Elevator Drives

Past, Present and Future

As Presented at NAVTP Annual Forum Atlanta, Georgia May 3, 2007

Elevator Drives - Discussion

 History  Requirements  Motor and Control Types  Industry Trends  Future Drives

History

 236 BC First Passenger Lift,

Archimedes

 1853 Safe Elevator Demo,

Elisha Otis

 1857 First Safe Elevator

Installation, Cooper Union, NYC

 1861 Otis Elevator Patent

Otis Patent 1861

History

 1873 First Modern DC Motor  1874 J. W. Meaker Door Opener Patent  1880 First Electric Motor Controlled
Elevator Siemens / Sprague

 1882-1889 Tesla AC Induction Motor  1889 Otis Elevator Uses DC Motor

3-Phase Squirrel Cage Design

Otis DC Elevator Motor

Circa 1889

History

 1891 Ward Leonard Variable

Speed Control
AC Induction Motor Turning DC Dynamo Rheostat to Control Generated Voltage DC Voltage Controls DC Motor Speed

 1900-1970s Ward-Leonard M-G Sets

and DC Motors Used for Variable Speed Elevators

 AC Motors Used 1 and 2 Speed Starters

Otis No. 1 Geared DC Machine with DC Motor

Circa 1915

Otis Gearless DC Machine

Circa 1919

M-G Set Controls

(Otis Elevator, 1920s)

Otis Type 84
26 Broadway,NYC

Circa 1930s

History

 1975-Present
Thyristor (SCR) DC Drives Control Elevators All Analog Components in the 70s Replaces Aging M-G Sets

 1980s Microprocessors Improve

Car Dispatch and Motor Drive Controllers

Otis type 84,NYC

with Encoder

Westinghouse #205 with Encoder

History

 Late 1980s
Variable Frequency Inverters AC Induction Motors, Geared Applications Only

 Early 1990s
More AC Inverters and Motors Begin to Displace Small DC, 3-15 HP

 Mid-1990s
Vector Control AC Inverters 10-40 HP Almost as Good as SCR-DC. KONE Introduces PM EcoDisc AC Machine

History

 Late 1990s

Custom Gearless AC Induction Machines First Fully Regenerative AC Elevator Drives Much Discussion on PM-AC and MRL SCR-DC Still Used for Medium and Large Building Mods

History

2000-Present

More PM-AC Motor Manufacturers. PM Gearless Begins to Replace AC Geared EU Focus on Efficiency and Harmonics/EMC Lower Cost IGBT Inverter Components North America Begins to Focus on Energy Reduction New Construction Leaning toward AC SCR-DC Still Used on Medium-Large Building Mods

Elevator Drive Requirements

5.2-

RAC LLUF

RAC YTPME

0.10 0.1

S T T A W O L I K

RAC YTPME

RAC LLUF

R E W O P

5.2

Elevator Duty Cycle

Four Quadrant Operation

What Customers Want

 Repeatable Elevator Performance  Smooth Operation  Reliable Operating Life  Effortless Installation  Custom Control Interface  High Efficiency  Conformance to All Codes  Low Installed Cost

Elevators vs. Industrial Applications

 Infinitely Variable Speed Range  Infinitely Variable Torque Range with

Smooth Bump Less Operation with High Peak Torque

 Millions of Repeated Operating Cycles  High Inertia Resonant Load  Accurate Stopping Position  Unattended Operation 24/7/365

Elevators vs. Industrial Applications

 Quiet Operation  Long Operating Life  Long-Term Product Support

Types of Motors

 DC Shunt Field
High Speed Geared Low Speed Gearless Full HP Range 5 600 HP 8994% Efficient High Torque Capacity Accel/Decel In Elevator Service for 70+ Years Requires DC Generator, SCR or Other AC-DC Power Conversion from AC Utility Power DC Motor Can Act Like a Generator

Types of Motors

 AC Induction
High Speed Geared, 275 HP Few Low Speed Designs for Gearless 8594% Efficient Many with Single or 2 Speed Starters Can be Variable Speed by Inverter Control of Frequency Torque Strength Derived from Out of Phase Excitation Current Requires Flux Vector Control for Wide Operating Speed Range Can Act Like a Generator

Types of Motors

 AC Permanent Magnet (PM)

New Designs for Compact Gearless Machines Torque Strength from Permanent Magnets 9095% Efficient Compatible with Inverters to Control Speed Requires Synchronous Flux Vector / Angle Control to Regulate / Modulate Torque Supply Limited to Specialty Machine Builders Not Suitable for High rpm Speed Geared Designs Can Act Like a Generator

Modernization

 Why keep a DC machine?

