2. Why Energy Efficient Appliances ? The Need ….
Extracts from Bureau of Energy Efficiency’s presentationsExtracts from Bureau of Energy Efficiency’s presentations:
– Energy is essential for the economic growth of the country
– India is facing severe shortages on the energy supply-
demand
– Additional 100,000 MW required by 2012, costing approx Rs.
8000 Billion
– Energy efficiency / conservation can reduce peak and
average demand
– One unit saved, avoids 2.5 to 3 times of fresh capacity
addition
– Investment in energy efficiency is highly cost effective
contd…
3. The Need ….
– BEE introduces Standards & Labeling program
– Focus Products:
» Refrigerators, Air ConsRefrigerators, Air Cons
» Lamps and Ballasts
» Motors, Distribution Transformers
» Agricultural pump sets
– Energy performance parameters to be monitored
– Enforce minimum efficiency standards by prohibiting
manufacture, sale, and import of products not meeting the
minimum standards
– BEE to recommend to Central Government on Labeling,
introduce comparative labeling as the first step followed by
minimum energy efficiency standards.
contd…
4. The Need ….
What are we doing to comply with the Energy Conservation
Act?
5. Key Objectives
• Introduction to IR i-Motion & Deltech
» Brief about IR i-Motion & IRAM Module?
» Design & Development - by Deltech
• Energy Efficient Appliances
» Why Variable speed Refrigerator?
» Why Variable Speed Air conditioner?
» Comparison 3 & 1 phase Motor control
• Cost Vs Benefit Analysis
» Benefits Variable speed drive
» Cost Feasibility Analysis Refrigerator
» Cost Feasibility Analysis Airconditioner
» General concerns & Redressal
• Methodology
» Technology Development Methodology
» Technology Development Model
» Action Items
8. Integrated Design Platform
Analog, HVIC Power Silicon IRAM ModuleDigital Control
Technology
Software
IR has the capability to provide all necessary silicon for motion
control with the highest performance and the lowest cost
IR i-MOTION – Integrated Design Platform for Motion Control
9. Complete Power Stage Solution for Low Power Motor
drive application in a compact, cost effective module
IR IRAM Module - Intelligent Power Module
10. Bill Of Materials - Inside IRAM Module
IR21365
6x IGBT + 6 Anti-Parallel Diodes
6x Gate Resistors
3x Bootstrap Diodes + Resistor
1x 3-Phase IC Driver
Temperature/Current Protection
11. How Does the Product Work?
Add bootstrap capacitors
Set RC values for desired
TTRIP
Add controller
(µC or DSP)
Optional:
Add
phase
shunts for
current loop
Plug n drive the
Motor
12. Benefits
• Low EMI
• Smaller PC Board requirements
• Reduced system design time
• Reduced assembly costs/time
• Does not require additional isolation
• Higher reliability (as compared to discrete solution)
• Manage one SKU* versus 25
• Fewer parts to qualify
• Fewer parts to manage inventory
• Fewer parts for price negotiation and part ordering
*Stock Keeping Unit
$$ Reduced System’s Cost $$
14. Dalmia Electrodyn TechnologiesDalmia Electrodyn Technologies
DeltechDeltech
Mission StatementMission Statement
Deltech will be a Premier Provider of
Cost Efficient, Leading Edge
Embedded Control Solutions in the
Mixed Signal Domain, for Mass
Market Products
15. DeltechDeltech Embedded Controls
STRENGTHS
• Team of experienced professionals lead by
– Dr.R.Ramarathnam, Managing Director
» B.Tech from IIT, Madras and M.Tech & Ph. D. – IIT,
Bombay (Expertise on Motors, Power Electronics and
Embedded Controls)
• Expertise in system integration & interfacing and handling mission –
critical projects
• Excellent support in application engineering
• Established track record of product development
• Seamless Integration of Analog/Digital domains
• Very Good R&D facilities
16. DeltechDeltech Embedded Controls
• Specialist R&D House in Embedded Controls
– Patented Innovations for licensing
– ODC and Contracted R&D
• Areas of Specialization
– Appliances
– Automotive
– White Goods
– Factory Automation
Vision
20. Refrigerators
Refrigerators account for up to 20% of energy
usage in a home. Conventional refrigerators
equipped with single phase RSIR/CSCR/CSIR
motors work only at full speed. EC motors work at
variable speed to reach the target temperature
more smoothly. This allows for up to 30% energy
savings.
