ABSTRACT. The digital twin in the process industry today offers very extensive options for simulating system performance. The simulation of the power electronics, but also the drive system with the connected machines, are important tools for optimizing the system. For this purpose, real-time simulation based on hardware-in-the-loop (HIL). HIL is a testing procedure in which real physical components or subsystems, such as controls, automation, are integrated into a virtual simulation environment.

In the application for platform electrification to reduce CO2 emissions, the system performance is simulated and verified in real time in all relevant operating modes. M2C converters were used, which have particularly network-friendly properties due to the converter topology. The behavior in the event of possible malfunctions such as asymmetrical short circuits on both the network side and the consumer side is simulated and the behavior of the entire system is optimized on the platform. For this purpose, HIL simulators were set up for the relevant systems and simulations were carried out in real time.

In another example, the behavior of an LCI converter including a compressor load in the event of asymmetrical network drops could be examined and optimized. Here, with the help of HIL simulation, the performance of the system could be significantly improved and proven.

The investigations show that simulation tools such as HIL enable significant optimization of the performance of the VSD or SFC system, which would only be possible to a limited extent or with a high expenditure of time and money with conventional tests in test fields or during commissioning.

ABSTRACT. A large part of the costs of an industrial plant is due to the maintenance of indus-trial assets. To reduce them, low-cost sensors were developed for online assets monitoring. Most of these sensors use vibration measurements as a method for detecting, monitoring, and diagnosing faults or behavior deviations. This paper shows a method for Operating Deflection Shape (ODS) vibration signal analysis technique with low-cost wireless condition monitoring IoT sensors. The devel-oped method was confronted with commercial devices that perform traditional ODS. Additionally, laboratory and field validations are presented.

ABSTRACT. The development of highly integrated drive systems,comprised of a motor, gear units, sensing and electronics, forapplications where performance is critical, is challenging. Therelevant performance metric in this context can mean efficiency,mass, power-density, etc. Challenging aspects include the highnumber of optimization variables and the existence of multipleoptimization criteria. In this paper, we show our framework forsimulation assisted development with a focus on motor modelswhich allows to tackle these challenges. The motor models arebased on a low number of computationally expensive finiteelement method (FEM) calculations. The framework is used togenerate large data sets that can be used to conduct trade-offstudies on drive system level. An example is provided on how toanalyze the large dataset.

ABSTRACT. Construction of high efficiency motors normally requires the use of high performance, higher cost materials and/or larger amounts of materials. This increases the selling price of such motors and limits their potential applications in the marketplace. It is much more challenging to achieve high electric motor efficiency and overall performance when low-cost materials like ferrite magnets and aluminum conductors are used. However, this has recently been accomplished.

A new motor design approach was used to achieve high motor efficiency with these lower cost materials. This motor design is based on a dual-rotor axial flux machine, but has the same form factor as a standard radial motor. Efforts were made to reduce all aspects of the motor production cost, including material type, material volume, manufacturing processes, retrofitting of existing applications, and inventory requirements to meet worldwide demand in numerous applications.

Details regarding efficiency, performance, design approach, material usage, and manufacturing processes will be presented.

ABSTRACT. The design of electric machines is constantly improving and modern tools respect both thermal and electromagnetic boundary conditions. While these tools allow for the consideration of designs for specific parameters under ideal assumptions, the final real-world machines additionally depend on deviations due to uncertainties from material data or production processes. These deviations lead to differing results for temperatures and loss data. Considering the influences of many uncertainties at once - e.g. with Monte-Carlo-Methods - can be overly time-consuming. The paper deals with a methodology of computing machine setpoints including the uncertainty propagation through the model in a faster manner. To achieve this goal, existing models for electric machines are extended by an inherent uncertainty modeling. The error propagation throughout the models is based on derivatives computed by automatic differentiation. This approach leads to a very efficient calculation of complete characteristic maps including uncertainties with respect to large numbers of parameters. The uncertainties generated from high dimensional input parameters are of particular interest for motor calculation based on flux linkage characteristics. A novel modeling approach for these parameters is presented and verified with respect to capability and performance by numerical experiments. The benefit of this method is demonstrated by computational examples of general interest, e.g. the computation of maximum torque characteristics with confidence intervals.

ABSTRACT. This work aims to demonstrate the practical application of Design for Six Sigma (DFSS) in enhancing alternator performance. DFSS, a design approach leveraging various methodologies, proves particularly effective for making incremental improvements during the redesign phase, with a focus on Critical to Quality parameters (CTQs). The paper concentrates on implementing DFSS concepts and methodologies to elevate the quality and performance of alternators. Computer Fluid Dynamics (CFD) is employed to evaluate temperature and mechanical performance, both crucial CTQs for alternators. The initial step involves identifying the key components contributing to the analyzed parameters. Subsequently, the variables of each component are categorized as critical or non-critical for further examination through a design for experiment approach. Numerical experiments are conducted to attain the optimal solution for the CTQs. The application of this methodology successfully reduces the temperature from the initial design to an optimized one, with a notable decrease of 16 Kelvin in the average temperature of the rotor, while maintaining mechanical losses within an acceptable range. In conclusion, the application of DFSS proves instrumental in improving product quality incrementally, without requiring substantial investments, in a systematic manner.

