Historical Evolution of Motor Technology
Historical Evolution of Motor Technology
Historical Evolution of Motor Technology
Hiroyuki Mikami, Dr. Eng. OVERVIEW: Driven by a strong desire to produce electric motors using
Kazumasa Ide, Dr. Eng. domestic rather than foreign technology, Hitachi’s founder, Namihei Odaira,
Yukiaki Shimizu produced three 5-HP electric motors in 1910. Now, a century later, electric
motors incorporate a variety of different technologies and have undergone
Masaharu Senoo
significant changes in their size, performance, and other features. They have
Hideaki Seki become a key device that underpins society in a wide range of fields including
power generation, industry, transport, and home appliances.
Household AC
Home Refrigerator
appliances
Washing machine
Vacuum cleaner
General purpose
(pump, blower, etc.)
Elevator
Industrial
Railroad
Fig. 1—5-HP (horse power) Induction Motor. Steel mill
After building up experience and skills through the repair of
Power Wind power
electrical machinery, Hitachi produced three induction motors systems
Thermal power
with an external diameter of approximately 400 mm and a
weight of approximately 150 kg. The motors were designed EPT: electric power train HEV: hybrid electric vehicle
EPS: electric power steering AC: air conditioner
by Naosaburo Takao (who later became Vice-President) and
manufactured from parts made using a sheet steel processing Fig. 2—Examples of Hitachi Electric Motor Products.
machine imported from the UK and a coil winding machine Motors and generators have advanced to become key devices
they built themselves. that help underpin society.
Hitachi Review Vol. 60 (2011), No. 1 39
40% of all electricity consumption (1) . As well as 5-HP (3.7-kW) 4-pole induction motor
playing a major role in industrial progress, it is no
exaggeration to say that rotating machinery in the form
1910 1916 1935 1951 1955 1963 1970 1991 1994
of motors and generators form part of the foundations
1977 2001
of modern society. 100
Total prod. = 20 M Total prod. = 40 M
Journal bearing Ball bearing
This article reviews the historical evolution of
Stator Frame
Hitachi turbine generator
Conventional 4-pole
Max. capacity (MVA)
−60
r
60
de
400 250 MVA Tim
Or
eH 0
arm
ic
70 MVA onic
on
n Ord
m
arm
er
End
60 0
0
eH
Base
ac
cover
Sp
3D analysis
Quasi 3D analysis Electromagnetic field Spectral force resolution Structural vibration
2D analysis
Relative calculation speed (p. u.)
Fig. 5—Advances in Analysis and Design Techniques Relating Fig. 6—Motor Electromagnetism and Noise Analysis.
to Electromagnetic Field Analysis. Motor noise can be estimated quantitatively based on a
Large and complex analyses have facilitated the development coupled electromagnetic force, structure, and fluid analysis.
of motors, generators, and other machines thanks to advances
in the computing environment.
the calculation time by taking advantage of the various 320 SmCo magnet
cyclic aspects of internal motor operation based on 160 AlNiCo magnet
motor theory(3). These expanded the range of cases that Ferrite magnet
0
1910 1950 2000
could be analyzed and allowed a complete cycle of the
Air conditioner compressor motor
waveform to be calculated from analysis information
for a particular region only, including analysis of Stator
1983 have played a major role in reducing motor size of the coil wound around the mold. Technology was
and improving performance. also developed to ensure that the stator core is put
Fig. 7 shows the history of permanent magnet together with a high degree of roundness when it is
development and advances in permanent magnet separated and reassembled, resulting in small size and
motors. Magnet energy product improves progressively low cogging torque. This technology has been used in
from ferrite through alnico and samarium-cobalt industrial servo motors since 2000 (6).
magnets. While the most commonly used magnet in
earlier times was the low-cost ferrite magnet, use of INVERTER AND DRIVE CONTROL
neodymium magnets (the strongest type of magnet) TECHNOLOGIES
grew rapidly after their invention. Looking at the Changes in Variable-speed Systems
influence these magnets have had on Hitachi’s air Whereas DC motors had previously been the
conditioner compressor motors, initially these motors mainstay for variable-speed motor control, a major
used ferrite magnet rotors combined with distributed- shift to AC motors took place in the 1980s. Fig. 9
winding stators. The arrival of the neodymium magnet shows the history of advances in motor drive control.
saw the adoption of concentrated windings for the The major factors behind these advances are the
stator and, as shown in the figure, smaller coil end performance improvements in microcomputers and
size. Although coil ends with concentrated windings the main circuit elements used in inverters. The main
are smaller, because they produce large harmonic control method changed progressively to AC motor
components in the magnetic flux distribution, the vector control and, in terms of precision, response, and
stator and rotor shape become important design speed range, the performance of AC motors came to
considerations. Consequently, advances in the surpass that of DC motors.
electromagnetic field analysis techniques described
above have been complementary with those in magnet Sensorless Control
materials and have allowed both axial length to be Fig. 10 shows how vector control of induction
roughly halved and efficiency to be improved. motors has evolved. The general-purpose inverter has
One example of production technology is a provided the driving force behind induction motor
technique for achieving a high space factor (winding control technology. Sensorless vector control was
density) through use of a split core. Fig. 8 shows an incorporated in general-purpose inverters in 1989.
example of a technique for increasing the density of
wires in the winding slots by using a press-forming
1960 1970 1980 1990 2000
machine to pressure-mold an aligned pre-wound core.
