DMI Outstanding Performance (NXPowerLite)

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Presentation

DMI motors - innovations beyond the limits

DMI - DC motors for peak performance

Johan Swrd, Area Sales Manager DC Motors Vsters Sweden

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Agenda

Brief information about ABB DC Motors General information DMI Motor Technical requirements and how the DMI motor

fulfill these demands Typical applications for DC Motors

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Who is Johan Swrd?

Johan Swrd

Mechanical Engineer, Master Degree. University of Vsters Sweden

Married with Annika, Two Children Hampus 12 years old and Julia 11 years old

Lieutenant at Swedish Army

Started at ABB 1995

1995 1998 Sales Engineer at ABB Nuclear division within ABB Atom 1998 2005 Area Sales Manager for Robot Automation within ABB Robotics 2005 Area Sales Manager for DC Motors within ABB Machines

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ABB PRU DC Motors

Key figures Part of BU Machines Located in Vsters, Sweden

and Ostrava, Czech Republic Delivers ~1000 motors annually

>120 years of experience

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Steady growing DC business within ABB

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2001 20062005200420032002 2007

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+30

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Location Vsters, Sweden

Marketing & Sales Technical

development Assembly Testing

Ostrava, Czech rep.ABB Service Production of

complete rotors and stators

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Our offer

DMR-design (replaces DMP) Shaft height 112-180 mm Power output < 170 kW

DMI-design (replaces DMG, DMA) Shaft height 180-400 mm Power output < 1400 kW

LAN-design Shaft height 710mm Power output < 2200 kW

After sales Inspections Upgrade Spare Parts Replacement

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Small Stock Motors for a very short deliverytime We will have stockmotors available at a very short

deliverytime. (2 days) Standard motors also available at a short deliverytime (2

weeks)Cooling from N-end P nbas ntop IA P nbas ntop IA IF

DMI180M-BFA 125 1701 2720 339 148 2018 3228 339 8,0DMI180P-AXA 123 1421 2273 336 146 1688 2700 336 9,3DMI200P-DDA 160 1249 1998 435 189 1484 2374 433 13,0DMI200U-CMA 157 908 1452 433 185 1082 1731 429 13,5DMI225S-FDA 262 1318 2108 699 310 1561 2497 699 13,9DMI225U-EXA 262 1103 1764 703 310 1308 2092 702 15,2

Cooling from D-endDMI180M-BFA 106 1717 2720 286 126 2034 3228 287 8,0DMI180P-AXA 105 1436 2273 284 124 1703 2700 284 9,3DMI200P-DDA 136 1262 1998 367 161 1496 2374 367 13,0DMI200U-CMA 133 920 1452 363 157 1094 1731 361 13,5DMI225S-FDA 223 1328 2108 592 264 1571 2497 593 13,9DMI225U-EXA 223 1113 1764 595 264 1318 2092 595 15,2

UA = 400V UA = 470V

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General data

Armature voltage up to 810 V Field voltage 110-440 V Standards IEC, CE, CSA (up to 710 V) IM:

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General dataGeneral data

Degrees of protection and methods of cooling

IP 23IC 06Separatelycooled by maschinemounted fan unit,filter available

IP 23IC 17Separately cooledby ductedventilation

IP54, IP55IC 37Separatelycooled by ductedventilation

IP54, IP55IC 86WCooling by top or sidemounted air-water coolerwith filter for circulating air

IP54, IP55IC 666Cooling by top or sidemounted air-air cooler with filter for circulating air

IP54, IP55IC 410Totallyenclosed, framecooled withoutfan

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DC Theory

Base speed Field

weakeningnb nmax

UN

IN

IN

TN

PN

UA

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If

T

Pn

Armature voltage

Armature current

Field current

Torque

Output [kW]

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Market for DC Motors

DC is a stable market Global market size ~250

MUSD Consolidations of suppliers

Used where DC has its advantages a niche market

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Technical requirements and how the DMI motor fulfill these demands

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General requirements from the metals industry

High output and torque, but the space is limited The speed has to be able to variate over a wide range Requirements for high overloads High adaptability for replacement market How about the maintenance? Wide motorrange for several different applications Quality How can we together save the environment?

