The design Alfa IE4
Using an advanced simulation program of Finite Elements (Flux 2D Simulink - Math Lab) with improved designs of the motor, GAECE was able to confirm that the concept easily reaches efficiency and performance beyond the IE4 standard (Super Premium Efficiency) and outperforms the technologies currently available in the market.
The main features of the simulated motor, which was given the name of AlfaIE4, are:
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Each stage in a different plane or stage
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-
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ICE Size
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180
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Nº of phases
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3
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Nº rotor poles
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4
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Nominal speed (rpm)
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2000
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C.C. Tension (V)
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800
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Mass (kg) 134 with iron casing. With aluminium casing
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110 Kg
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The outstanding results of this design include:
| Nominal power | 68 HP |
| Efficiency | 97% |
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Power/mass ratio with iron casing With aluminium casing |
374 W/kg 474 W/ Kg |
| Category | IEC 60034-31 IE4 (superior) |
Additional features of the technology
The table below shows how the same machine (motor) working with our technology can maintain high efficiency at different input tension levels:
| Vcc Tension | Nominal power (kW) | Average output at diff. speeds & loads % | Category | kW/Kg. of Mass | Ratio w/kg. of mass |
| (Input) | (output) | (Efficiency) | IEC 60034-31 | ||
| 320 | 19,3 | 97% | IE4 Super Premium Efficiency | 0,14 | 144,03 |
| 400 | 24,04 | 97% | IE4 Super Premium Efficiency | 0,18 | 179,40 |
| 500 | 23,87 | 96% | IE4 Super Premium Efficiency | 0,18 | 178,13 |
| 600 | 26 | 97% | IE4 Super Premium Efficiency | 0,19 | 194,03 |
| 800 | 50,2 | 97% | IE4 Super Premium Efficiency | 0,37 | 374,63 |
* Efficiency of the motor only, without the loses of the controller
After deducting the losses of the electronic controller, which are calculated at 3.5%, the motor itself has an efficiency of about 97 %. This efficiency keeps almost constant at any speed and load or power output.
A remarkable characteristic of this technology is that it allows the same motor operate with the same tension (voltage) and obtain from very low to very high power outputs. These efficiency levels (with 600 and 800 V) are above the international norm IE4. For motors as big as the above mentioned, the IE4 norm requires an efficiency of 94% considering only the efficiency of the motor itself, without taking into account de losses of any electronic drive. Thus this technology in relation to efficiency will outperform those requirements, and if the very low weight of the motor in relation to others of the same power output is considered, the overall performance will be outstanding.
Regarding the examples shown above, the output power and efficiency are obtained with a motor that weighs only 134 Kg with iron casing. In contrast, a 33 Kw (44 HP) similar motor in the market weighs 276 Kg. With aluminum casing our design would weight only 110 Kg.
The experimental laboratory works and Finite Elements Analysis showed that the magnetic induction in its air gap reaches 2.3 to 2.7 Tesla, exceeding the densities of 1.2 to 1.3 Tesla reached by current electric motors and generators available in the market. This magnetic densities enable the construction of motors with considerably less weight, which represents an additional contribution by saving materials, thus the energy for the production and maintenance of machines based on our technology.
The table below features a comparison with other comparable technologies available in the market
| Multistage Motor Simulation at 800 Vcc |
Simulated Multistage motor (AlfaIE4) with our technolgy |
Asynchronous 4-pole motor – competing technology |
Asynchronous 6-pole motor – competing technology |
| Speed (rpm) | 2000 | 1500 | 1500 |
| Nominal power (HP) | 70 | 70 | 70 |
| Motor mass with steel housing (kg) with iron casing | 134 | 380 | 400 |
| Peak performance % | 97 | 93.2 | 93.2 |
| Given power W/kg | 374 | 137 | 130 |
* With aluminum housing the weight decreases to 110 kg
The Alfa IE4 weights approximately 1/3 of an equivalent motor
The table above and the figures below show the enormous differences when a motor using our technology is compared to the best performing motors available in the market.
