Cross-border technological innovation, the world's first Vplus-Pin flat wire low-voltage industrial motor released!

Zou Deming, Director of Inovance Technology Drive Motor SPDT

In the opening video, the development process of motor technology is shown, and the question is also raised, that is, what kind of motor do we need today, 200 years later? Today we are trying to give Inovance's answer.

From the signing of the Paris Agreement in 2016 to President Xi's "3060" dual-carbon strategy in 2020, carbon reduction and emission reduction have become a common goal.

We can look at a set of data, in 2023, China's industrial electricity consumption accounted for 65.8% of the total social electricity consumption, of which 75% came from industrial motors, that is to say, the motor is the largest power consumption of a single type of transmission equipment.

We have made a simple calculation that if these motors are increased by 3%, then 182.1 billion kilowatt-hours of electricity will be saved every year, which is equivalent to the annual power generation of the Three Gorges Dam. Therefore, the popularization of high-efficiency motors must be the trend of the future industry.

When it comes to high-efficiency motors, another topic has to be mentioned, and that is the motor volume. If the existing technology is used to improve the energy efficiency of the motor, the volume of the motor will be increased to a greater or lesser extent, so that many scenarios where the motor is used will have problems, such as the overall structure of the equipment factory needs to be adjusted, the load-bearing of the motor installation needs to be redesigned, and the transformation of the end user is affected by the change of the original equipment structure, which ultimately directly affects the return on investment cycle.

In addition, Inovance also found a problem, that is, the reasonable selection of the motor and transmission structure. Motor technology has been developed for nearly 200 years, and many technical routes have evolved, but the development of the transmission structure with the motor is actually relatively rough, which also means that with the progress of motor technology, the innovation of the entire transmission chain has a relatively large excavation space.

To give an example of Inovance in the textile industry a few years ago, the customer's original plan was:Asynchronous machineBelt connection, Inovance Electric uses frameless permanent magnet motor to achieve direct drive, directly remove the efficiency loss of the belt, increase energy efficiency by 25%, achieve maintenance-free, and shorten the installation time from two hours to 10 minutes, at present, the program has been fully promoted in the weaving industry, and the proportion of high-efficiency motors in the industry has also increased year by year.

The content of the above talk is mainly two conclusions, one is that the popularization of high-efficiency motors must be the trend of future industrial development, and the other is that with the development of motor technology, there is still a lot of room for exploration in the transmission chain.

Based on the above conclusions, today's protagonist is the MV33 series Vplus-Pin flat wire industrial motor. This is a motor that uses flat wire technology across borders, and it is also the first permanent magnet synchronous motor that Inovance applies flat wire hairpin technology to the low-voltage industry.

The range of this release is mainly four speeds: 750rpm/1000rpm/1500rpm/3000rpm. Among them, the 750rpm power is 18.5~90kW, the 1000rpm power range is 30~132kW, the 1500rpm power range is 37~200kW, the 3000rpm power range is 55~315kW, and the 180~250 frame is four. IE5 energy efficiency for all series.

What are the features of this product?

First of all, it is the smallest IE5 energy-efficient low-voltage industrial motor available. Let's make a comparison, taking the IE3 energy-efficient asynchronous motor that is currently the most circulating on the market as an example, if the asynchronous machine is used to achieve IE5, the volume will increase by 10%~15%. If the permanent magnet motor design is adopted, the volume can be flat or reduced by 10%, but the MV33 with flat wire design is 25%~40% smaller than the IE3 energy-efficient asynchronous machine!

What are the benefits of volume reduction? Here are a few examples.

First of all, the first scene. A typical application scenario of industrial motor is to connect the reducer through the coupling, the motor installation position is usually at the tail of the equipment, if the traditional IE3 asynchronous motor is replaced with MV33, taking the commonly used 160kW, 1500 rpm motor as an example, the length of the whole equipment will be reduced by 385mm, which is significantly shorter. Can it be shorter on top of that? OK. Because the flat wire motor in addition to the axial size of the smaller radial size also becomes smaller, the motor can be turned to the reverse side of the installation, so that the length of the whole equipment is shortened by 1700mm compared with the original structure, the original motor installation part is all omitted, the installation is flexible and convenient, and the space utilization rate of the end user is also greatly improved, these savings are real money value to customers.

