Tests demonstrated up to 10% system efficiency improvement for HVAC systems; recommends advising motor manufacturers of the potential impact of the technology

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Performance Testing Results For FlexMod Controller (pdf)
Performance Testing Results For FlexMod Controller
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Executive Summary
Most of the electricity generated in the United States is used in an electric motor. In U.S. industry, there are more than 13 million motors. Many of these are operating inefficiently because of changing loads or less than optimum control schemes. The U.S. Department of Energy estimates that improved system controls including variable speed drives could save nearly 15,000 gigawatt-hours per year and potentially $900 million per year in energy savings in pump, fan and compressed air systems alone.

Therefore, there is a market need for an efficient, modular motor controller capable of operating with a range of motor sizes and types. The wide applicability and low cost could result in substantial energy savings in industry, residential and hybrid vehicle markets. The overall objective of this project was to develop and evaluate such a controller.

Symetron FlexMod Controller

Under this project, Raser Technologies developed the FlexMod controller using Symetron technology. This motor controller design uses adaptive tuning to optimize performance based upon unique motor characteristics. The prototype drive can use various power modules and different IGBT designs. The modular construction methods should reduce manufactured costs.

EC Dynamometer with 20 hp Motor

Advanced Energy tested the FlexMod controller and a comparable, commercially available controller on a 5 hp and a 20 hp AC induction motor. The tests produced a system efficiency map over 300 to 1800 rpm and 25% to 125% rated torque. The tests demonstrated that the FlexMod design was 2 to 10% more energy efficient on average.

The results of this project should be provided to major motor manufacturers and the utility industry in order to reduce energy costs in the industrial, residential and hybrid vehicle markets.

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Performance Testing Results For FlexMod Controller (pdf)
Performance Testing Results For FlexMod Controller
File Size: 1.1 MiB