Executive Summary | Introduction | Conclusion

 

View Full Report: Performance Testing Results For FlexMod Controller. 44 Pages (PDF)

Conclusions and Recommendations

1. Electric motors are the dominant consumers of electric energy in the United States. Previous studies have shown that applying variable speed drives can result in significant energy savings for many motor driven systems. However, existing variable speed drives have high initial costs relative to other motor system components.

2. There is a market need for low cost, efficient and modular motor controllers. Such a product could substantially reduce energy consumption in many areas, including industrial motor systems, residential HVAC systems and hybrid vehicles. In addition, a modular platform could reduce industrial motor maintenance costs by providing an inexpensive and standard platform for motor controllers.

3. This project documented the performance and characteristics of the FlexMod motor controller. Advanced Energy measured motor system efficiencies for multiple motor sizes at a range of loads and speeds for a FlexMod controller and a comparable, commercially available ABB controller. Other estimates indicate that a mass produced version of the controller would meet the stated performance targets of cost and power density.

4. The FlexMod controller using Symetron technology involves adaptive tuning to continuously optimize motor and system efficiency for the speed and torque operating point. During the testing, the adaptive algorithm or table calculations were performed offline and then input to the controller. The algorithm and table data were still being optimized by Raser at the time of the test at Advanced Energy. Future testing should include controllers that have the adaptive tuning algorithm activated.

5. The FlexMod controller showed substantial (2% to 10%) increases in system efficiency at various load points when compared to the ABB drive, considered a popular, high end controller in widespread use.

6. A recommended follow-on activity is to provide the results of this study to the electric utility industry and major equipment manufacturers that use electric motors. Such dissemination should encourage these industries to include more efficient motor controllers as part of any energy efficiency programs.

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View Full Report: Performance Testing Results For FlexMod Controller. 44 Pages (PDF)