When to Use custom high voltage motor manufacturer？

Instrumentation equipment and precision automation systems manufacturers rely on motion components in applications from optical scanning to micro-mechanical assembly. PI supports these applications with a large variety of standard and custom motion and positioning solutions. A combination of in-house-developed and off-the-shelf mechanical and electronic components, including actuators, guiding systems, position sensors, and motion controllers, allows for great flexibility and performance at reasonable cost.

Goto CHANGLI ELECTRIC MOTOR to know more.

While gearbox / screw-driven positioning elements provide advantages for vertical and high force applications, direct drive electrodynamic motors are higher speed, zero-wear, and friction-free transmission devices that are preferable in positioning and scanning systems that require high dynamics & repeatability along with reliability over millions of cycles. 

In addition to designing piezo-ceramic direct drive linear and rotary motors, engineers at PI have a long history of developing custom motion systems with electrodynamic motors, especially for high-precision and/or high-dynamics applications. The main goal is to achieve specific performance targets that cannot be reached by off-the-shelf products sourced from the market. Here’s a link to a paper dating back to , describing a novel  momentum compensated high-speed voice coil linear scanner; other examples include multi-axis Maglev systems, high-speed hexapods, and compact voice coil motors with force and position control. 

This blog explains the functional principle and properties of voice coil, 3-phase linear, and torque motors, and provides examples on how performance characteristics of the various motor types can be adapted to the specific requirements of the positioning solution through an individual design, e.g., to achieve a high force density or a compact design.

Simulation tools allow customization and optimization for voice coil motors for different parameters, such as force and motor constant. The motor constant denotes the ratio of force to power loss, or the efficiency of the motor in regard to converting electrical into kinetic energy. The higher the motor constant, the less heat is produced when a certain force is generated. The motor constant is temperature-dependent; with a rise in temperature comes a rise in the winding resistance leading to increased power loss.

PI has developed cylindrical motors, as shown in Figure 4, to maximize the motor constant.

They are characterized by a maximized ratio of motor constant to installation space and can be manufactured in various sizes. Cylindrical motors can be used in fast focusing applications, for moving a measuring head in a metrology system vertically. In combination with a flexure guiding system, especially compact units can be built.

Table 1 shows the performance characteristics of three examples in different sizes.

Custom encapsulated linear motors for vacuum applications are also available from PI. This results in improved heat dissipation, allowing for higher nominal forces. In addition, the sealing compound ensures that the motor is protected from external damage, e.g., during assembly.

For special applications that require high velocities or fast current rise times, PI can design motors for very high operating voltages up to 600 VDC. In this regard, linear motors benefit from the same effect that was previously described for voice coil motors. Standard industrial high-voltage servo amplifiers are available to drive these motors.

Halbach Arrays

PI can customize the length of the magnetic tracks for OEM positioning systems. Single-sided or U-shaped magnetic tracks are available. U-shaped magnetic tracks achieve higher magnetic field strengths and higher forces than single-sided magnetic tracks. If the magnets are arranged in a Halbach array, the magnetic field strength can be increased by about 10% compared to a North / South Pole arrangement. In addition, the iron counter plate can be omitted in a Halbach array, making these magnetic tracks significantly lighter (Fig 8). The advantages of using a Halbach array also apply to single-sided magnetic tracks. In this case, the use of Halbach arrays avoids the generation of high stray fields on the back of the single-sided magnetic track. PI can provide carbon supports for applications that require ultra-light magnetic tracks.

Iron-core linear motors are suitable for applications requiring high forces and accelerations with limited installation space. The iron maximizes the magnetic forces and contributes to high thermal stability. To reduce eddy current losses, the iron is laminated and it is mostly made of stacked and insulated transformer plates. The disadvantage of iron-core motors is the attraction force that arises between the iron and the magnets arranged on the opposite side. This is increased further still if a steel linear guide is used. “Cogging” is also a problem since the displacement force varies over the travel range – while this can be minimized by means of special geometries, it cannot be completely eliminated but advanced control algorithms can make it negligible for most applications. An example of an iron-core linear motor is shown in Figure 9.

Ironless and iron-core linear motors are available. For example, motors of both types are used in the V-508 linear stage series. An example of a linear stage of this series is shown in Figure 8.

The sealed motor shown in Figure 10 is an example of a proprietary linear iron-core motor developed by PI.

