Rockwell Automation, Inc. · NYSE:ROK
Rockwell Automation — Energy Summit 2005
35 slides from Rockwell Automation's conference presentation, Oct 17, 2005
Slide 1: High Temperature Superconducting Motors at Rockwell Automation
High Temperature Superconducting Motors at Rockwell Automation: Economic Considerations for Industrial Applications Energy Summit: October 17, 2005
Slide 2: Superconducting Motor Development
Superconducting Motor Development Technology Drivers Compared to conventional high efficiency induction motors, HTS motors will be . . . smaller (approximately half the volume) and lighter more efficient (half the losses) lower in life cycle costs Projected Applications Commercial large mot
Slide 3: 5000 Horsepower, 1800 rpm Motor Example
5000 Horsepower, 1800 rpm Motor Example HTS Motor High Efficiency Conventional Efficiency = 98.6% Efficiency = 96.8% 43% of the loss in the 230% of the loss in the conventional motor HTS motor Smaller volume Annual energy costs to 47% of the volume of the operate may be $50,000 convent
Slide 4: Rockwell Automation Superconducting Motor Development
Rockwell Automation Superconducting Motor Development Significant Events - 1986 High temperature superconducting 1st Gen (HTS) ceramic materials discovered HTS Rockwell Automation Activities Wire 1987 Project initiated with EPRI funding 1990 World’s first DC HTS motor demonstrated at Reliance 1993 W
Slide 5: Outline
Outline What is Superconductivity How are Superconductors used in Motors Benefits of Superconducting Motors Economics of Superconducting Motors HTS Wire Technology Overview of HTS motor Demonstrations Conclusions Superconducting Motors 5
Slide 6: What is Superconductivity?
What is Superconductivity? Property of certain materials where virtually all resistance to the flow of electric current disappears below some critical temperature, magnetic field, and current density. Low Temperature Superconductivity (LTS) Discovered in 1911 by Dutch Superconductor Resistivity
Slide 7: Superconducting Material Discovery and Critical Temperature
Superconducting Material Discovery and Critical Temperature HgBaCaCuO Critical Temperature (K) 140 TIBaCaCuO Most 120 Common BiSrCaCuO HTS Wire 100 Materials YBaCuO 80 Liquid Nitrogen ( 77 K or -321 F ) O Typical 60 HTS LaSrCuO Operatin 40 Liquid Neon ( 27 K or -411O F ) LaBaCuO Nb3Sn g Range 20 V3S
Slide 8: Cost to Cool Superconducting Materials
Cost to Cool Superconducting Materials The cost to cool at cryogenic temperatures varies approximately as the inverse of the Kelvin temperature Low Temperature Superconductors Operate at 4 Kelvin High Temperature Superconductors operate at 30 to 80 Kelvin The cost to cool high temperature su
Slide 9: 5000 Horsepower Motor Cooling Costs with Field Coils
5000 Horsepower (3730 kW) Motor Cooling Costs with High Temperature Superconducting Field Coils Cryocooler input power = 7 kW Motor output power = 3730 kW Cryocooler input power = 0.2% of motor output power GM Cryocooler for 5000 horsepower motor Superconducting Motors 9
Slide 10: Superconductors in Electric Motors
Superconductors in Electric Motors Superconductors have the lowest loss when operating with DC current in DC magnetic fields In Electric Motors … Lossless DC superconducting coils carry high current densities to produce a very high magnetic field Synchronous motors with HTS field windings Relati
Slide 11: Why are Superconductors Used in Electric Motors?
Why are Superconductors Used in Electric Motors? Compared to conventional high efficiency induction motors, HTS motors will be Smaller Half the volume or less Lighter Half the weight or less More Efficient Half the losses Lower life cycle costs Superconducting Motors 11
Slide 12: Where will Motors be Used?
