Thor power, technical summary, 1210
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The document describes Thor Power Corporation's Trezium power system. The system consists of a patented microelectronic power converter and permanent magnet power unit called Grismir. The power converter uses vector control for high efficiency and torque control. Grismir is a brushless, slotless, sensorless AC motor that can operate as a motor, generator, or alternator with over 90% efficiency. The Trezium system provides benefits like universality, high efficiency, compact size, and wide input voltage range.
Thor power, technical summary, 1210
- 1. THE COMPANY PRODUCTS Thor Power ® Corporation has developed a unique Power System called Trezium®. The Trezium® System consists of a patent-pending power unit and a patented electronic power converter. Its patented microelectronic power converter, which behaves similar to a controller and permanent magnet power unit, can be a motor, generator or alternator. They are perfectly matched for maximum efficiency, power and control. Both the microelectronic power and control elements are mounted on one printed circuit board (“PCB”) for maximum reliability, durability, and safety, as well as for lower production costs. The controller utilizes vector control, which contributes to the system’s exceptional torque control and high efficiency. It is an ac → dc → ac power converter. The Company can modify it into a dc → ac system for use in DC facilities.) The power unit is an alternating current (AC), synchronous, sine wave, permanent magnet device that is also brushless, slotless and sensorless. It provides the benefits of variable speed, forward/reverse, high power to weight ratio, and unparalleled efficiency. It is classified as a brushless AC motor and shares the positive characteristics of a brushless DC (“BLDC”) motors without having some of the disadvantages such as overload, which BLDC motors can do when an amount of torque beyond the rated torque is applied; or ratchet, which happens with BLDC motors when they run at variable speed at lower speed RPMs. Using standard world voltages (100 to 267 volts, 50/60hertz (Hz)), the Trezium® System can generate up to 400 volts. The power unit and power converter, together the Trezium® System, have proven efficiency levels of 90% and 95%, respectively, and a combined efficiency of 84% at load factors from 50% to 100%. This performance level is substantially greater than the less than 60% efficiency level typical of motors at the 5kW and under power level. A summary of the benefits of the Trezium® System are below (a full technical specifications sheet is found in appendix I): Universality, it can be used worldwide. The Trezium® System plugs into any outlet in the world with a simple plug change, operating at 50/60 Hz or, in aerospace, applications at 400Hz. 10% to 15% higher efficiency than brush type universal motors of comparable power Less than half the size of machines with comparable power Less than half the weight of machines with comparable power Wide input voltage range 110Vac to 264Vac Power Factor better than .995 for loads 50% to 100% at all voltages Power Factor better than .997 for all loads at 120Vac 1
- 2. Controller uses “Field Orientation Control” also known as “Vector Control”, the benefits of which include the ability to operate in hotter, duster, more humid environments when compared to either the “Hall Effect” or “Back-emf” methods of control. The Power Unit (“Grismir®”) Grismir® is an alternating current, synchronous, sinewave, permanent magnet device that is also brushless, slotless and sensorless. The power unit can be used as a motor, generator or alternator from the end of the production line. Since it utilizes alternating rather than direct current, it can be classified as a BLAC motor. However, it can also be classified as a permanent magnet AC motor (“PMAC”) or a permanent magnet sinusoidal motor (“PMSM”). In other words, the motor defies classification using current motor nomenclature, because it combines several advantages into a single unit. Being brushless, Grismir® requires no point of electrical or mechanical contact between the source voltage and the rotating component of the device, which means that it is maintenance free. In addition to reduced maintenance and its related costs, brushless motors offer higher efficiency and reliability, reduced noise, longer lifetime and overall reduction of electromagnetic interference. The Grismir® power unit achieves all of this and more, as the unit can be used, as is, as a motor, electric generator, or an alternator Grismir® is also slotless, which means that it has no series of teeth with slots between the teeth where the stator (the stationary part of the motor) windings are inserted. Slotless motors are significantly superior to slotted motors. They have an electrically more efficient design, weigh about half that of the slotted motor, smooth rotation and eliminate cogging, a better power response, and more internal space for magnets and wire. So, not only do these features improve Grismir® as a motor, but also enhance performance as an electric generator or alternator. As an example, the Grismir® unit as a replacement alternator produces 400AMP’s weighing approximately 30lbs, in the same volume package as the current 100AMP alternator weighing approximately 27lbs. Figure 1: Power unit, Grismir® 2
