WORLD'S LARGEST 3-PHASE MOTOR THAT IS DRIVEN BY SINGLE-PHASE POWER
The revolutionary motor system shown here uses a PhaseAble® circuit that connects a low-cost three-phase motor to a Single-Phase supply to make a high-performance single-phase motor system. The patented Smith PhaseAble® Enabler® has a single-phase 2-pole circuit breaker, line contactor, start contactor, start capacitor bank, and run capacitor bank. This injects currents into the motor windings so that the motor has the same full-load high efficiency from a single-phase supply that it would have on a 3-phase supply.
Motors as large as 150 horsepower (HP) with Smith PhaseAble® controls are more efficient than the alternatives: static and rotary-phase converters, and diesel engines. The Smith systems are more economical and eliminate the high cost of extending a three-phase line. Applied to air conditioners, these new motors can both reduce the electricity bills, and benefit the power companies by providing a leading power-factor load to compensate for the poor lagging power-factor load of all other motors.
HIGHEST TORQUE-TO-CURRENT RATIO
The starting current for the 40-HP motor was less than the full-load current. Many motors with PhaseAble® controls between 0.3 HP and 40 HP (0.2KW and 30KW) have been tested. Full-load power-factor is near unity for small motors and is leading for large motors. Starting currents are low and are unity power-factor.
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The engineering design and research report on High-Efficiency Single-Phase Air Conditioners for the California Energy Commission was completed by Dr. Otto Smith. The use of an Enabler will increase efficiency by ten percent and save the consumer ten percent of his electricity cost for his air conditioner. This 46-page report is available on request from Dr. Smith. The report is also available at the URL: http//eisg.sdsu.edu/Approved-FARs.htm
Using three-phase motor-compressor designs now available, with Smith PhaseAble® controls, more efficient air-conditioner, freezer, refrigerator and air compressor motors can be created.
The US agriculture market is estimated to be over one hundred million dollars per year in new sales of these Smith motor systems for the symmetrically-wound motors. A substantial manufacturing facility assembling contactors and capacitors will be needed. All components are readily available at low cost from several different suppliers.
We can save billions of dollars in electricity costs, benefiting both the house holder and the power company, which will not need to import as much oil.
The need for these Smith high-efficiency motor systems in other countries is enormous. China and India have limited energy resources. Australia and Brazil can afford low efficiency, but also recognize the benefits of high efficiency. Each of these countries manufactures all of the components for the controls and the motors. They would not need to import anything except know-how and intellectual property.
Here in the USA our southern and western electric power companies are strained on summer afternoons by air-conditioning loads, much of which originates in small single-phase inefficient units. New air conditioners using 3-winding motors and Smith PhaseAble® controls can increase the EER by 8 to 10 percent, reducing the customer electricity bill by a similar amount, and reducing the critical loads on the power companies. The southern and western power companies could subsidize these new high-efficiency high-EER air conditioners which use 3-winding motors and Smith PhaseAble® controls. The power companies could initiate effective rebate programs. Energy savings can be a billion dollars in one decade.
Dr. Smith is willing to cooperate with anyone who plans a demonstration of a 1-ton to 5-ton air conditioner using this new method.
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PHASE-ABLE® ; ENABLER CONNECTING 100-HP 3-PHASE MOTOR TO 460-VOLTS SINGLE-PHASE SUPPLY.
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Dr. Smith's 40-HP 4-pole 460-volt delta motor draws 74.6 amperes from single phase 480 volts at 42.8 HP with 95.6% leading power-factor. The starting current is unity power-factor and less than full-load current. Efficiency is 94%.
This revolutionary circuit changes a low-cost three-phase motor into a high-performance single-phase motor. The patented Smith PhaseAble® control has a single-phase 2-pole circuit breaker, start contactor, run contactor, start capacitor bank, and run capacitor bank. The PhaseAble® control injects currents into the motor windings so that the motor has the same full-load high efficiency from a single-phase supply that it would have on a 3-phase supply.
Using a Smith PhaseAble® controller, any 3-phase motor less than 175 HP is enabled to run from a single-phase supply with the same full-load efficiency that it would have on a three-phase supply, and with reduced starting current.
Every new product needing a single-phase motor can use instead a 3-phase motor with a Smith PhaseAble® control, with lower electricity bills and lower line currents because of higher efficiency and improved line power-factor.