Where will High Temperature Superconducting Motors be Used? High horsepower industrial motors that are operated continuously 1000 (746 kW) horsepower and above Energy efficiency improvement will provide economic advantages Note: About 33% of electrical energy utilized in the United States is u
Slide 13: Superconducting Synchronous Motor with HTS Field Winding
Superconducting Synchronous Motor with HTS Field Winding Nonmagnetic Armature Armature Winding Support Heat Exchanger Motor Frame Magnetic Shield Cold AC Flux Shield Drive Shaft Coil Support Structure Physical Air Gap Warm Vacuum Jacket Composite Torque Tube Extension Brushless Exciter Cryogenic Tra
Slide 14: Composite Torque Tube Development
Composite Torque Tube Development 20 - 6” tubes tested to 210,000 in-lb Scarf Joint for 6” tubes 20 - 8” tubes fabricated for 1k hp 20 - 3” motor & tubes tested tested to to 70,000 in- 600,000 in-lb lb 60 - 3” tubes tested to 40,000 in-lb 960 butt joint samples tested with 9 different Two Related Pa
Slide 15: Composite Torque Tube Development for SC Motor (cont'd)
Composite Torque Tube Development for SC Motor (cont’d) • Prototype composite torque tube extensions fabricated and tested for 1600 hp motor • Prototypes tested at better than 17x rated torque Torque Tube Sample for 1600 hp HTS Motor Demonstration Bolt failure during composite torque tube test Torqu
Slide 16: Why aren't there any Industrial Superconducting Motors in Operation
Why aren’t there any Industrial High Temperature Superconducting Motors in Operation Superconducting Motors 16
Slide 17: High Temperature Superconducting Wire
High Temperature Superconducting Wire Up until 2004, ALL HTS motor demonstrations used first generation high temperature superconducting wire Powder in tube with BSCCO material Superconducting Motors 17
Slide 18: Superconducting Material Discovery and Critical Temperature
Superconducting Material Discovery and Critical Temperature HgBaCaCuO Critical Temperature (K) 140 TIBaCaCuO Most 120 Common BiSrCaCuO HTS Wire 100 Materials YBaCuO 80 Liquid Nitrogen ( 77 K or -321 F ) O Typical 60 HTS LaSrCuO Operatin 40 Liquid Neon ( 27 K or -411O F ) LaBaCuO Nb3Sn g Range 20 V3S
Slide 19: High Temperature Superconducting Wire: First Generation
High Temperature Superconducting Wire Up until 2004,“First Generation” ALL HTS motor demonstrations used first generation high temperature superconducting wire Powder in tube with BSCCO material Material cost and manufacturing costs are high 1st Generation BSCCO HTS Wire Cross Section Silver M
Slide 20: Second Generation HTS Wire
High Temperature Superconducting Wire “Second Generation” Second generation HTS wire is lower cost and simpler to produce Uses YBCO material Superconducting Motors 20
Slide 21: Superconducting Material Discovery and Critical Temperature
Superconducting Material Discovery and Critical Temperature HgBaCaCuO Critical Temperature (K) 140 TIBaCaCuO Most 120 Common BiSrCaCuO HTS Wire 100 Materials YBaCuO 80 Liquid Nitrogen ( 77 K or -321 F ) O Typical 60 HTS LaSrCuO Operatin 40 Liquid Neon ( 27 K or -411O F ) LaBaCuO Nb3Sn g Range 20 V3S
Slide 22: High Temperature Superconducting Wire: Second Generation
High Temperature Superconducting Wire “Second Second generation Generation” HTS wire is lower cost and simpler to produce Uses YBCO material Can be produced in an automated continuous process - minimal handling Over 90% of the material is comprised of high strength, economical nickel alloy s
Slide 23: Second Generation HTS Wire
