Permanent Magnet Technology

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 DRS PM Machine Architectures

Radial (iron core) Radial Cup (iron core) Axial (iron core) Axial Air Core
PRE & PR classes PC Class PA Class PAAC Class
Standard for most Rotor outside stator Single Rotor Twin Rotor
motors
May need cover Ironless Stator
Dotted line
DRS PTI is World Leader in High Power/High Torque PM Machines

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 1,000 HP PA57 Axial Field PM Motor
Our Largest
Off-The-Shelf Motor

2,700 N-m (2,000 ft-lb)

output torque at stall
750 kW (1,000 HP) @
3,600 rpm
320 kg (780 lb)
800 mm (31 in) diameter
260 mm (10.5 in) long
Applications in:
Oil drilling equipment
High torque vehicle drives
Gensets

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 PA57 Production Shaft Coupled Alternator
Boston Silver Line Hybrid Bus
500 HP at 1800 RPM shaft coupled
to engine
Production run of 32 plus spares
delivered to the integrator
In active service since 2005

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 The PA57 Powered the Midfoil
Advanced Surface Ship

1,000 Hp marine diesel (MTU 12V183) Skid-mounted generator

light weight, compact DRS generator assembly in upper hull

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 450 HP PA44 Axial Field PM Motor
2,000 N-m (1,475 ft-lb) output torque at stall
336 kW (450 HP) @ 2860 rpm
195 kg (395 lb)
648 mm (25.5) diameter
224 mm (8.8) length
Totally enclosed, liquid cooled
3 phase, full bridge connection
Applications in:
Oil drilling equipment
High torque vehicle drives
Generator

Certified
intrinsically safe
for hazardous
service

60 G shock Testing

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 DRS PA44 Permanent Magnet Motors Have
Proven Themselves in Extreme Conditions
Application: Top drive drilling machines Drilling service entry: 1996
for oil and gas
Total units in service: 300+
Locations: More than 20 worldwide sites
Total operating hours: ~
Motor model: DRS PA44-5W-002 (336 kW) 1,000,000
Drive model: DRS MD500 (336 kW) Availability: >>99.9%

DRS PA44
PM Motor
Typical Rig Site 1 Motor 2 Motor 3 Motor
Portable Land Based Offshore
Top Drive Top Drive Top Drive

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 DRS PRE34-600 Motor
Testing Status/Schedule
Motor successfully completed low speed (below
1200 RPM) testing with 2 drives
Motor output exceeds performance objectives
Motor Application & Objectives
Oil & Gas Drilling Top Rigs
Standard stator with state-of-the-art rotor design
Combines rugged PM characteristics with low cost
commercial motor
Compatible with commercial drives
Distributed Motor Manufacturing
Key Performance Features
Air cooled & DPFV for use in Non-sparking Class
I, Zone 2 applications
2400 to 2800 ft-lbs torque with operation
Operation up to 2440 RPM
PRE1200 to be developed this year for top rigs
& draw works applications

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 Worlds Largest High Speed PM Machine
Permanent Magnet Technology offers
significant savings in weight and efficiency
Synch vs PM Comparison
Convention Permanent
Machine
al Field- Magnet
Type
Excited Cypress
Cooling Air Water/Air
Width (in) 103 71
Length
200 89
(in)
Height
142 119
(in)
Mass (MT) 44 17
10 MW Air Cooled
Cypress Test Cell

Canopy Technologies is a joint venture to address

the oil and gas market with a modular design
from 4 to 32MW at 7000 rpm, which is
synergistic with Naval power applications.

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 Why Permanent Magnet Motors?
Improved Efficiency
2-4 % full load
15-30% part load
Smaller and Lighter
Up to 50%
Robust
Larger Rotor to
Stator Gaps

Configuration Flexibility
DRS Permanent Magnet Motor Legacy Synchronous Motor
Adaptable Non-adaptable
L ~ 0.1 to 3.5D L ~ 1.5D

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 Why PMM Now?

