pyrhönen, P. Lindh and W. Cao, "Voltage Source Converter Energy Efficiency

Classification in Accordance with IEC 61800-9-2," in IEEE Transactions on Industrial Electronics.2. L. Aarniovuori, H. Kärkkäinen, M. Niemelä, K. Cai, J. Pyrhönen, W. Cao, “Experimental Investigation of a 75 kW Induction

Motor Drive System Losses and Efficiency”, 45th Annual Conference of the IEEE Industrial Electronics Society (IECON’2019),Lisbon, Portugal, Oct. 14-17. 2019.

3. H. Kärkkäinen, L. Aarniovuori, M. Niemelä and J. Pyrhönen, “The Instrumentation Influence on the Motor Loss DeterminationUncertainty”, 45th Annual Conference of the IEEE Industrial Electronics Society (IECON’2019), Lisbon, Portugal, Oct. 14-17. 2019.

4. L. Aarniovuori, H. Kärkkäinen, M. Niemelä and J. Pyrhönen, “Measurement Accuracy Requirements for the EfficiencyClassification of Converters and Motors”, 21st European Conference on Power Electronics and Applications (EPE'19 ECCEEurope), Genova, Italia, 2019, pp. 1-10.

5. L. Aarniovuori, P. Lindh, H. Kärkkäinen, M. Niemela, J. Pyrhönen and W. Cao, “Analytical Evaluation of High-EfficiencyInduction Motor Losses," 2019 IEEE International Electric Machines and Drives Conference (IEMDC), San Diego, CA, 2019.

6. H. Kärkkäinen, L. Aarniovuori, M. Niemelä and J. Pyrhönen, "Advanced Uncertainty Calculation Method for Converter-FedMotor Loss Determining," 2019 IEEE International Electric Machines and Drives Conference (IEMDC), San Diego, CA, 2019.

7. L. Aarniovuori, M. Niemelä, J. Pyrhönen, W. Cao, E.B. Agamloh, “Loss Components and Performance of Modern InductionMotors,” 23st International Conference on Electrical Machines (ICEM), Alexandroupuoli, Greece, 3-6 Sep. 2018.

8. P. Lindh, L. Aarniovuori, H. Kärkkäinen, M. Niemelä, J. Pyrhönen, “IM Loss Evaluation using FEA and Measurements”, 23stInternational Conference on Electrical Machines (ICEM), Alexandroupuoli, Greece, 3-6 Sep. 2018.


REFERENCES9. H. Kärkkäinen, L. Aarniovuori, M. Niemelä, J. Pyrhönen, J. Kolehmainen, T. Känsäkangas, J. Ikäheimo, “Direct-on-line

Synchronous Reluctance Motor Efficiency Verification with Calorimetric Measurements”, 23st International Conference onElectrical Machines (ICEM), Alexandroupuoli, Greece, 3-6 Sep. 2018.

10. H. Kärkkäinen, L. Aarniovuori, M. Niemelä and J. Pyrhönen, “Advanced Uncertainty Calculation Method for Variable SpeedDrives Loss Determination,” 20th European Conference on Power Electronics and Applications (EPE'18 ECCE Europe), Riga,Latvia, 2018, pp. 1-10

11. H. Kärkkäinen, L. Aarniovuori, M. Niemelä and J. Pyrhönen, “Induction Motor Efficiency Verification with Mass Flow Meter,”20th European Conference on Power Electronics and Applications (EPE'18 ECCE Europe), Riga, Latvia, 2018, pp. 1-10.

12. L. Aarniovuori, A. Kosonen, H, Kärkkäinen, J. Pyrhönen, Z. Liu, W. Cao, “Overview of Calorimetric Systems Used in LossDetermination of Electric Motor Drives,” 43rd Annu. Conf. IEEE Industrial Electronics Society (IECON), Peking, China, November2017.

13. H. Kärkkäinen, L. Aarniovuori, M. Niemelä, J. Pyrhönen. “Technology Comparison of Induction Motor and SynchronousReluctance Motor”, 43rd Annu. Conf. IEEE Industrial Electronics Society (IECON), Peking, China, November 2017.

14. H. Kärkkäinen, L. Aarniovuori, M. Niemelä and J. Pyrhönen, “Converter-Fed Induction Motor Efficiency: Practical Applicability ofIEC Methods,” in IEEE Industrial Electronics Magazine, vol. 11, no. 2, pp. 45-57, June 2017.

15. L. Aarniovuori, H. Kärkkäinen, M. Niemelä and J. Pyrhönen, “Induction Motor Drive System Losses,” Energy Efficiency in MotorDriven Systems 2017 (EEMODS’17), 6–8 Sept. 2017. Rome, Italy.

16. L. Aarniovuori, H. Kärkkäinen, M. Niemelä, J. Pyrhönen, “PWM power distribution and switching frequency analysis in motordrives,” IECON 2016 - 42nd Annual Conference of the IEEE Industrial Electronics Society, Florence, 2016, pp. 4356-4361.