Second Generation HTS Wire g ttin Sli 4mm wide Cu Electroplated with surround Cu plate Ph str oto iat lith ion 100 m long, og rap 10-12 mm wide hic with thin Ag over- For reduced ac layer losses Superconducting Motors 23
Slide 24: HTS Conductor Performance in Magnetic Field
HTS Conductor Performance in Magnetic Field 1.E+07 HTS Motors Critical Current Density 1.E+06 and Generators 64 K (A/cm ) 2 1.E+05 Second- generation HTS 77 K 1.E+04 First-generation HTS, 77 K 1.E+03 0 1 2 3 4 5 6 7 8 Magnetic Field (Tesla) Second Generation Wire will Outperform First Generation Wir
Slide 25: Wire Cost Impact on Economic Viability of HTS Motors
Wire Cost impact on Economic Viability of HTS Motors 5000 hp (3740 kW) Example of Sell Price of Conventional Cost of HTS Wire as Percent 200% 178% 150% 100% Motor 50% 33% 9% 5% 0% 1st Gen 1st Gen 2nd Gen 2nd Gen HTS Wire HTS Wire HTS Wire HTS Wire Today Best Cost Expected Best Cost in Future Cost in
Slide 26: Reliance Electric Motor Demonstrations
Reliance Electric High Temperature Superconducting Motor Demonstrations 5 hp in 1993 1600 hp in 2001 200 hp in 1996 Superconducting Motors 26
Slide 27: High Temperature Superconducting Motor Coils
High Temperature Superconducting Motor Coils 1st Generation HTS Coils 5 hp motor in 1993 1600 hp motor in 2001 Reliance Electric 200 hp motor in 1996 Motors Superconducting Motors 27
Slide 28: Second Generation HTS
Second Generation HTS All motor demonstrations before 2004 were based on using 1st Generation HTS wire Too costly for industrial motors Second Generation HTS wire is now being developed in lengths that are sufficient to demonstrate small rotating machines Superconducting Motors 28
Slide 29: HTS Generator Demonstration with 2nd Generation Wire
HTS Generator Demonstration with 2nd Generation Wire HTS Coils YBCO coils produced by SuperPower, Inc. 20-turns of HTS tape (approximately 5.9 m in length) per coil. Tape 1.2 cm in width. Superconducting Motors 29
Slide 30: Load Testing of the Generator (1800 rpm)
Load Testing of the Generator (1800 rpm) Tested with a three-phase resistive load (light bulbs) to a load of 900 W (1.2 hp) at a field current of 40 A and HTS coil temperature of 81K. World’s First Rotating Machine with 2nd Generation HTS Wire July 22, 2004 Superconducting Motors 30
Slide 31: Second Generation HTS Motor
Second Generation HTS Motor Four HTS coils with second generation wire from SuperPower, Inc. 26 meters of wire in four coils 25 turns per coil 7.5 HP motor with 2nd Gen HTS Field Coils July 2005 Superconducting Motors 31
Slide 32: Rockwell Automation Motor Demonstrations
Rockwell Automation High Temperature Superconducting Motor Demonstrations 10000 Motor Output Power (hp) 1st Gen HTS Wire 1000 100 10 2nd Gen HTS Wire 1 1990 1995 2000 2005 2010 Year of Demonstration Superconducting Motors 32
Slide 33: Conclusions
Conclusions High temperature superconductors (HTS) enable smaller and more efficient electric motors Half the volume and Half the losses of conventional motors HTS industrial motors will be in ratings above 1000 hp HTS wire cost reduction is key to successful industrial motors Second gen
Slide 34: Conclusions
Conclusions HTS motor demonstrations have increased in rating over the last decade Technology is in place when economic wire becomes available A second generation wire motor has been demonstrated in 2004 and 2005 HTS technology will impact electric machinery markets in the future. Supercondu
Slide 35: The Beginning ...
High Temperature Superconducting Motors The Beginning … This work was partially funded by the U.S. Department of Energy through a Superconductivity Partnership Initiative program under Cooperative Agreement DE-FC36-93CH10580 Superconducting Motors 35