Let's look at another scene. The motor is usually connected to the load by a pulley, and as can be seen from the figure, there is no way to achieve a direct connection due to the large size of the motor. However, if you use an MV33 motor, you can put the motor on it and connect it directly to the load through the coupling, eliminating the need for belt drive. Through calculation, the high-efficiency motor itself can bring 1.7%~3.1% energy efficiency improvement, and the energy efficiency of canceling belt drive will also be increased by 3%~8%, and the overall efficiency of MV33 motor can be improved by 4.7%~11.1%. More than that, if the structure of the load end allows, the frameless structure can be used to further eliminate the coupling, and the stator and rotor of the motor can be directly installed on the load end, eliminating the bearing of the motor, and the overall transmission structure can be further optimized.

是不是所有的皮带连接都是可以用这种方案？并不是。要根据实际设备的传动结构，结合电机本身的性能通过专业分析来选择最适用的传动结构。汇川的专业电机工程师团队每天都在研究对传动结构的创新，我们扁线电机小体积等特点为我们工程师团队在传动创新上提供了更多的可能。

再看MV33系列电机的另外一个特点，高能效。

MV33全系高能效设计，满足IE5和永磁电机国标一级能效，由于IE5和永磁国标一级能效在有些功率电机上效率值有所不同，MV33电机在设计时取两项标准同规格下的最高能效数值。另外，MV33支持IE6能效的拓展，相较IE5电机，IE6电机损耗降低20%。

It is worth mentioning that the energy efficiency level of the motor is nominal according to the efficiency value of the motor operating at the rated point, and the high efficiency area of the general motor is near the rated point. However, when the customer actually uses it, most of the motors are not running at the rated point for a long time, which means that the actual efficiency of many motors is lower than the nominal value when they are used. In response to this scenario, Inovance has proposed the concept of double "90", and the MV33 motor can achieve an efficiency higher than 90% in 90% of the working area. To give a practical case, in the application scenario of variable speed constant torque, compared with the IE5 permanent magnet motor designed by ordinary round wire, the overall energy saving is about 2%, and the annual energy saving can be saved by 3~6,000 yuan after conversion. In the same scenario, compared with IE3's asynchronous machine, the MV33 will have greater energy efficiency benefits.

Whether it's the world's smallest IE5 energy-efficient low-voltage industrial motor or the scalable IE6 ultra-high efficiency, the MV33 has both features thanks to flat wire technology.

Compared with traditional round wire motors, flat wire technology motors are more conducive to the improvement of the slot filling rate, that is, more copper wires can be filled with the same space in the stator slot. Compared with traditional round wires, the slot filling rate of flat wire motors can be increased by more than 20%, so that the motor can generate a stronger magnetic field. In addition, compared with the round wire winding, the end size of the flat wire motor is reduced by 30%~50%, so that the MV33 can achieve the ideal small size.

Some people may wonder, how reliable is the motor made so small? There are three main factors that affect the reliability of motors: bearings, insulation systems, and demagnetization of permanent magnet motors.

How does MV33 do it?

First of all, the bearing, although the MV33 motor is about 1/3 smaller than the traditional IE3 motor, but the bearing selection can still meet the same bearing model as the same power industrial motor in the market, and it is an international first-line brand, in addition, in order to prevent the bearing corrosion problem caused by the shaft current, 110kW and above models are equipped with anti-erosion design as standard.

Looking at the insulation system, the general low-voltage industrial motor adopts a B-class temperature rise design, and the temperature of the whole machine does not exceed 130 degrees. MV33 not only meets the temperature rise of class B, but also has a class H insulation design, with a temperature resistance of up to 180 degrees, and uses a flat wire and an insulation system higher than class C, with a temperature resistance of more than 200 degrees.

There is also the problem of demagnetization, in view of the two "culprits" of demagnetization, high temperature and high current, the MV33 rotor adopts the design of low temperature rise, the permanent magnet has been specially treated, and the standard two temperature sensors are used with the inverter, which can receive alarm information in the case of abnormal temperature to prevent the demagnetization problem caused by long-term overload. What's more, Inovance has 20 years of experience in the development of permanent magnet motors, with more than 20 million permanent magnet motor shipments and rich experience in anti-demagnetization design. Under normal operating conditions, the MV33 will not demagnetize.

MV33还有其它重要特点。

首先，MV33做了模块化设计，可灵活适配各种工业场景。如接线盒做了强弱电分离选配，可以避免干扰问题，同时支持加装强制风冷，加装编码器，支持轴承类型的选配，支持防潮加热带的选配等等，客户可以结合需求选择最优配件。

MV33还针对极端场景做了设计。如针对高湿和高粉尘的IP66高防护设计，针对高腐蚀场景的C5等级防腐设计，针对高温和高海拔场景的超低温的设计等，可适用于全天候多工业场景。

目前，MV33电机已经获得UL、EAC、SA、CE、UKCA、CQC等多个国家和地区的认证，满足客户的出海需求。