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‘Groundbreaking’ HV motors make a Hannover debut

06 April, 2014

At this week’s Hannover Fair, ABB has launched a new generation of “groundbreaking” high-voltage, rib-cooled motors that combine compact dimensions, high power densities, high reliability and easy maintenance.

ABB says that the motors, which have a new frame design, will set a new benchmark for rib-cooled machines, offering more power from the same frame size, and more power per kilogram. The motors’ running temperature is said to be more “balanced”, resulting in longer intervals between servicing.

“I like to think that our motor has not only more kilowatts, but also more know-how per kilogram than any high-voltage, rib-cooled motor before,” says Thomas Ek, ABB product manager for HV motors. “This has been a major engineering effort where we have thought through the entire lifecycle of the motor, and every detail of it.”

Cooling has been improved, both inside and outside the motor. “We used cooling fluid dynamics to study airflow and investigate different cooling mechanisms,” explains Karita Forss, another ABB product manager for HV induction motors. “There is not a single detail we haven’t optimised.”

The cooling surface area has been maximized and the shape, size and placement of the cooling ribs have been optimised. When optimising the structure, the designers took into account possible additional devices mounted outside the frame. The external cooling airflow is always free along the motor, no matter what devices have been added.

The operating temperature inside the motor is said to be well-balanced between the two ends, extending bearing lives and lubrication intervals. The coil design has also been improved to increase the motor’s power density. ABB developed new coil-forming tools to ensure the optimum use of active material.

ABB says that its rib-cooled HV motors will set a new benchmark

The motors have a flexible, interchangeable construction, said to provide new levels of installation freedom. Any external components can be mounted in the ideal position. For example, the main and auxiliary terminal boxes can be mounted on either side or either end of the motor.

Finite element modelling was used to optimise material usage in the frame. This has resulted in details – such as wider feet and a smaller frame – that provide an rigid structure with minimal vibration. The result is said to be a reliable motor that is easy to install, maintain and operate.

The design allows easy access to all maintainable parts and permits rapid grease changes. The coil end and bearings can be checked with an endoscope without needing to remove the end shields. Condition-monitoring devices can be mounted on pre-designed fixing points.




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