Ironless linear motors are suitable for positioning tasks with the highest demands on precision, linearity, and speed stability because they are not affected by cogging. They are also suitable for the smallest installation spaces thanks to their particularly flat design. Power and dynamics requirements can be met by increasing the number or dimension of the motor coils. 

In most cases, ironless motors achieve lower nominal and peak forces than iron-core motors. This is due to the lack of thermally conductive metals in the design and the resulting limited heat dissipation from the coils. However, the motors can be protected against overload by means of additional temperature sensors. An example of an ironless linear motor is shown in Figure 12.

The flat motor with a U-shaped magnetic track, shown in Figure 13, is an example of a proprietary ironless linear motor developed by PI.

Torque motors are often used in rotation stages for precision positioning and automation applications. Rotation stages based on direct drive torque motors exhibit zero play and backlash unlike worm-gear driven stages. When combined with frictionless air bearings, they provide virtually unlimited service life (Figure 14a). A torque motor is basically a radially designed 3-phase linear motor. In an alternative design, the rotor can also be represented as a rolled-up, single-sided magnetic track, while the stator houses the coils which are embedded in an iron matrix. An example of a custom torque motor developed by PI is shown in Figure 14b.

With the in-house expertise to develop proprietary motors and with the core technologies needed for a complete positioning solution, such as sensors, guides, and motion controllers, PI offers its customers competitive solutions with performance characteristics that are optimally adapted to the requirements of the application. Figure 17, for example, shows an application that combines different motor types. The multi-axis setup for autofocus applications shown consists of an X and a Z axis. The X axis, for example, holds a workpiece that is to be machined on a V-508 linear stage. As a supplement to the commonly used piezoceramic drives, the voice coil Z axis enables long travel ranges up to several millimeters. This is important, among other things, for laser material processing. Travel ranges of 1 to 7 mm are typically also required for multiphoton fluorescence microscopy and deep tissue microscopy. Furthermore, voice coils offer particularly high maximum speeds which can, for example, be used to increase throughput when using “scanning-on-the-fly mode” in digital slide scanning processes.  

High voltage motors are essential components in various industrial applications, driving machinery and systems that require significant amounts of electrical power. These motors are designed to operate on high voltages, typically above 1,000 volts, and play a crucial role in industries like manufacturing, oil and gas, mining, and power generation. This comprehensive guide will explore the different types of high voltage motors, their applications, benefits, and maintenance considerations.

1. What Are High Voltage Motors?

High voltage motors are electric motors designed to operate with voltages above the standard 1,000 volts. These motors are typically used in heavy-duty applications where large amounts of mechanical power are required, such as in large industrial plants, power stations, and large-scale manufacturing facilities. Unlike low-voltage motors, which are commonly found in smaller appliances and equipment, high voltage motors can handle much greater electrical loads, making them ideal for high-demand environments.

Contact us to discuss your requirements of custom high voltage motor manufacturer. Our experienced sales team can help you identify the options that best suit your needs.

These motors come in various types, including AC (alternating current) motors and DC (direct current) motors. The most common type of high voltage motor is the squirrel cage induction motor, which uses an induction principle to convert electrical energy into mechanical energy. High voltage motors can also be either asynchronous or synchronous, depending on their application requirements.

 High Voltage Electric Motor

2. Types of High Voltage Motors

High voltage motors can be classified based on their design and application. The following are the most common types:

Induction Motors

Induction motors are the most widely used type of high voltage motor. They are popular due to their simplicity, reliability, and cost-effectiveness. Induction motors work on the principle of electromagnetic induction, where the rotor is induced to rotate by the magnetic field produced by the stator. These motors are used in a variety of industrial applications, including pumps, fans, compressors, and conveyors.

Synchronous Motors

Synchronous motors operate at a constant speed, determined by the supply frequency. These motors are often used when precise speed control is required, such as in power generation and other applications where maintaining a fixed rotational speed is critical. Synchronous motors are more efficient in certain applications, as they can run at a constant speed without the slip typical of induction motors.

DC Motors

DC motors are less commonly used in high voltage applications but can still be found in specialized industries. These motors offer precise speed control and are often employed in applications where variable speed is necessary. DC motors are widely used in equipment like cranes, electric trains, and other machinery requiring continuous speed regulation.