There are no power electronic devices in the Smith PhaseAble® controls. During normal operation supplying a shaft load, there are no current spikes or switching operation as in Adjustable Speed Drive (ASD). Consequently the current and voltage harmonics are very low. In many cases, the Smith PhaseAble® capacitors "short out" the power company voltage harmonics created by neighboring electronic loads, so that the power quality when the Smith motor is running is superior to the power quality when the motor is turned off.
During starting this is a unity-power-factor motor, which is a minimum-current motor, yielding maximum torque per unit of line current. In performance, this motor acts like a resistance load in parallel with a power-factor-compensation capacitor bank. This low-cost 3-phase motor driven by a Single-Phase power supply itself can also be a phase converter. With the PhaseAble® circuit, this is a rotary-phase converter (three-phase converter) which can supply several other three-phase motors.
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The "Phase-Able®" circuits create "Free-Wheeling Magnetic Flux" in the motor air gaps. This flux is rotating synchronously smoothly with almost constant magnitude. The interaction between this magnetic flux and the currents injected into the windings produces the desired shaft torque. The performance with a single-phase supply is superior to the performance on a three-phase supply. Three-phase unbalanced supply voltages on the motor terminals can distort the flux distributions so that they are not "free-wheeling", and the shaft torques can be correspondingly reduced.
The "Enabler®" supplies two motor terminals directly from the single-phase power line. At rated speed, the geometry of the windings creates a rotating magnetic flux field in the air-gap. This flux field generates a voltage which appears on the third motor terminal. This voltage appears even when the third terminal is open. When there is a current into or out of this third terminal, the voltage changes slightly.
The run-capacitor circuit connected to this third terminal injects a current which is proportional to the capacitance and an almost constant voltage difference. This is almost a constant current. When this injected current is the full-load current at the correct full-load phasor angle, then when the shaft torque is the rated value, all of the windings carry the same current magnitudes at the same power-factors. All of the currents and all of the terminal voltages are automatically "balanced", because the winding impedance's are also "balanced".
Three-phase motors are sensitive to unbalanced terminal voltages and insensitive to unbalanced winding currents. With "Free-Wheeling Flux", the sensitivity to terminal voltages is removed.
Automatically, for large motors, the "Enabler®" circuits change the single-phase line power-factor to approximately 87% leading, which is a current phasor of 30 degrees leading.
For very small motors, the PhaseAble® circuit makes the line power factor near unity.
This Enabler® is NOT a phase converter. The Enabler® specifies an injected winding current, not a terminal voltage. There is negligible negative-phase-sequence air-gap flux.
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A high-inertia band-saw in a Wooden-Boat manufacturing facility. The three-phase motor has 9 leads available. The W7, W8 AND W9 leads are a Star (Wye) half-power half-motor winding in parallel with a Semi-Hex(TM) half-power half-motor winding across 230-volts single-phase. The accelerating capacitors are energized for six seconds and the shaft continues to accelerate on the run capacitors for an additional four seconds to bring the band-saw up to full speed in ten seconds. The multi-pole motor full speed is 430 rpm. Nine motor wires are used by the Enabler®;. Full load torque is excellent.
Franklin submersible 3-phase 3-erminal motor at the bottom of a well drives submersible Jacuzzi pump. At the well head, motor winding terminal W1 and W2 are connected to a 230-volt single-phase 60-hertz supply. The Enabler® circuit has one run capacitor C3 connected between W1 and W3 to inject a 50% power-factor current component into W3. An autotransformer connected between W2 and W3 has a center tap CT. A second run capacitor C2 is connected between W1 and CT. The autotransformer connection at W3 injects a second current component of 87% power-factor into the same winding at W3. Capacitance values for C2 and C3 are chosen for full-load equal currents in the three motor leads. Performance on single-phase matches the catalog and nameplate performance values for balanced three-phase 230 volts. Power-line current is superior because it is leading power-factor instead of the lagging power factor inside the motor.
An air compressor delivers compressed atmospheric air into an 80-gallon tank at 175 psi (pounds per square inch). The three-phase motor has all twelve available and these are in a SemiHexTM winding configuration for 230 volts single-phase. The three-phase motor rated power is 7.5 HP. At 175 psi output, the motor is delevering 8.1 HP, which is a 1.08 service factor. The motor nameplate has a 1.15 service factor. The run capacitors were chosen for an optimum motor current balance of 19 amperes at 175 psi, with a single-phase line current of 38 amperes and a motor efficiency of 87.5%. The pulleys on the belt drive could be modified to change the shaft power at 175-psi which is the maximum power point. Reducing the compressor speed can reduce the cubic feet per minute and reduce the motor power. Our Enabler® design was for 8.1 HP.