REFERENCES17. H. Kärkkäinen, L. Aarniovuori, M. Niemelä, J. Pyrhönen, “Converter-fed Induction Motor Losses in Different Operating Points,”

18th European Conference on Power Electronics and Applications (EPE'16 ECCE Europe), 5-9 Sept. 2016, Karlsruhe, Germany,pp.1-8.

18. L. Aarniovuori, P. Rasilo, M. Niemelä, J. Pyrhönen, “Analysis of 37 kW Converter-Fed Induction Motor Losses,” IEEETransactions on Industrial Electronics, vol.63, no.9, pp. 5357-5365, 2016

19. L. Aarniovuori, J. Kolehmainen, A. Kosonen, M. Niemelä, H. Chen, W. Cao, J. Pyrhönen, “Application of calorimetric method forloss measurement of a SynRM drive system,” IEEE Transactions on Industrial Electronics, vol.63, no.4, pp. 2005-2015, April2016.

20. L. Aarniovuori, H. Chen, N. Yang, W. Cao. “New Shunt Calorimeter for Testing Electric Motors,” IEEE IAS Annual Meeting 2015,Dallas, Texas, 18–22 Oct. 2015.

21. L. Aarniovuori, T. Musikka, A. Kosonen, M. Niemelä, J. Pyrhönen. ”Three alternative methods to determine voltage sourceconverter losses,” 17th European Conference on Power Electronics and Applications, EPE’2015 ECCE Europe, Geneva,Switzerland, 8-10th Sept. 2015

22. L. Aarniovuori, A. Kosonen, M. Niemelä, J. Pyrhönen. ”Determining Losses of Motors Designed for Converter Operation,” 17thEuropean Conference on Power Electronics and Applications, EPE’2015 ECCE Europe, Geneva, Switzerland, 8-10th Sept. 2015.

23. R. Kanchan, L. Aarniovuori, M. Niemelä, R. Chitroju, F. Gyllensten,”Loss Measurements Analysis of VSD Motors Using BothDirect Input-Output and Calorimetric Methods,” Energy Efficiency in Motor Driven Systems 2015 (EEMODS’15), 15–17 Sept.2015. Helsinki, Finland.

24. L. Aarniovuori, A. Kosonen, M. Niemelä, J. Pyrhönen. “Loss Measurement System for Variable Speed Drives,” Energy Efficiencyin Motor Driven Systems 2015 (EEMODS’15), 15–17 Sept. 2015. Helsinki, Finland.


REFERENCES25. L. Aarniovuori, J. Kolehmainen, A. Kosonen, M. Niemelä, J. Pyrhönen, “Uncertainty in Motor Efficiency Measurements”, 21st

International Conference on Electrical Machines (ICEM), Berlin, Germany, Sep. 2014.26. L. Aarniovuori, A. Kosonen, M. Niemelä, J. Pyrhönen, “Applicability of an open- and balance-type calorimeter to VSC loss

measurement”, 16th European Conference on Power Electronics and Applications, Lappeenranta, Finland, Aug. 2014.27. A. Kosonen, L. Aarniovuori, J. Ahola, J. Backman, J. Pyrhönen, M. Niemelä , “Loss definition of electric drives by a calorimetric

system with data processing,” IEEE Trans. Ind. Electron., vol. 61, no. 8, pp. 4432–4442, August 2014.28. L. Aarniovuori, A. Kosonen, P. Sillanpää, M. Niemelä. “High-Power Solar Inverter Efficiency Measurements by Calorimetric and

Electric Methods”, IEEE Transactions on Power Electronics, vol. 28, no. 6, pp. 2798-2805, 2013.29. A. Kosonen, L. Aarniovuori, M. Niemelä, J. Pyrhönen, J. Backman, “Calorimetric Concept for Measurement of Power Losses up

to 2 kW in Electric Drives”, IET Electric Power Applications, vol. 7, no. 6, pp. 453–461, July 2013.30. L. Aarniovuori, A. Kosonen, M. Niemelä, J. Pyrhönen, “Frequency converter driven induction motor losses,” 39th Annu. Conf.

IEEE Industrial Electronics Society, Vienna, Austria, Nov. 2013.31. A. Kosonen, L. Aarniovuori, J. Pyrhönen, J. Ahola, M. Niemelä, K. Tammi, “Scalable open- and balance-type calorimeter for

measuring power electronics and motor,” 39th Annu. Conf. IEEE Industrial Electronics Society, Vienna, Austria, November 2013.32. L. Aarniovuori, L. Laurila, M. Niemelä, J. Pyrhönen, “Measurements and Simulations of DTC Voltage Source Converter and

Induction Motor Losses”, IEEE Transactions on Industrial Electronics, vol. 59, no. 5, pp. 2277-2287, May 2012.


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