3. Applications of High Voltage Motors

High voltage motors are used in numerous industrial and commercial applications. Below are some of the most common areas where these motors are essential:

Power Generation

In power plants, high voltage motors are used to drive large machines like generators, pumps, and fans. These motors convert electrical energy into mechanical energy, helping to generate the power that supplies electricity to the grid. In large power plants, such as nuclear, hydroelectric, or thermal plants, high voltage motors play a critical role in ensuring the efficient operation of equipment like turbines and compressors.

Oil and Gas Industry

High voltage motors are used in oil rigs and refineries to power pumps, compressors, and other equipment that handle the extraction and processing of oil and gas. These motors are built to operate in harsh environments and under extreme conditions, including exposure to volatile chemicals and extreme temperatures. They are essential for the efficient operation of drilling systems, refining processes, and pipeline operations.

Mining

The mining industry relies heavily on high voltage motors to operate large machinery like crushers, conveyors, and pumps. These motors are designed to withstand tough conditions such as high temperatures, vibration, and exposure to dust and dirt. High voltage motors in mining applications provide the power needed to process materials and transport them from extraction sites to processing plants.

Chemical and Manufacturing Plants

High voltage motors are widely used in chemical plants, manufacturing facilities, and production lines. They power large machinery like mixers, extruders, and industrial fans. These motors are used to drive the critical processes involved in chemical manufacturing, assembly lines, and various other production processes that require substantial power to maintain efficiency and output.

HVAC Systems

In commercial buildings and large industrial facilities, high voltage motors are used to power HVAC (heating, ventilation, and air conditioning) systems. These motors drive large fans, compressors, and blowers that maintain temperature and air quality. High voltage motors in HVAC systems provide the necessary power to regulate air circulation and ensure the comfort of building occupants while maintaining energy efficiency.

4. Benefits of High Voltage Motors

High voltage motors offer several advantages, making them the preferred choice for many industrial applications:

High Efficiency

One of the key benefits of high voltage motors is their efficiency. They are designed to operate at optimal power levels, ensuring that energy is used effectively. High voltage motors have higher efficiency than low voltage motors, especially in large-scale applications, reducing overall energy consumption and operational costs. In industries where energy consumption is a significant part of operational costs, this efficiency can translate into substantial savings.

Durability and Reliability

High voltage motors are built to last, with robust designs that can withstand demanding environments. They are typically made from high-quality materials that resist wear and tear, corrosion, and temperature fluctuations. This durability ensures that these motors have a long operational life, which is essential in critical industrial applications where unplanned downtime is costly.

Scalability for Large Applications

High voltage motors are ideal for powering large machines and systems. In industries like manufacturing, mining, and power generation, high voltage motors provide the scalability needed to handle large-scale operations. These motors can be used in tandem to supply the necessary power for larger projects, offering flexibility in meeting the demands of evolving industrial needs.

5. Maintenance Considerations for High Voltage Motors

While high voltage motors are designed for durability and reliability, regular maintenance is essential to ensure optimal performance and extend their lifespan. Here are some key maintenance considerations for high voltage motors:

Routine Inspections

Regular inspections are necessary to detect potential issues such as overheating, vibration, or wear on critical components. Inspections should include checking the electrical connections, rotor and stator condition, bearings, and cooling systems. Identifying problems early can prevent costly downtime and damage to the motor.

Lubrication

Proper lubrication of bearings and other moving parts is essential to ensure smooth operation and minimize friction. Inadequate lubrication can lead to overheating, premature wear, and motor failure. Regularly checking and replacing lubrication is a simple but crucial maintenance task for high voltage motors.

Cleaning

High voltage motors should be kept clean to prevent the accumulation of dirt, dust, and debris, which can interfere with performance and cooling. Cleaning the motor’s exterior and ventilation areas can help maintain efficient operation, especially in harsh environments like mining or manufacturing plants.

6. Conclusion

High voltage motors are indispensable components in industrial operations where large amounts of power are required. Their efficiency, durability, and ability to scale for large applications make them essential for power generation, mining, oil and gas, and other heavy-duty industries. Regular maintenance is necessary to ensure the longevity and reliability of these motors, but their performance and efficiency justify the investment. Whether you’re looking to power a large manufacturing plant or a power station, high voltage motors provide the necessary performance to meet demanding operational needs.

For more Medium voltage electric motorinformation, please contact us. We will provide professional answers.