Many large DC machines cannot be easily replaced with AC. Large Installed Base of DC Machines Worldwide DC Motors and Machines are in Good Working Order and Provide Excellent Ride Quality

Large DC Machines
Otis 72 and 269

Types of Motor Drives

For DC Motors For AC Motors

 M-G Set  SCR-DC  PWM-DC

 Variable Voltage  V V V F Inv. (V/Hz)

Open/Closed Loop Open/Closed Loop Closed Loop

 Vector Control Inv.

 Synchronous PM Inv.  Regen or Non-Regen

Elevator Power Consumption

the need for Regeneration

 Horsepower = Torque x Speed  Gearless Friction Losses are 10-20% of Elevator

HP Rating

 Moving inertia absorbs energy during acceleration

that must be removed during deceleration. proportional to torque or current flow. = Heat

 Mechanical, electric and electronic losses are  Energy Wasted / Dissipated During Deceleration  Excessive heat in control rooms must be removed.

Practical Energy Considerations

 Low Speed Elevators 50150 fpm

Almost Always Geared or PM Gearless Low Speed Usually Means Low Power 2-35 HP / 2-25 kW Most power is consumed by frictional losses. True regeneration is not critical. High Gearbox Losses During Regeneration Drive type makes little difference in overall energy consumption. If DC, Good Candidate for Conversion to AC by Replacing Motor Low Installed Cost is Usual Critical Issue

Practical Energy Considerations

 Medium Speed Elevators 150450 fpm

Geared and Some Gearless Including PM 15-60 HP / 12-45 kW Lower Frictional Losses in Gearbox Recovery of inertia energy becomes important, particularly with gearless. Resistive Braking Still Possible but Need to Perform Heat Load Calculations for Equipment Room

Practical Energy Considerations

 High Speed Elevators 500-1,600+ fpm

Low Friction Gearless 45-600 HP / 34-450 kW or Larger True Regeneration is Mandatory

Industry Trends  Energy Consumption Reduction

kW-hrs / Month Harmonics, Power Factor

 Performance
Reduced FloorFloor Time Reduced Vibration

 Low Maintenance
Cleanliness

 Larger PM Machines
More Gearless Applications

Energy Consumption

 Elevator Speed and Payload  Frequency of Use  Hoist Way Efficiency  Motor Efficiency  Power Conversion Efficiency  Idle Losses  Regeneration

Drive Type Comparison

Desired Feature Installed Cost Smallest vol. Wt. Pwr conv efficiency External XFMR 90%
w/ XFMR

Diode SCR-DC PWM Inv

PWM PWM

 
93-96% 92-94%

Drive Type Comparison

Desired Feature Regeneration Low Harmonics Unity Pwr Factor SCR-DC Diode PWM Inv No No PWM PWM


No

  

No

No

Drive Type Comparison

Desired Feature Flexible Motor V Stand-by Friendly AC / DC Motor SCR-DC With XFMR No No Diode PWM Inv Below Vac input PWM PWM

  


No

Future Expectations

 More PM Gearless
Low and High Power

 More Interest in Energy Conservation

Overall Efficiency Regeneration

 More Restrictions on Harmonics and EMC

Sinusoidal High pf Utility Line Current All Inclusive Drive Units with Filters

Future Elevator Drives

 PWM-PWM Double Converter-Inverter

Regulated Harmonics Unity pf Fully Regenerative Compatible with DC Stand-by Power

 PM Operation without Resolver

Electronic Alignment Sensing

 Compact All Inclusive Packaging  Works with AC Ind. or PM or DC Motors

Worlds Tallest Buildings

Magnetek has Elevator Drives in 17 of the 30 tallest buildings in the world.