Why?
21. Conventional Frostless Variable Speed RefrigeratorVs
Comparison
Conventional Vs Variable speed Refrigerator
•Higher energy usage because of
timed de-frost cycle which must be
designed for worst case conditions
•Enclosure heat loss is higher
because temperature must be
lowered beyond set point.
•Compressor is larger than needed
because it needs to reduce
temperature below the set point.
•On-off thermostat causes wide
hysteresis (6 to 10°F) and poor
energy efficiency.
•De-frost energy is minimized by
comparing evaporator temperature
with enclosure temperature and
initiating de-frost cycle only when
needed.
•Negligible heat loss due to operation
at fixed temperature without
hysteresis.
•Analog to digital thermostat
continuously controls compressor
speed in response to heat loss and
optimizes energy usage.
•Compressor capacity is optimized
for enclosure heat loss only.
22. Improving Efficiency in Refrigerator
• Most of the energy used by a refrigerator is used to pump heat out of
the cabinet. A small amount is used to keep the cabinet from
sweating, to defrost the refrigerator, and to illuminate the interior.
• Improved energy efficiency can be achieved through:
– Addition of vacuum insulation panels (too expensive)
– Increased door and wall thickness (not acceptable by the market)
– Addition of polyurethane foam to the doors to double insulation
thickness problems for pollution (material)
– Replacement of automatic defrost control with an adaptive defrost
that operates only when needed
– Replacement of AC motors with more efficient DC motors
• The most cost-effective solution is via variable speed electronic
motor control
23. Present Refrigerator Technologies
• Single-phase RSIR/CSCR motors power most of the present refrigerator
compressors
• An On/Off thermostat carries out the temperature control
• No or Less Electronics
• High-end frost-free models presently have timers and Electronics
Merits & Demerits of Present Methods
Merits:
• Simple ON/OFF control & proven technology
Demerits:
• Energy intensive and inefficient
• As the demand for power and torque increases the motor becomes bulkier and
expensive
• Single-phase motors have low power to weight ratio
• Since the motor is selected for peak duties the capacity of the motor is not optimal
• High inrush makes it incompatible to low Power Backups viz. Generator/Inverter
• Threatened obsoletes just like 2 stroke motor-bike technology
Present Technologies
25. Why Variable speed Air conditioner?
Energy Efficiency
Room air conditioners are now being assigned an efficiency rating, known
as energy efficiency ratio (EER). The EER is defined as the cooling output
(in Btu per hour) divided by its energy input (Watts) at specified indoor and
outdoor temperatures. The minimum EER allowed is between 8 and 10,
depending on the capacity and type of unit. A higher rating means more
efficiency. The best available EER is about 13.These specifications are
regulated by the Department of Energy in US & by Bureau of Energy
Efficiency in India.
26. Variable speed Air conditioner
Inverter Driven Air Conditioners
Technology used in AC inverter air conditioners, control the electrical
current frequency to the compressor according to the cooling and heat
load of a room for optimum performance. Inverter technology promotes
maximum compressor efficiency by adapting the rotation speed to
accurately match requirements and offer finely-tuned operation. AC
inverter air conditioners can reduce electricity consumption by up to 30%
when compared to non-inverter units.
28. Existing & Future Aircon Technology
• Single phase motors are used up to 1.5/2 ton capacity air-conditioner
compressors. Beyond 2 ton, three phase motors are used.
• Both are bulky, without drive mechanism & less user friendly. Thus it’s with
» No Electronic Controls,
» Poor efficiency,
» Large size,
» No Mass appeal
Existing Aircon
• Three phase motors will be used in all Aircon compressors with Electronic controls.
• Lower capacity AC segment also, Single phase motors will be phased out
giving way to more efficient, less bulky, with drive three phase Compressor &
fan motors. Hence, Future Aircon will be-
» Trendy,
» User Friendly
» More efficient,
» Affordable
Future Aircon
29. Availability of the Technology
Reliability of the Technology
Technology available for over a decade or more & Now IR cost effective Inverter
Modules are available for bulk purchase.
Earlier Commercial viability could not be established due to high Technology & Inverter
component costs.
Now IR i-motion family has enabled low cost & high performance solutions for high
volume applications
Technology is proven & Reliable
Laboratory tests have proved that it makes machine to perform better & improves the
life of moving components.
