Motor Efficiency for Industry and the Home Jim Kirkhoff Product - PowerPoint PPT Presentation

Motor Efficiency for Industry and the Home Jim Kirkhoff Product Manager – Joyal, A Division of AWE Inc

Joyal-Alliance Winding Equipment • Provide equipment to automatically assemble motors and generators

Overview • What is an electric motor? • How do electric motors work and what makes them efficient? • So what? – Where are motors used – What they cost to operate • Where can I make improvements? • What is the future for electric motors?

What is an Electric Motor? • An electric motor uses electricity to create a magnetic field • With magnetism – Likes repel (N repels N) – Opposites attract (N attracts S) • By forcing two different magnetic fields together, these forces will interact to cause rotation.

Basic DC Electric Motor A permanent magnet on the outside and the rotors magnet field is reversed by the commutator

AC Style Induction Motor Alternating current (AC) is passed through winding on the stator that “induce” a magnetic field in a die cast rotor.

What Makes a Motor Efficient? • Efficiency is the measure of how well the motor transfers electrical energy into mechanical energy. • Typical efficiency – 1Hp: 78% to 83% – 100Hp: 92% to 95%

What Improves Efficiency? • AC motors are typically more efficient than DC • Newer motors more efficient than older designs (better bearings, materials, manufacturing methods) • Variable speed drives improve efficiency (motor never stops running!) • More copper in the stator core!

So What? • Electric Motors Consume Approximately 60% of the Electricity Used in the Home and Industry • Home – Fans/blowers (box, ceiling, furnace) – Pumps (AC, refrigerator, freezer, sump etc…) • Industry – Blowers – Conveyors – Pumps, AC etc…

So What? • Breakdown of use for a “typical” house – Rate of $0.07 to $0.08 per kWh – Central AC – Gas central heat – Gas water heat – Gas stove/range • Electric motor devices can consume 19% to 70% of your monthly bill • Refrigerator, freezer and AC can be responsible for up to 70% of your monthly bill!!! – In the winter, as low as 15% for just the fridge and freezer.

Min Max Low High Appliance Watts kW/Mo kW/Mo $/Mo $/Mo Air Conditioner (Central) 2.5 Tons 3500 0.0 3000.0 0 225 Blender 300 1.0 2.0 0.8 0.15 Ceiling Fan (2 per home) 120 2.0 40.0 0.16 3 Clock 5 4.0 4.0 0.3 0.3 Clothes Dryer (Motor Only) 500 3.0 16.0 0.23 1.2 Clothes Dryer (Heating Unit) 5000 30.0 140.0 2.25 10.5 Clothes Washer, Automatic (With Non-Electric Water Heating) 500 3.0 16.0 0.23 1.2 Coffee Maker 900 4.0 27.0 0.3 2.03 Computer (Monitor & Printer) 200 5.0 32.0 0.38 2.4 Dehumidifier 350 42.0 252.0 3.15 18.9 Dishwasher (Motor) 1300 3.0 16.0 0.23 1.2 Dishwasher (Electric Heating) 1300 17.0 86.0 1.27 6.45 Drill 300 1.0 2.0 0.8 0.15 Fan (Portable) 115 2.0 6.0 0.15 0.45 Food Freezer (15 cu. ft.) 335 60.0 140.0 4.5 10.5

Min Max Low High Appliance Watts kW/Mo kW/Mo $/Mo $/Mo Furnace Fan Motor (Intermittent) 350 56.0 145.0 4.2 10.88 Twenty Lighting Single Lamp (60W) 1200 200.0 1400.0 0.16 18 Four Compact Fluorescent (60W Equiv) 72 12.0 14.4 0.08 3.6 Two Ceiling Fixture (3 bulbs) 180 4.0 70.0 30 5.26 Microwave Oven 1300 5.0 30.0 0.38 2.25 Refrigerator-Non Freezer Frost Free (17 cu. ft.) 500 56.0 90.0 4.2 6.75 Stereo 30 0.0 5.1 0.01 0.38 Television 180 5.0 35.0 0.38 2.63 Toaster 1150 1.0 4.0 0.08 0.3 Vacuum Cleaner (Portable) 800 2.0 5.0 0.15 0.38 Water Heater Typical Family of 4 3800 375.0 525.0 28.13 39.38 Total Consumption 24287 893.0 6102.5 82.52 373.24 Total Motor Appliances 8625 193.0 3482.0 15.95 261.16 % Cost Motor Appliances 36% 22% 57% 19% 70%

How to Improve Home Efficiency

How to Improve Home Efficiency • High Efficiency Refrigerators – Replacing old refrigerators • 1,000-kWh per year (pre 1980 model) • 500 kWh per year (18.5ft3 top-freezer model) • Yearly savings of $50.00 to $80.00 and that is conservative! – When comparing new units, a 100kWh difference can result in up to $75 to $100 savings over the life of the refrigerator (2004 DOE) – Other items to consider • Look for a unit with a freezer on the top or bottom • In-door icemakers/water dispensers reduce the need to open the door • Automatic defrost can increase power consumption by 40% • Above numbers for refrigerators – chest freezers will be about 25% to 50% more!!!

How to Improve Home Efficiency • Replace Old Central AC units – Look for Seasonal Energy Efficiency Ratio (SEER) • As of 2006, minimum SEER is 13. – Linear relationship. A unit with a SEER of 6 will have to run twice as long to cool the same space of a SEER 12 unit. – Possible environmental threat with old units leaking CFC’s. • Leaking refrigerant also reduces efficiency and increases your costs!

Side Note - SEER and Regulations • According to American Council for an Energy-Efficient Economy, SEER 13 units will reduce energy use over the old SEER 10 standard by 23%. • Reduce the peak demand for electric power by 41,500 Megawatts by 2020 (equivalent to 138 typical new power plants of 300 MW each) • Save consumers approximately $5 billion over the 2006-2030 period. • Reduce smog forming nitrous oxides (NOx) emissions by up to 85,000 metric tons • Cuts greenhouse gas emissions by up to 33 million metric tons.

How to Improve Home Efficiency • Lower temperature in the winter (wear a sweater) and higher temperature in the summer – no duh!!! • Run washing machine and cloths at night (typically, cost per KwHr is $0.01 less at night) • Consider high efficiency products when replacement time comes

How to Improve Home Efficiency • Federal Legislation – NEVER rely on the Government. • SEER 13 legislation started by the Clinton Administration and was hung up by the courts and Congress until 2004! • What do YOU Have??? – At least look into your appliances. – How old are they and what is their efficiency rating? • Keep it Clean! – Clean filters and do yearly maintenance. • Awareness – Word of Mouth!!! Talk to friends about the long term cost benefits if they are shopping for an appliance.

Crunch Your Numbers • http://www.energystar.gov/ • Includes questionnaire to help you calculate energy savings of new high efficiency units over older unit • Takes into account initial investment and maintenance costs • http://www.aceee.org/press/Tax_incentive05.pdf

Summary • Motors Are Everywhere!!! • Motors Like Electricity and the Utility Companies Like Old Motors • Be Aware and Educate – Find out what is in your homes and ask your friends what they have. – “Dude, that is a SEER 6 unit. You are soooooo 1985!” • More to Cost Than the Initial Purchase Price • Replacement is Not the Final Answer – Old fridges, freezers and AC’s should be disposed of properly.

Special Thanks • Frank Cicela – Indiana Energy Conference • John and Anita Easton • Larry Pund