ABSTRACT. Fans are often driven directly by an external rotor motor. In the case of a PMSM, the electromagnetically active components of such a drive usually consist of permanent magnets, copper and electrical sheet metal. The Corona crisis and geopolitical conflicts have shown that readily available materials, such as electrical steel, become scarce in times of crisis and are subject to sharp price increases.

A possible alternative to electrical sheet is the SMC material (soft magnetic composite). Due to the poorer magnetic conductivity compared to electrical sheet, a direct replacement in a radial flux machine is not possible. An interesting alternative is being offered by the axial flux topology. This article presents the electromagnetic design of an axial flux machine with SMC stator. The proposed permanent magnets consist of ferrite, which ensures high availability as well. Relevant parameters such as efficiency and smooth running, which are particularly important for fan drives, are discussed. A comparison and evaluation to an existing external rotor radial flux motor is carried out.

ABSTRACT. This paper aims to present maintenance cost and energy consumption, the major Life Cycle Costs (LCC) of a pumping asset, in a manner that can be appreciated by non-technical project stakeholders. The efficient operation of a centrifugal pump extends beyond reducing the energy consumed. As demonstrated by Barringer, efficiency and reliability are related. That is, the pump operation point relative to the Best Efficiency Point (BEP) affects the Mean Time Between Failure (MTBF) significantly. To demonstrate the LCC implications of design decisions, the expected rate of component wear will be evaluated using a technique that considers pump and systems specific parameters to give a cost per unit volume pumped for various flow rates. This will then be combined with the expected specific energy and presented in a table for the system being analyzed. The results shown clearly identify that the minimum combined expense does not necessarily correlate with either the minimum specific energy or maximum pump efficiency. Additionally, a graph that is representative for the entire operating range of a variable speed driven centrifugal pump is presented. The graph has the ability to allow various operational scenarios and system designs to be reviewed in a financial context by non-technical project stakeholders. Finally, an example of the increased energy consumption that might occur due to expected operational wear will be presented. This acts a demonstration of the proportion of energy lost to component wear, the effect this has on the system efficiency, and the value of operational monitoring systems.

ABSTRACT. With the 2009 regulation of heating circulators (EC 641/2009), a first efficiency regulation was established that created significant energy savings in reality. The regulation for this product group is based on the description of the entire unit, consisting of hydraulic components, motor and control electronics. Under time pressure, the regulation of the water pump (EU 547/2012) was launched in 2012. Unfortunately, this is only based on the hydraulic part of the pump itself. The efficiency of this component is described by the so-called MEI (Minimum Efficiency Index). This is based purely on the hydraulic efficiency. A limit value of MEI=0.4 was set here. The MEI should be seen as a cut-off criterion (pure market access criterion) and not as a pure description of efficiency. As a result, 40% of the most energy inefficient pumps may no longer be sold within the EU. In 2017, work began on the revision of the Water Pump Regulation (EU 547/2012). Article 7 "Review" sets out the aim of including the extended product approach. The background to the extended product approach is the consideration of the entire unit under the most realistic operating conditions possible. The advantage of this methodology is that, in contrast to the efficiency analysis, which is always carried out at the optimum operating point, the extended product approach uses a realistic load profile to evaluate efficient operation. Conversely, a significantly higher energy saving potential can be realised.

The introduction of the EPA for pump units with an output of up to 45kW results in an energy saving potential of 35TWh in the EU. On the other hand, savings of 3TWh can be realised by increasing the MEI value.

This energy saving and the problems associated with optimisation using the wrong criteria are demonstrated using suitable examples. One of the good optimisations is operation in a fixed-speed application using a frequency converter. The bad optimisations include raising limit values such as the MEI and the resulting additional energy consumption.

ABSTRACT. In the context of Industry 4.0, the industrial landscape is facing significant challenges related to energy consumption and environmental responsibility. The energy demand of electric motors accounts for approximately 70% of the electricity consumption in industries. As the industries strives to reduce its carbon footprint and bolster sustainable practices, the efficient operation and monitoring of industrial assets have become paramount. This paper explores the symbiotic relationship among Industry 4.0, energy efficiency, and environmental responsibility within the industrial context and presents an assets digital condition monitoring solution to estimate energy consumption and CO2 emissions from electric motors, in addition to practical cases. It underscores the importance of adopting smart technologies for asset monitoring and highlights the competitive edge gained through comprehensive insights into carbon emissions, further reinforcing the significance of Environmental, Social and Governance (ESG) cosiderations in today's corporate landscape.

ABSTRACT. Variable-speed drives have been utilized for many years in order to achieve energy savings. In recent years, the variable speed drive has also been seen as a valuable source of data, benefiting from the current and voltage sensing capabilities of the drive. The aim of digitalization in motor drive systems is to improve both energy and operational efficiency.

In this paper, we will dive into the concept of using the drive as a sensor, as well as the role of Industrial IoT (IIoT) in data visualization and analytics. This allows for the monitoring of energy usage and deviations due to wear-out and other operating conditions. Our final paper will share the experiences of the last five years and highlight both the challenges and opportunities.