30. Performance of the Technology
Demo unit is ready & concept may thus be demonstrated
Performance however proven, may be evaluated
Also, No need of stabilizers i.e. product becomes all terrain & rugged
Automatic control of blower fan
Product improves EER/SEER ratings
31. Present Technologies
Single-phase RSIR/CSCR motors power most of the present air conditioner
compressors up to 2 ton capacity
An On/Off thermostat carries out the temperature control
No or Less Electronics
Merits & Demerits of Present Methods
Merits:
Simple controls & proven technology
Demerits:
Energy intensive and inefficient low capacity segment
Single-phase motors have low power to weight ratio
Since the motor is selected for peak duties the capacity of the motor is not optimal
up to 2 ton capacity
High inrush generally makes it incompatible to Power Backups viz. Generator/Inverter
Threatened obsoletes just like 2 stroke motor-bike technology
Present Technologies
33. Parameter Single Phase Motor + Control Three Phase Motor + Control
Size Bigger motor for a unit output For the same power the size of the three-
phase motor reduces to 2/3rd
size of single-
phase motor. Can be further optimized for
the loading requirements.
Starting Needs Auxiliary winding, Capacitor for
starting. The quality of the auxiliary
winding & Capacitance defines the starting
characteristics
Inherently self-starting with good starting
torque. No Capacitor required
Windings Presence of a optimized auxiliary winding
to generate Cross field
Balanced three phase active windings
uniformly distributed in all equal slots
Operation
al merit
Pulsating torque Uniform Torque is operational merit, since
it sets up a revolving field in the air gap
Comparison 3 & 1 Phase Motor Control Configuration
34. Parameter Single Phase Motor + Control Three Phase Motor + Control
Iron
Content
Iron Content is Higher Minimum Iron content and optimal to a
design
Copper
Content
Copper Content is Higher For the same power the copper content is
typically 25% less than single phase motors
Speed
Control
Not popular, Non-standard designs and
expensive control. Reversing through
complex mechanisms and step speed change
by only pole changing
Very popular and Highly standardized and
economic. Easy speed reversal through
phase sequence reversing. Variable speed is
achieved by simple Voltage/Frequency
control
Motor
Speeds
Limited to the mains frequency Can be increased beyond 50Hz to deliver
more cooling capacity when required
Comparison Contd…
39. Volumes Drive Costs
Typical VSD control for a 100-Watt Refrigerator Compressor
BOM costs for Electronic Basic Variable speed drive
In Quantities of 20,000 - Rs. 1200/- * and
In Quantities of 100,000 - Rs. 760/- *
Note (*) -
- Target System can be developed
Cost Negative/ Cost Neutral
- Costs may vary vis-à-vis volumes/ costs
prevailing at the time of actual ordering
Above costs are indicative only.
- It may be possible to drive costs further
down in case 1m units are targeted as indicated
Tentative Electronic Drive Costs
Cost
Per Drive unit
Volumes Produced20000 No’s 100,000 No’s
Rs 1200/-
Rs 550/-
target
Rs 760/-
1,000,000 No’s
40. Drive is Cost Negative / Cost Neutral ?
Implementing Variable speed drive enables-
• Possible reduction in motor costs – 25%
• Elimination of components used in present control – XX%
• Addition of Electronic Motor Control – YY%
• Further the compressor speeds can reach – 135Hz
• In absolute terms a smaller compressor will deliver higher cooling
capacities
• Savings in compressor cost
Note:
Can be Driven cost negative for premium segments (with sufficient electronics) & Cost neutral in Mid
range Appliance (with less electronics) & Marginal or Negligible increment in direct Cool segment
41. Costs Involved
Components (added for implementing drive)
a) Three phase control electronics
b) Thermistor for Appliance temperature control
Optional Components (for added features @ extra cost)
a) User Interface
b) Visual controls
c) Thermistor for Motor Temperature sensing
d) …
42. Savings from Elimination of Electrical components
Drive Eliminates Following Components of
Conventional system
• Defrost Timer
• Capacitor if Motor is CSCR / PSC
• Over Current relay
• Heater Control Switch
• Thermal Overload Protection, which can be replaced by
Thermistor
• Bulky Thermostat (Which will be replaced by Thermistor)
• Savings in Converting to three Phase Motor
• Other Electronics, if any
43. Further The manufacturer to estimate savings through reduction in
following other/ Mechanical Components
1. Savings in Cubicle/Thermal Volume?
2. Savings in heat reservoirs/ Linings?
3. Savings in PUF?
etc…
Savings from Elimination of other components
48. Volumes Drive Costs
Typical VSD control for a 1.5-ton Air-conditioner Compressor
is highly competitive.
