SBIR Phase I: High Efficiency Synchronous Speed Neodymium Iron Boron Motor for Machine Drives

这个小型企业创新研究(SBIR)第一阶段项目将开发一种设计，将电容启动分数马力多极交流电机的效率提高33%。通过将电机改装到现有的工业机械中，大幅降低电力消耗和运营成本，结果将为制造商带来显著的优势。该电机还将通过降低运营成本和提高生产率，为新型工业机械制造商提供竞争优势。小型交流电机的平均效率为60%。涡流和I2R损耗是主要的损耗，并以热的形式存在。该项目将确定一种设计的可行性，该设计将大大减少这些损失，从而将效率提高到80%。该方法将包括开发定义电机的算法、新的转子结构、使用软磁复合材料、优化使线圈部分通电的特性，以及由材料科学和建模的进步支持的研究。为了提高工业机械的竞争力，预期的研究结果包括一种工作模式，它将满足以下性能指标：效率达到或超过80%；温度上升20摄氏度；外壳尺寸减少50%；以及与标准现有产品的成本相当。该项目更广泛的(商业)影响可能是将小型电机的效率从60%提高到80%，同时降低运营成本和材料，替代可回收材料，并保持现有的制造成本。将能效提高到80%将为美国制造商节省30-70亿美元的净现值，并减少5.2-8.6万亿BTU的能源消耗。它还将每年减少40-6700万兆瓦时的发电量，并消除对9-15个化石燃料电力公用事业的需求。运营成本的降低和生产效率的提高将使制造企业、员工和社区显著受益。相互竞争的技术仅使效率提高3%，成本至少增加21%。商业化将通过改造和实现利用更高的效率、更高的可靠性、更低的废热、更小的空间和更快的精确控制的新机器设计来提高制造生产率。

This Small Business Innovation Research (SBIR) Phase I project will develop a design to increase efficiency of capacitor-start fractional horsepower multi-pole AC motors by 33%. Results will drive significant advantages for manufacturers by retrofitting motors into current industrial machinery to dramatically reduce electricity consumption and operating costs. The motor will also provide competitive advantage to manufacturers of new industrial machinery by reducing operating cost and increasing productivity. The average efficiency of small AC motors is 60%. Eddy currents and I2R losses are the primary losses and are in the form of heat. This project will determine feasibility of a design that dramatically reduces these losses thereby increasing efficiency to 80%. The approach will consist of developing algorithms that define the motor, novel rotor construction, use of soft magnetic composites, optimizing characteristics that leave the coil partially energized, and research supported by advances in material science and modeling. To increase competitiveness of industrial machinery, the anticipated results of research include a working model that will meet the following performance metrics: efficiency at or above 80%; temperature rise of 20 degrees C; envelope size reduced 50%; and comparable cost to standard available products.The broader (commercial) impact from this project could be increased efficiency of small motors from 60% to 80% while reducing operating cost and materials, substituting recyclable materials, and maintaining current manufactured cost. Increasing efficiency to 80% will save American manufacturers $3-$7 billion net present value and reduce energy use by 5.2-8.6 quadrillion BTUs. It will also reduce electricity generation by 40-67 million megawatt-hours per year and eliminate the need for 9-15 fossil fuel electric utilities. Reductions in operating cost and increased productivity will significantly benefit manufacturing companies, employees, and communities. Competing technologies increase efficiency by a mere 3% and increase cost by at least 21%. Commercialization will increase manufacturing productivity by retrofitting and enabling new machine designs that leverage increased efficiency, higher reliability, lower waste heat, smaller space, and faster precision control.