Challenges include the unknown application output power without additional sensors, cost, insufficient use cases, and complexity. However, there are also opportunities to be had such as data analytics, the use of AI and machine learning (ML), and the use of data from VSD.

ABSTRACT. Small wireless IoT smart sensors are becoming increasingly common in both domestic and industrial applications. They can store, processing, and transmitting large amounts of data, making them a valuable tool for decision-making. In this article, a new application for wireless IoT smart sensors is presented: the estimation of load and energy consumption in electric motors. This information is essential for the correct sizing of the motors. To perform the estimates, the smart sensors associate the use of Machine Learning techniques with electric motor modeling. These techniques allow that predictions of load and energy consumption are made with an adequate level of accuracy when compared to traditional techniques, such as dynamometer bench and energy analyzers. To validate the accuracy of the proposed technique, the 6 Sigma methodology was used to compare the energy consumption estimates by the IoT sensor with consumption readings performed by reference equipment as a commercial energy analyzer. The results of the comparison showed that IoT smart sensors are capable of estimating motor load and energy consumption within an average error of 10%. This margin is acceptable for most applications, considering the difference in cost involved in the two solutions and the ease of installation of the smart sensor. Thus, this paper demonstrates that the wireless IoT smart sensors are a promising tool for estimating load and energy consumption of electric motors. These estimates can contribute to reduce energy consumption and greenhouse gases emissions, positively impacting sustainability.

ABSTRACT. The method of determining efficiency by segregating motor losses is the preferred method adopted by most efficiency regulation programs in the world, but because the standards adopted are different, there are some differences in the methodologies used to calculate these losses and consequently the motor's efficiency. There is a movement among standardization bodies to harmonize test methods in order to achieve equivalent results between the methods adopted by the standards. The aim of this article is to analyze and compare the latest editions of the NBR, IEC, IEEE and CSA standards for determining the efficiency of three-phase induction motors using the loss segregation method, in order to verify their equivalence and harmonization. To do this, the power supply requirements, instrumentation requirements and test procedures adopted are checked and compared. The test procedures used for loss separation in each standard were compared: method 2-1-1B of IEC 20034-2-1(FDIS 2022), method B of IEEE 112:2017, method 2 of NBR 17094-3:2018 and the single method of CSA C390:2016. Finally, the results of the efficiency determination obtained in tests carried out on 10 motors with power between 0.75 kW and 750 kW (0.75 kW, 3.0 kW, 7.5 kW, 15 kW, 30 kW, 75 kW, 150 kW, 300kW, 400kW and 750kW) according to the procedures and methodology of each standard analyzed, in order to verify the variation in the efficiency of these motors when subjected to the methodologies of the different standards, in order to show the existence of equivalence of the results between them.

ABSTRACT. Technologies, Research, and Innovation (including case studies) Topic 1: Electric motors Topic 2: Emerging motor technologies

This paper presents a back-to-back facility and the testing procedures aiming to obtain the optimum control maps of the synchronous reluctance machine avoiding the energy-consuming test sessions typically carried out with a purely dissipative braking bench. The tested machines are 3kW synchronous reluctance machines designed for industrial applications. Maximum torque per ampere, maximum torque per voltage, maximum power factor, and maximum efficiency maps are detected. The results are compared to those of a purely dissipative bench.

ABSTRACT. This article introduces the performance of medium-sized induction motors (50kW-300kW) with die-casting large-sized copper rotors. Benefited by copper’s excellent conductivity, copper rotors can significantly reduce rotor losses and thus improve motor energy efficiency. However, the production process of copper rotors is complex and costly, resulting in the use of copper rotors mainly in the small power range (<50kW) and the large power range (>300kW). Copper rotors for the small power range are mainly produced by die casting, while copper rotors for the high power range are mainly produced by copper bar welding. This article compared the induction motor performance and cost analysis between copper and aluminum rotors. The results proved that economically producing large-sized rotors through die casting can significantly improve the performance of medium-sized induction motors while also being cost-effective.

ABSTRACT. Detecting upcoming machine outages as well as energy saving potentials combines two of the main use cases of companies’ digital transformation: predictive maintenance and energy optimization. By implementing sensor-based as well as sensor-less digital solutions for drive trains and machines, which are addressing both use cases in industrial environments, operators are not only achieving a fast return on invest but also ensure continuous transparency and improvement of their equipment, resources, and processes. Providing the flexibility to run the different software solutions either on premise or in the cloud enables a seamless integration into the different IT ecosystems and is an important aspect of IT/OT integration.

ABSTRACT. This paper compares traditional approach with VSD controlled motor applications like pumps and fans against digitalisation boosted VSD controlled applications. Traditional approach meaning in this case VSD parameter based optimisation. Some basic energy efficiency drive parameters are presented and energy saving potential estimated. These benefits are then compared to estimated benefits possible to generate using state of the art digitalisation tools and systems. These benefits are estimated based on university researcher interviews and key information technology suppliers offering. Digitalisation tools available are Internet of Things, cloud-based services, digital twins for planning and resource optimization, artificial intelligence and augmented reality.