A 10-HP three-phase Baldor motor drives a Cornell pump to irigate a poplar plantation. The motor is supplied from a 230-volt Idaho Power Company transformer. All twelve leads were brought out from the motor Wye windings and a SemiHexTM circuit configuration was used. The motor efficiency was 91%. Winding currents were balanced.
A 40-HP three-phase Baldor motor on 480 volts single phase drives a Cornell pump for a center-pivot sprinkler. The pump delivers 1,350 gallons per minute. (gpm). The motor shaft power is 43 HP output at 94% efficiency. The motor was Delta wound, and all twelve leads were brought out. The unbalance of the winding voltages was 0.07%. No power company can provide this excellent voltage balance.
Unlike a three-phase motor on a three-phase power supply, each of these systems has only ONE voltage applied and two injected currents. For all loads, the winding currents are each less than the service-factor current. No motor has excessive currents due to unbalanced voltages. In every case the three-phase motor performance on single-phase supply was superior to the performance on the three-phase supply. In every case, the PhaseAble® system is superior in almost every respect to the best single-phase system available.
A typical motor rated voltage is 460 volts. Our PhaseAble® Enabler® systems are designed for balanced winding currents at 460 volts, rated shaft power. The power company might provide a rated voltage of 480 volts, with a company specification that the voltage range is +/- 4.2 %. At -4.2% the voltage supplied would be approximately 460 volts.
At 480 volts supplied, the motor receives 104.2% voltage. The capacitor currents are each proportional to the applied voltage, so each current is 104.2% of the design current. All the winding voltages will be balanced at this higher value. At this new balance point, not only are each of the currents at 104.2% of the design amperes, but the air-gap flux is also near 104.2% of rated, and the shaft torque is near 108.6% of rated. The speed change is negligible. Our new balance point would be 108.6% of rated torque and rated power.
When the power company delivers +4.2% of their target of 480 volts, the motor receives 500 volts. At this new balance condition, the currents are all near 108.5%, the flux is near 108.5%(neglecting saturation), and the shaft torque at balance must be near 118% of nameplate torque. Consequently with a load torque approximately at constant speed, the motor will operate at 85% of the new balance condition. The motor windings not driven by capacitors will have much lower currents. The low-current windings will have low temperature losses due to copper losses, and the capacitor-driven windings will have higher temperature rises. These loss effects partially balance each other, so the full-load motor performance at 500 volts is near to the expected performance at 460 volts and the rated torque.
These PhaseAble® Enabler® systems are relatively insensitive to very large motor voltage changes, and are robust for the consumer. This is the opposite of the situation when the motor is connected to a three-phase voltage source. A 4% unbalance in the three-phase voltages produces a 2% efficiency loss. A 32oC average extra temperature rise of the motor, and a 56oC extra temperature rise in the hottest windings. This is a factor of 50 reduction in the life of the motor. A 40-year life motor is reduced to a 10-hour life, and immediate burn-out.
None of these excessive current problems exist in the PhaseAble® Enabler® systems. All rewound three-phase motors should use PhaseAble® Enabler® systems and not reconnect to the three-phase power supply.
See Reference 30. "Effects of Unbalanced Voltages on the performance of Polyphase Induction Motors", NEMA MG-1, 1993, Revision3, Section 14.35. See also Reference 31.
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One Smith invention is an external connection of the motor terminals so that there are two half motors in series. This allows capacitors to insert the full-load current at the correct phase angle into the motor windings so that the winding currents and voltages are balanced, and the single-phase full-load motor efficiency is equal to the 3-phase motor efficiency. The magnetic flux inside of the motor air-gap is sinusoidal and "free-wheeling". No attempt is made to constrain the terminal voltages in an arbitrary manner, as occurs from a "phase-converter". Additional Smith inventions are applicable to 3-terminal WYE and DELTA motors, also yielding full-load balanced winding currents and voltages and high efficiencies.
Any 3-phase motor can be enabled to be operated from single-phase with one of these PhaseAble® controllers. Most load-torque characteristics can be achieved with minimum line current. Power companies have constraints on the maximum starting current permitted on a distribution line. Almost all Smith PhaseAble® controls can satisfy these starting current constraints. Starting currents can be specified as less than full-load current, or less than two times full-load current.
All Smith systems on single-phase are superior to the same motor on 3-phase, because the single-phase line current is leading power-factor, instead of lagging power-factor, and this improves the power quality and increases the power company efficiency.