- 3. The Power Converter (“Trezium®”) The Company’s power converter represents the state-of-the-art in power electronics and a substantial improvement over existing motor controllers. It incorporates a fifth-generation IGBT (Insulated-gate Bipolar Transistor) Intelligent Power Module, and uses novel silicon bonding/packaging thermal management techniques for miniaturization. In addition, the Power Converter uses sensorless, space vector control rather Hall Effect sensors that other brushless controllers use to detect the position of the rotor and feed that information to the motor controller. In using space vector control, the controllability of the motor torque closely matches the load requirement and is less affected by background-electromotive force (“EMF”) noise. (Background-EMF is a voltage that occurs in electric motors where there is relative motion between the armature of the motor and the external magnetic field.) The motor has less vibration, less torque ripple and better efficiency. Eliminating the Hall Effect sensors also reduce component, assembly costs and provides better operating profiles in humid and dusty environments. Figure 2: The Power Converter, Trezium® Figure 2, shows how all the electronics are placed on a single printed circuit board, reducing the size of the controller. The electronics are separated and divided into two parts. On the left side, there is input power control circuitry connected by a DC link to control circuitry; on the right side is the power output circuitry. AC electric power comes into the controller, is converted into DC power, and then converted into AC mechanical energy to power the motor. Using a standard 110/240 voltage, the system can generate up to 400 volts. The motor runs at 360 volts. The power converter has a power rating of up to 5kW and works with all major international voltages, eliminating the need for having different control electronics and motors for the global market. Finally, the power converter is completely enclosed which means that no fan is required. So, not only is the system quieter (no fan) for environments like operating theaters, but it can also be completely sealed for use in explosive environments and desert conditions. The Company’s power converter can be used with other motors to improve the performance of those motors. 3
- 4. TREZIUM® TECHNICAL SHEET Unit Specification Trezium® System Stand-alone, direct-drive 0.3 to 25+kW Controller and engine characteristics Vector/BLAC Nominal power (kW) 2.0kW Peak power (kW) 9.9 kW Base speed (rpm) 30,000 Max speed (rpm) 30,000 Par nominal Nxm 0.6Nm Peak par (20 seg.) Nxm 400% Motor Efficiency (15% - 100% of max speed) 90% Inverter Efficiency % 95% Maximum current of the inverter (A) 600V/50AMP Motor Weight Kg 1.5kg Volume (l3) 1.1l³ Inverter weight (Kg) 5kg Inverter volume (l) 6.1l³ w/o h.sink 8.4l³ w. devl h.sink T C º refrigerant Inverter No fan T C º refrigerant inlet Machine Fan with motor Firmware- Vector control Life 5000 hr Life, type of electrical protection and EMI's, cooling type, harsh enviro; ;cable; yes soft-start Source: Thor Power Corporation Below there are a series of graphs which show Trezium® System parameters results taken under the following conditions: All measurements taken at room temperature. Line voltage is nominal value, actual line voltage varied with load. Line frequency was 60Hz. Electrical power measured with Yokogawa WT1600. Mechanical power measured with Magtrol WB43. 4
- 5. Figure 3: Inverter Efficiency vs. Torque at 120Vac Input for Motor Speeds 5k-30krpm Figure 4: Inverter Efficiency vs. Output Power at 120Vac Input for Motor Speeds 5k-30krpm 5
- 6. Figure 5 System Efficiency vs. Torque at 120Vac Input for Motor Speeds 5k-30krpm Figure 6 Inverter Power Factor vs. Output Power at 120Vac Input 6
- 7. Figure 7 Inverter Efficiency vs. Torque at 240Vac. Input for Motor Speeds 5k-30krpm Figure 8 Inverter Efficiency vs. Output at 240Vac. Input for Motor Speeds 5k-30krpm 7
- 8. Figure 9 System Efficiency vs. Torque at 240Vac Input for Motor Speeds 5k-30krpm Figure 10 Inverter Power Factor vs. Output Power at 240Vac Input 8
- 9. Figure 11 Motor Efficiency vs. Torque at Motor Speeds 5k-30krpm 9
- 10. GRISMIR GENERATOR TECHNICAL SHEET Generator Specification Grismir® Generator Catalogue of engines (Stand-alone, direct-drive) 0.3 to 25+kW Direct-drive, double-fed, variable frequency Nominal power (kW) 2.0kW Peak Power (20 sec.) kW 3.5kW Speed RPM base 250 to 3100 Maximum speed RPM 30,000 Rated torque Nm 0.6Nm Peak torque (20 sec.) Nm 400% Machine efficiency (15% - 100% speed. Max) 90% Weight (Kg) 3.3lbs/ (1.5kg) Volume in liters 1.1l³ T C º refrigerant inlet Machine No fan Life, type of electrical protection and EMI's, cooling type, soft- 5000 hr harsh start environment; cable; yes Figure 12: Volts vs. Speed of the generator 10