Material Cost
Raw l
Higher Energy Costs Mag
nets
ria
Mate e
Efficiency Value Cu,
F

Material CostsCross Over

Much smaller machine
Fe, Cu costs > added NdFeB costs Time Scale

2005-2008
1987-1990
Affordable and Reliable VFDs
Market Acceptance
Elevators (UTC), Wind (GE), Drill Rigs
(NOV, TESCO), PODS (ABB), Auto
(Toyota, Honda, GM)
Ship Propulsion Investments (US Navy)
PMM No Longer a Technology Risk
Superconducting technology doesnt
meet Cost and Risk needs
Fundamentals Favoring PM
Technology
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 Permanent Magnet Motors
Work Best When
Application requires VFD
Efficiency a main driver Traditional PM Drawbacks:
Size and weight a main driver Voltage ControlPower
Rotor dynamics are an issue Electronic Cost
Rotor losses (heating and/or windage) Magnet Retention
an issue Cost
Higher speed-power product desirable
(e.g. to match compressor De-magnetization in
performance) severe transient modes
High starting or stall torque
Gear Elimination potential Solutions Available
Experience Key
Very high reliability
Unique geometry (L/D) necessary

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 DRS External Rotor (Inside-Out) DesignDirect
Drive to Draw works Potential
Internally Mounted Magnets 6-8 PSI in air gap can be
Rotor Tire used for rough sizing

Stator w/ Slots
External Rotor Geometry Electromagnetic Circuit Analysis

Co-Development Opportunity

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 DRS 1.5 MW 191 RPM Wind Turbine
Generator
DRS Co-Mfg. Low Gear Ratio PM Demonstrator
at National Renewables Energy Lab (NREL)now testing

Completed generator assembly

including a single stage, 9.3:1
ratio planetary gearbox

Integrated Generator Gear Reducer

Note: Demonstrator Does Not Include Field Control Innovation

DRS Has Experience In Cooperative Design and Manufacturing

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 DRS PTI Wind Power
Objectives/Status
Objectives: Leverage PM Machine Leadership into Wind
Market with production on rotor
Potential Business Model
Wind System Provider

Nacelle

Gear Gen Power Conv

TBD DRS+ Local Prod AETI

Co-Design and Built 1.5MW prototype @ NREL

AETI Agreement

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 3MVA Wind Generator Conceptual Design
Single Stage Reduction Gear Option

2.5 m (100 in)

Generator
Casing OD

2.0 m (80 in)

Air Gap dia

1.5 m (59 in)

Generator 690 Vrms
Casing length
Sized for 97.5 RPM, 6.5:1 Reduction gear for 15 RPM Turbine
Size constraint: 6m dia x 2 m length
Weight: 23,600 kg (52,000 lbs)

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 Bomay Wind Generator Conceptual Designs
Direct Drive Option

4.9 m (192 in)

Generator
Casing OD

4.6 m (180 in)

Air Gap dia

2.1 m (82 in)

Generator 690 Vrms
Casing length
Sized for 15 RPM, Direct drive
Size constraint: 6m dia x 2 m length
Design utilizes Air Cooled open end bell on drive
Weight: 57,000 kg (125,000 lbs)
end to leverage wind turbine hub bearing support,
minimize material usage, weight and cost~1.5x
cost of single stage Geared Approach
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 Cost Trade Vs Speed
1.5MVA Cost Estimations

Gear Ratio Speed Weight Length Efficiency

1:1 Direct Drive 16 RPM 57,000 kg 2.1 m 98.3%
6.5:1 (single) 98 RPM 23,600 kg 1.5 m 96.5%
13:1 (planetary) 200 RPM 16,600 kg 1.0 m 97.5%

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 DRS PTI Innovation - PM with
Field control
Synchronous Permanent Magnet

Additional Field to PM

Voltage
Permanent Magnet with Field PM Field
ControlInnovation
Field Ctrl. Gen.
Subtracted Field from PM

Normal
Operation

Extended Operation
Shaft RPM
Can either Extend Operating Range or Lower Electronics Costs
or a balance of the 2

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 DRS Innovation - PM Field Control

Efficiency (Est.) Generator Only

Voltage High Electronics Full- 70% Length Weight Cost
Regulation Speed (Cost & Size) Load Load
ok
Wound Field Yes Yes 1 94% 70% 1 1 1
Synchronous (VR Only)
PM Generator No Yes 5x 98% 90% 70% 70% 0.9 1.1
(Drive)
DRS PM Gen Yes Yes 1* to 6** 96% 93% 74% 73% 1.0 1.3
Field Control (VR Only)
*Assumes <20% range extension
** Max Duty Range with same Voltage range as PM as is machine

DRS Innovation Potential Game Changing Value to Wind Generation

Lower System Costs
Exportable Power at wider range of Wind Speeds

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 Next Steps
PRE/PA Needs?
Co-Development?
Drawworks
Mud Pump
Wind
China Mfg?