Due to a lot of factors including availability
costs may vary.
Note (*) -
-Costs may vary vis-à-vis volumes/ costs
prevailing at the time of actual ordering
Above costs structures are indicative only.
- It may be possible to drive costs further
down in case 1m units are targeted as indicated
Tentative Electronic Drive Costs
Cost
Per Drive unit
Volumes Produced20000 No’s 100,000 No’s 1,000,000 No’s
Rs. X
Rs. X less y%
Rs. X less z%
49. Drive is Cost Negative / Cost Neutral ?
Implementing Variable speed drive enables-
• Possible reduction in motor costs up to 2 ton capacity– 25-40%
• Elimination of components used in present control – XX%
• Addition of Electronic Motor Control – YY%
• Further the compressor speeds can reach – 135/150Hz
• In absolute terms a smaller compressor will deliver higher cooling capacities
• Savings in compressor cost
50. Costs Involved
Components (added for implementing drive)
a) Three phase control electronics
b) Thermistor for Appliance temperature control
Optional Components (for added features @ extra cost)
a) User Interface
b) Visual controls
c) Thermistor for Motor Temperature sensing
d) Remote control
51. Savings from Elimination of Electrical components
Drive Eliminates Following Components of
Conventional system
• Capacitor if Motor is CSCR / PSC up to 2 ton capacity
• Thermal Overload Protection, which can be replaced by
Thermistor
• Bulky Thermostat (Which will be replaced by Thermistor)
• Savings in Converting to three Phase Motor in the lower
capacity segment
• Capacitor for PF improvement above 2 ton capacity
• Other Electronics, if any
52. Further The manufacturer to estimate savings through reduction in
other Process or Mechanical Components
1. Savings in Process ?
2. Savings in Mechanical components ?
3. Overall Savings after implementation ?
etc…
Savings from Elimination of other components
54. Concerns Redressal
a) Component Changeover
Motor – Negligible Change is required to make 3 phase motor
Electronics – Can be outsourced as a entire assembly, If the manufacturer possesses
the capability of Motors & Electronics the effect is minimum
b) Parallel operation of 1 and 3 phase motor winding –
Motor - Intelligent tooling activities can lead to negligible loss of time in process change.
Same single phase machine may be used to Produce 3 phase Motors.
Electronics – Simple adoption if the process is captive
Feasibility Study in adopting 3 phase design
55. c) Technology appraisal– Early dissemination of the technology across the board once the
decision of technology change is considered. Benefits of change should be punched
properly down the line
d) Training – Aided/Augmented by the guidance provided by technology developer and
component supplier
e) Compressor
Development of Higher speed compressor.Higher speed brings the rationalization of
compressor models
Note : The increased power density of the compressor should be the Drive & Motive
Feasibility Study in adopting 3 phase design contd…
58. DEVELOPMENT METHODOLOGY
• Demonstration of a conceptual model
• Customer engagement and Sign off Non Disclosure Agreement
• Specification Exchange
• Agree to a development specification
• Agree on a Development cost based on Time & material basis
• Agree to a business understanding before development process in form of MoU
• Development of Prototypes
• Prove out the prototypes
Methodology
59. • Conduct External/ Statutory reliability tests if any Sign Final Agreement
• Release Pilot batch Documents
• Pilot Batch Feedback correction
• Release mass manufacturing documents
• Customization/s for other products
• Technology Up gradation & Support
Development Methodology contd…
61. Technology Development Model
Commercial Models
a) Prototype development costs will be borne by customer (Time & material model)
OR
Alternatively retainer basis (Specific group dedicated to client requirements) model
for time charges+ Material costs
b) Technology Upfront/Commitment fee with the signing of agreement (Depending on
the Segment, Market size, Geography, Exclusivity/Non-Exclusivity)
c) Per unit Royalty [Based on commercial model point No.(b) above]
d) Customization Charges on each model. + Time & Material Cost
e) Technology up gradation Charges. + Time & material cost
