Real-Time Test Results from HBM - for the New Super-Efficient Motor

Researchers from Japanese institutes NEDO and MagHEM are working on a Super-efficient Motor with 40% (*) less energy loss. The HBM eDrive testing system is used to test the motor’s efficiency for its further development - for good reasons.

The Japanese New Energy and Industrial Technology Development Organization (NEDO) is one of the world's leading public research organizations dedicated to the development of new energies. In a recent research project, researchers from NEDO worked with the organization "MagHEM" (which develops innovative magnetic materials) on a "super" motor that uses new magnetic materials to reduce its energy loss and increase its power density by 40% compared to conventional electric motors.

There are many areas of application for such a highly efficient motor ranging from household appliances to industrial machinery, and automobiles, to name just a few.

Problem

Researchers at NEDO and MagHEM (Japan) are developing a magnetic motor with 40% less energy loss. Previous efficiency testing systems could not provide synchronized data in real time - an important prerequisite for further development of the motor.

Solution

By using the HBM eDrive testing system, including the dynamic GEN7tA power analyzer, the measured values and calculations are available in seconds.

Result

Phase 1 of the motor development has already been completed - thanks in part to meaningful measurement results. Now it's time for Phase 2, which provides for further miniaturization of the motor.

40% less energy loss: Japanese Super-efficient Motor from NEDO tested with Genesis HighSpeed from HBM

NEDO/MagHEM's test bench for the new ultra-high-efficiency motor with magnetic bearings uses the HBM eDrive testing system, including the highly dynamic GEN7tA power meter, for electrical efficiency measurement. In conventional systems, synchronous measurement was difficult because it was done with a torque meter, a power meter, and multiple measuring instruments, depending on the measurement parameters. Synchronizing the measurements of all measured parameters by introducing the eDrive GEN7tA system makes measuring substantially easier. In addition, real-time computation enables simultaneous observation of measured waveforms such as magnetic flux and torque waveforms as well as computed waveforms such as iron loss separation, thereby significantly improving test efficiency.

Since iron-loss separation requires data in the switching frequency range of the inverter, high-speed sampling is necessary. However, with the conventional power meter, the sampling was relatively slow and it was impossible to capture the phenomenon in the relatively high-speed regions in order to investigate torque ripple or switching frequency related issues. Only the HBM eDrive system can measure voltage and current signals with high-speed sampling of 2 MS/s and provide 1/2 cycle power measurement calculation. (However, since the maximum speed of motor rotation is 20,000 rpm and the switching frequency is 20 kHz, further high-speed measurement is required for high frequency component measurement.)

With the conventional power meter, only analysis based on the averaged calculation results was possible, but since HBM eDrive processes all the raw data (instantaneous data) at high speed, both the speed and the accuracy of the analysis have greatly improved. A high voltage of 600 V can be measured directly by using the Genesis HighSpeed 1000 V input card. It is also more convenient; there is no need to switch between the time-axis display and the FFT display, so the researchers can check the output on the same screen.

(*) The NEDO/MagHEM researchers are now focusing on developing new high-performance magnets, together with the results of the development of soft magnetic materials and motor evaluation technology in the first phase, aiming to develop magnetic materials that can reduce its energy loss and increase its power density by 40% compared to conventional electric motors. The specific development goals of each research and development item shall be in accordance with the research and development plan of the separate sheet.

Fig. 1: Overall high-accuracy motor loss analysis. The measurement points of the evaluation system and the measurement points of the HBM products

Fig. 2: External view of the ultra-high-accuracy motor loss analysis evaluation device

Fig. 3: The newly developed magnetic bearing

NEDO

The Japanese New Energy and Industrial Technology Development Organization (NEDO) combines the efforts of industry, government and academia and leveraging established international research networks and is committed to contributing to the resolution of energy and global environmental problems and further enhancing Japan's industrial competitiveness.