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 An Experienced Power Team
With a broad understanding of HM&E engineering
Aircraft DDG 1000 LM LCS VCS
Carriers

HV (15KV) & LV LV Power Machinery Control Panels

(450) Power Distribution Control System Detectors
Distribution (IFTP) (MPCMS)
Loadcenters
Mach. & Prop. Gas Turbine
Controllers
Plant Control Packaging Controllers
Systems Drives
Switchgear
(MCMS/PPMC) Gas Turbine
Controllers
Turbine Design Packaging

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 DRS Engineering Capabilities
Turbomachinery
Performance: thermodynamics, CFD
Rotating parts: buckets & rotors
Stationary parts: casings & diaphragms, etc.
Bearings & rotor dynamics

Package Integration
Generators, Gears
Fluid Systems: Air, oil, fuel, & fire protection
Electrical & control systems

Electric Machines
Electromagnetics
Thermal
Mechanical design and integration
Custom drives

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 DRS Engineering Capabilities
Additional Capabilities
Motor test and validation
Turbine test and validation
Program management: controls & risk management

Mil- Spec
Shock
Noise
EMI

Business Systems & Processes

Drafting: 3D Modeling & Teamcenter Document Manager
Deltek MRP System
ISO 9001 Certified, ABS NVR & Mil-Q-9858 Experience

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 Permanent Magnet
Propulsion Motors
Power-dense solutions
for advanced
naval propulsion
Advantages in size, weight and
power over more conventional
electric propulsion motors
po werful
ost or
Smaller motor footprint leads to The m magnet mot
nent
increased flexibility in engine perma the world
in 2 7 rpm
room design 1
m e gawatts
36.5
Improved efficiencies with
substantial part load advantages,
greater endurance and superior
acoustic performance

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 PAAC PM Motor
with Core Technology
Axial air gap PM motor with
printed circuit board stator
Inexpensive
Short design & production cycles
Inherently quiet
Power dense (30-50% smaller
than induction!)
Ideal For:
- Fans
- Integral Motor Pumps
- Actuators (rotary or linear)
Prototype
5 HP Integral
- VFD applications
Motor Pump
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 PM vs- Wound Field Synchronous

Exciter
Rect.
Rotor
Rotor (many Poles)
(few Poles)
Can drive
Short
Single End Stator (thin) both ends
end
Drive Stator Long end turns
(thick) turns

Simple & Compact

Permanent Magnet Motor
Complex & Inflexible Legacy
Synchronous Motor
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 Figure 6: Examples of integral machines built by DRS from left to
right, a geared wheel motor for a bus, an axle drive for a people
mover, and an integral motor pump.

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 DRS Manufacturing Capability
Skilled workforce
Large Component Assembly
Prototype Development
Mechanical and Electrical
Piping
Flushing
Packaging
Testing
Precision Assembly and Alignment
Manufacturing Engineering
Extensive network of fabrication
suppliers and machine shops in local
area with rotating equipment
background
Outsourcing
Project Management
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 ISO 9001 Certified
Management System
Quality System
Design Control
Document and Data Control
Purchasing
Control of Customer Supplied Product
Product Identification and Traceability
Process Control
Receiving, Identification and Testing
Inspection, Measuring and Test
Equipment
Inspection and Test Status
Control of Non-conforming Product
Corrective & Preventative Action
Handling, Storage, Packaging,
Preservation and Delivery
Control of Quality Records
Internal Quality Audits
Training
Servicing
Statistical Techniques
Export/Visitor Control/ Travel
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 NREL 1.5MW Model
Cooling tube

Thermal gasket/slot liner

Laminated Tie down bolt

steel pole

Edge Top stick/ pole

wound clamp
coil

Laminated
Pole clamp pole face

magnet

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 NREL 1.5MW Rotor and Stator
Designed for Gear Integration
Pole Cap

Pole Clamp
Magnet

Rotor Stator Segment and Rotor

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 Benefits of Motor Gear
Cooperation

Optimized Gear ratio vs Generator size?

Gen
e rato Gear
r

Cost
and
Wgt
RPM or Ratio
Gear Ratio Speed Weight Length Efficiency
1:1 Direct Drive 16 RPM 57,000 kg 2.1 m 98.3% Eff can be traded with Size
and Cost
6.5:1 (single) 98 RPM 23,600 kg 1.5 m 96.5% Diam and Length vs Cost
13:1 (planetary) 200 RPM 16,600 kg 1.0 m 97.5%

Integral design (1 housing)lower cost and weight

Production Mfg

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