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How does the DMI fulfill the demans

Power output and torque for DMI is above any competitor in the same size

How is it possible to get so much power from such a small motor

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How does the DMI fulfill the demansInsulation class

120145

165

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101025

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250

Material class FTemp.utilization B

Material class HTemp.utilization F

Material class 200 DMI Temp.utilization

T

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p

MarginHot spotAverage

Material Class FUtilazation B

Material Class HUtilazation F

Material Class 200Utilazation H

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Cooling Close Along the Rotor Windings


Safe Increase of Power Output

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Outstanding commutation

I will explain this later

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How is it possible to get so much power from such a small motor In an application this gives smaller and lighter motors

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146%113%127%100%t %

0,840,650,730,58t (0-1000)SIEMENS 280SICME 280 KL6Ansaldo GH 280PKDMI 280V

Size 280

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P

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DMIANSALDOSICMESIEMENS*


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P=319, n=698, U=470

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DMI 280 TSiemens 355SICME 315

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New motor year 2007 DMI 400V

400mm shaft height intermediate plate 310mm 900 kW 800 - 1700 rpm equal shaft dimensions drop-in replacement

Example Customer: COMITAL, Sweden Application: Rolling Mill Existing DC-motor

brand ASEA LAD 710 710mm shaft height 900 kW 800 - 1700 rpm 420 Vdc Ducted air inlet and outlet

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How is it possible to get so much power from such a small motor In an application this gives smaller and lighter motors Low inertia gives fast accelleration

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High torque and small rotor size mean outstanding acceleration.

High top speed.Higher acceleration and top speed shorten process cycles Higher output


Process cycle (t)

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Large speed range with constant power

The motor is more flexible and can be used in a large working area

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0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

rpm

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DMI 400DMI 315DMI 280DMI 250DMI 225DMI 200DMI 180

DMI power and speed range

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Long motors => High TorqueShort motors => High speed

DMI 180 B. E, H, M, P, S, UDMI 200 B, E, H, M, P, S, UDMI 225 K, N, S, U, XDMI 250 L, P, T, V, YDMI 280 L, P, T, V, YDMI 315 N, R, T, V, Y, ZDMI 400 H, L, N, R, T, V, Y, Z

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DMI peaks performance after decades of DC evolution

DMI


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Large speed range with constant power

The motor is more flexible and can be used in a large working area The use of gearboxes might be unnecessary

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Superior commutation performance Wide black band test

The electrical stress of the motor is down to one third of competitors

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The electrical stress of the motor is down to one third of competitors

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Supports increased torque

Saturation is eliminated

Conventional DMI design

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The electrical stress of the motor is down to one third of competitors The motor is less sensitive to external disturbances (polluted air, vibrations

etc.

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There are always commutation disturbances

Without margin Sparking occurs


Commutation Margin - Why?

load and supplydisturbances

Commutation margin

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DMI has an outstanding margin


DMI manages higher output power at higher speed than any other DC-motor.

load and supplydisturbances

Commutation margin

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The electrical stress of the motor is down to one third of competitors The motor is less sensitive to external disturbances (polluted air, vibrations

etc. Less brushwear => longer lifetime for the brushes => less need for

maintenance

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Large & old installed base of DC Motors ABB products very suitable

higher torque/power vs size always enough space

wider speed range reduced need of maintenance

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Superior mechanical design

Very high maximum speedlimit

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DMI combines high speed and less maintenance

Same rpm

Small commutator diameter reduces

surface speed

How does the DMI fulfill the demansConventional design DMI

...allows higher rpm

Lower surface speed...

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Substantially reduced maintenance

Multiple spokes ensures cummutatorstability

Highest Commutator Quality available


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Very high maximum speedlimit Small commutator => less brushwear

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Reduced brushwear


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1.Reduced peripheral Speed.

Reduced brushwear

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Very high maximum speedlimit Small commutator => less brushwear New standard brushes and new design of brushgear

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2. DMI Uses Longer Brushes

Reduced maintenance

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Changing brushes can be done during normal service stop

3.DMI uses more of the brushes.