There are different winding connections available for different applications:
Three-Phase Power Supply
These same methods can be applied to all conventional 3-phase motors supplied by 3-phase power, yielding high starting torque with low starting current, and much improved line power factor.
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For a 75-HP three-phase Wye-wound motor, the retail costs of the 460-volt Enabler® components plus the license fee cost, excluding labor and excluding all of the usual controls for the motor, sum to $200.00 plus ($45.00 times the HP), which is $3,575.00.
For a 10-HP three-phase Wye-wound motor, the retail costs of the 460-volt Enabler® components plus the license fee cost, excluding labor and excluding all of the usual controls for the motor, sum to $200.00 plus ($48.00 times the HP), which is $680.00. The smaller size is more expensive per horsepower.
For the same 10-HP three-phase Wye-wound motor, operating from 230-volt supply, the retail costs of the components plus the license fee cost, excluding labor and excluding all of the usual controls for the motor, sum to $200.00 plus ($70.00 times the HP), which is $900.00. The lower voltage supply requires much larger capacitor microfarads, and this increases the costs significantly, by approximately half again as much.
For a 230-volt system, a 12-lead Wye-wound motor is preferable. If only 9 leads are available, a motor rewinding shop should bring out W10, W11, and W12 leads.
When the motor is submersible with only 3 leads available, a 115/115-volt autotransformer is used, each winding rated approximately 25% of the motor kVA, depending upon the power-factor.
Low-voltage Delta windings also require a transformer.
High-voltage Delta windings should have all twelve leads brought out, similar to Wye-start Delta-run specifications'
Labor cost is variable, which depends upon location and the availability of competent electricians. For small systems, Labor cost can be double the component cost. For 75-HP labor cost can be less than the component cost.
For estimation purposes, the Enabler® plus Motor costs are approximately $400.00 per horsepower. Larger motors and higher voltages have lower costs per horsepower. A factory production run can reduce these costs to one third.
The total installed cost for this 100-HP PhaseAble® Enabler and Motor is approximately 220 dollars per horsepower, depending upon the locality. This is a significant saving over extending a three-phase line, or the cost of a rotary phase converter.
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SMITH HISTORY: Dr. Smith invented these methods for a micro-hydro single-phase induction generator about 18 years ago. He has built and tested many motors between 0.3 HP and 40 HP. He has demonstrated these motors at many Universities and laboratories. In response to a request, he will supply the names of the professors at the Universities where he had presented seminars and demonstrations.
In addition to these high-efficiency motor systems, Dr. Smith invented the Hewlett-Packard sine-function generators, and multi-megawatt variable-speed constant-frequency wound-rotor generators with shaft speeds from 50% below synchronism up to 50% above synchronism, using slip-excitation control and slip-power recovery for maximum efficiency. He invented the Posicast-controls for stepping motors, and feedback control systems for piping systems, canals, and dead-time delay processes.
Dr. Smith received his Ph.D. from Stanford in 1941. He is now Professor Emeritus in Electrical Engineering and Computer Sciences at the University of California in Berkeley. He has taught and conducted research on electrical machines, automatic control, computer optimization, solar power, wind turbines, and power systems. He has 30 patents in these fields.
Dr. Smith has lived and taught in Australia, Brazil, Germany, Romania, Italy and The Netherlands. All of the countries in the world need to increase the efficiency of their use of energy to reduce reliance on fossil fuel. The Smith motor systems make large increases in the efficiency of the small fractional horsepower motors.
Dr. Smith is willing to cooperate with anyone who plans a demonstration of a 1-ton to 5-ton air conditioner using this new method.
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Dr. Smith will license controls manufacturers to make and sell his PhaseAble® controlled 3-phase motors for agriculture, water and sewage pumping, augers, blowers, fans, air compressors, freezers, refrigerators, air conditioners, heatpumps, and tools. China, India, Brazil, Australia, and Mexico are potential markets.
Each of these countries manufactures all of the components used in Smith PhaseAble® controls and motors. Each can internally supply its own needs.
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For the reader who wishes additional references:
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For the reader who wishes additional references:
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PHONE (510)525-9126 FAX. (510)540-1057 ojmsmith@earthlink.net SNAIL MAIL Otto J.M. Smith 612 Euclid Avenue Berkeley, CA 94708-1332
EMAIL
ojmsmith@earthlink.net
The URL for High-Efficiency Single-Phase Air Conditioners is
http://eisg.sdsu.edu/Approved-FARs.htm
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