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Development of synchronous compact drives for operating in high demanding conditions (high danger of explosion)

The main project effort is to develop synchronous compact drives. Final product should be the line of drives within the range of 20 to 315 kw. This will be developed by stavus a.S., Dutch company dac electric and slovak vonsch s.R.O.

Compact synchronous drive consists of synchronous alternating-current engine with permanent magnets from rare earth on the rotor and statical frequency converter - controlling the functioning of synchronous engine according to requests set for each operation of the drive. Comparing to asynchronous engines, synchronous engines require reading of the rotor position and actuating power circuit. Controlling circuit is always formed by frequency converter and safety automatics. The main advantage of synchronous engines is mostly the possibility of controllability. Higher controllability is caused by minimising of stray magnetic fluxes between rotor and stator of the engine. Very high efficiency of the device is reached within the lower inertia torque of the engine which allows significantly higher dynamic of whole drive. Thus means the device is usable in applications where regular asynchronous engine does not reach given requests (fast change of speed, frequency of cycles, etc.). increased efficiency of magnetic fluxes (transfer of energies between poles of rotor and stator) generally allows smaller size of the device. Smaller outer dimension means smaller stator (eventually rotor) sheet-metal stock (magnetic conductors) investment costs and requirements for space are reduced during application the device in concrete developments in various technologies. Big size and material demandingness is generally significant disadvantage for using electric motor comparing to hydraulic motors. Synchronous motors in non-explosive construction are absolute unique. None of manufacturers such as Siemens, or AEG does not offer such product, not even in the form of made-to-order production for customers. The situation is similar even in countries, where using of the device logically suggest itself to use. such as Russia, Ukraine, China. In those countries mining of minerals is the basic part of national economy and where requirements for using flameproof technologies are high. Intrinsically safe apparatus have characteristic construction. The base of the construction is "flameproof enclosure". Generally, this is robust (steel or cast iron) casing that is able to liberate the energy of experimental explosion without any of gasses infiltrating to surrounding space. This trial test is the basic requirement for obtaining a certification for any other devices of this type. Of course the construction of the casing increases requirements for its weight and outer size. Second problem of non-explosive conditions is maximal temperature of any surface allowed. This cannot exceed 150 degrees Celsius even in the case of an accident, destruction brake down, etc. Everything is solved by external water-cooling system at classic asynchronous motors. That means, cooling depends on external cooling water source connected. This cooling water cools down partly the rotor inductors (coils) and in case of frequency converter both main semiconductor parts of power circuit. External cooling system is significant disadvantage for any aggregate. It also causes a lot of various problems to electric motors. Synchronous motors are much more applicable for non-explosive constructions, especially because of its 97% efficiency, thus 10-12% higher than asynchronous. Requirements for cooling are naturally much lower. Partial topic is the question of using synchronous motor with its own internal cooling system. The main customers will be machine manufacturers that need safety drives to technologies operating in high explosive conditions. Those technologies are used mostly in chemical industry, petrochemical industry, deep underground mining, agriculture, etc. In this case the solver of the project continued in the 100 years tradition of classic electric motors manufacturer EM Brno (earlier called VUES). Most of its production is sold through Siemens company. It is clear (from the above description), which way the product development is going to go in future. Final output of the project should be product line of electric motors in the range of 20-315 KW. Part of electric motors would be practically manufactured and tested in real. It is assumed to test 3-4 motors in real and 3-4 motors up to the stadium of product documentation. Final version of the device should involve synchronous circuit most probably with the rotor set from permanent magnet with the content of rare earth. Next, it should involve integrated frequency converter with regulative programme system which will simultaneously ensure the protection against circuit overheating and also control the cooling system functions. Internal cooling system should be closed and if possible - autonomous. All of those parts closed in flameproof enclosure. Considering the fact, that there is no such product equivalent from other competitor companies, this solution offers phenomenal export options to both European, and other world markets (U.S.A., Canada, South America, Russia, UK).
Acronym: 
ELSYN
Project ID: 
6 769
Start date: 
01-01-2012
Project Duration: 
36months
Project costs: 
960 000.00€
Technological Area: 
Mining Technologies
Market Area: 
Mining (non-energy-related)

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