Reduced maintenance

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Stable pressure finger with time stable neutral position

Accurate repositioning Brush wear sensor indicates

when it is time to change brushes (option)

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Very high maximum speedlimit Small commutator => less brushwear New brushgear and new brushes Easy to change brushes

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Very high maximum speedlimit Small commutator => less brushwear New brushgear and new brushes Easy to change brushes Flexible solutions for positioning terminalbox and fan to user preferences

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Terminal box location and cable entrance

Option: Flying leads without terminal box

Cable entrance from all directions

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6 Fan Locations...

There is always a way to mount the fan


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Very high maximum speedlimit Small commutator => less brushwear New brushgear and new brushes Easy to change brushes Flexible solutions for positioning terminalbox and fan to user preferences Smooth running at low speed

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Low noise

Skewed Rotor Slots

Eliminates cogging at low speed

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This gives DMI an even torque at the lowest speeds

To eliminate Magnetic Polarization, every sheet is turned in the stacking process

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Less need for and simplified mainenance

Maintenance is a considerable part of the lifetime cost of a DC motor

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Less need for and simplified mainenance

Maintenance is a considerable part of the lifetime cost of a DC motor

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A large Speed/Output area means high productivity in applications

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Long motors => High TorqueShort motors => High speed

DMI 180 B. E, H, M, P, S, UDMI 200 B, E, H, M, P, S, UDMI 225 K, N, S, U, XDMI 250 L, P, T, V, YDMI 280 L, P, T, V, YDMI 315 N, R, T, V, Y, ZDMI 400 H, L, N, R, T, V, Y, Z

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Quality

Long lifetime of the motor

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A dc drive with DMI gives a long lasting trouble free operation.


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Quality

Long lifetime High availability

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Quality

Long lifetime High availability All DMI motors are tested at full load

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A

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Quality

Long lifetime High availability All DMI motors are tested at full load Safe deliveries at right time

A

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Quality

Long lifetime High availability All DMI motors are tested at full load Safe deliveries at right time Long term customer co-operation, Close to service shops world wide

A

B

B

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Logistic center has a world wide coverage for spare parts. Spare Parts On-Line => Short deliverytimes

A

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Low environmental impact

The workshops has implemented ISO 14001.

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The workshops has implemented ISO 14001. Low noice

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The workshops has implemented ISO 14001. Low noice Less use of copper in motors

A

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The workshops has implemented ISO 14001. Low noice Less use of copper in motors Less brushwear => cleaner environment at customer site.

A

B

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Typical applications for DC Motors

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METALS

Mill stand High starting torque Load variations Wide speed range with high

maximum speed

Coiler/ Uncoiler High Base to top speed ratio Constant power for uncoiler Quick response to step load

A

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B

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METALS

Shear Short, repetitive duty cycle High overload for short time Fast acceleration, decelearation

Press machine Compact installation DC is a cost efficient solution Overload capacity

A

B

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Pulp & Paper, Cement

Re-winder Current sharing between forward &

reverse drums High overload Wide speed range

Kiln High Starting torque for long time (1 min) 2 motor configuration for redundant

operation Master/ Follower Cost effective solution

A

B

B

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Cranes & Mines

Harbor cranes Overloads during long time Fast acceleration, smooth start &

stop Compact installations Reliability

Mine hoists Very low base speed Smooth start & stop High starting torque High reliability

A

B

B

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Rubber and Plastics

Rubber mixer High starting torque Cyclic load patterns High reliability to avoid batch loss 2 motor configuration

(Master/Follower)

Extruder Running at low speed for long time High starting torque Variation in speed leads to product

rejection Compact installations

A

B

B

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Rope ways & Lifts, Marine

Ski lifts High reliability for safety standards High staring torque Smooth start & stop Low noise Compact installation

Marine applications High torque (300%) Limitation in space/ small footprint

A

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Food & Feed

Sugar centrifuge Cyclic load & speed changes Precise speed holding accuracy

due to high inertia of load High start / stopping torque for

acceleration & stopping

A

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[email protected]+46 21 32 94 27

Documents

DMI Outstanding Performance (NXPowerLite)