This achieves a high space factor by molding the wire Motor DCM ACM (IM, SM)
into the shape of the slot that is to hold the winding Power M-G Thyristor Leonard Cycloconverter
converter PWM invertor
without compromising the insulation performance
Control Analog-digital
circuit Analog hybrid Digital (microprocessor), ASIC
Response DCM 60
15 – 20 500 – 1000
(rad/s) 2
ACM
Press die Speed DCM 1:1000 –
1:40
Winding frame range 1:5 1:200
ACM
AC servo motor (2001) DCM: DC motor ACM: AC motor IM: induction motor
SM: synchronous motor M-G: motor-generator
• Small size PWM: pulse width modulation
• High space factor: 75% • Low cogging torque ASIC: application specific integrated circuit PI: proportional/integral
• High accuracy • High speed response:
roundness: 0.03 mm 500 Hz Fig. 9—History of Advances in Motor Drive Control.
State in slot section
The performance of variable-speed AC motor systems has
improved with advances in control and power conversion
Fig. 8—Split Core and Winding with High Space Factor. equipment (Reference: 2001 Annual Conference of Industry
Better motor performance was achieved by improving the coil Applications Society, The Institute of Electrical Engineers of
space factor and the precision of split core assembly. Japan, S11-1).
Historical Evolution of Motor Technology 42
200% torque
Permanent magnet motors were introduced in
frequency at
5.0 V/F
(Hz)
constant • HITACHI • HITACHI • HITACHI Hitachi air conditioners in 1982 and mass-market
1.0 HFC-VWA SJ300 SJ700
0.0 models have used sensorless control since that time.
1970 1980 1990 2000
4.0
• 120° control
• PAM washing machines as well as in other fields such as in
2.0 industry or for auxiliary automotive motors.
1970 1980 1990 2000
PMSM
sensor
energy consumption by making motors even smaller
Sin-wave
Development of position- current and more efficient. To achieve both smaller size and
sensorless control with 120° Ideal sine wave current drive
commutation, use of PM introduced in consumer appliances higher efficiency, it is necessary to minimize as far as
motors in air conditioners. using “less & less” technology.
possible the various types of energy loss that occur
COP: coefficient of performance PM: permanent magnet inside motors while simultaneously dealing with the
PAM: pulse amplitude modulation MPU: microprocessor unit
reduction in heat dissipation performance that results
Fig. 11—Advances in Sensorless Control of Permanent Magnet when motors are made smaller.
Motors.
Against this background and on the occasion of
Advances in control techniques for permanent magnet motors
that do not use position and current sensors and which were
the 100th anniversary of the company’s founding,
developed for use in air conditioners. Hitachi, Ltd. in collaboration with Hitachi Industrial
Equipment Systems Co., Ltd. produced a prototype
concept motor in 2010 with the intention of achieving
Compared to V/F (voltage/frequency) control used even smaller motor sizes in future. The prototype
previously which kept the flux swing constant, vector involved the development of technology to improve
control achieves a significant improvement in low-speed heat dissipation, a coupled magnetic field and thermal
torque by controlling the torque components. Zero- analysis technique that simultaneously analyzes the
hertz sensorless technology was first commercialized magnetic flux and heat flow in the motor, and design
in 1999 and succeeded in performing vector control at optimization techniques that are based on this analysis
0 Hz, something that was not previously possible. technology. It is this analysis technology that makes
Fig. 11 shows the history of sensorless control the greatest contribution to the design of motors for
techniques for permanent magnet motors. Development small size and the following sections describe the
of permanent magnet motor control was undertaken technology itself together with the prototype motor
primarily for air conditioning appliances. The size and that was investigated with its aid (8).
efficiency of permanent magnet motors underwent a
sudden improvement with the invention of rare-earth Coupled Magnetic Field and Thermal Analysis
magnets, but because they cannot be started without an and Shape Optimization Techniques
inverter, the applications for these motors have grown Because the objective was to make a smaller motor,
with the help of control technology. a permanent magnet configuration was chosen for the
Hitachi Review Vol. 60 (2011), No. 1 43
D e sp it e h av i ng su ch a h ig h d eg r e e of
miniaturization, the motor achieved a very high
Hitachi’s first motor (IM)
efficiency of approximately 94% in continuous
operation tests.
Current model
(IM)
Prototype FUTURE OUTLOOK
(PM) The evolution of the electric motor has been
underpinned by design, production, and material
technologies. In recent years in particular, motor
performance has received a major boost from a variety
of simulation techniques and other advances such as
in materials technology, particularly in the field of
permanent magnet motors. Prompted by concerns
Fig. 13—Comparison of Original 5-HP Motor, Current about reducing the burden on the environment, it is
Production Model, and New Prototype. anticipated that, in addition to the expected further
The body of the prototype motor is only one-fifteenth the size of improvements in efficiency, the future will also
Hitachi’s original motor. see further research into motor structure aimed at
reducing material usage through smaller motor sizes
and making available materials that do not include
scarce resources (9) . With use of electric motors
Prototype
5-HP motor and inverters becoming standard practice, it is also
designed by anticipated that motors, inverters, and motor control
Design
will become integrated in both a structural and design
Division
sense. In terms of control, vector control has entered
widespread use starting with 120° commutation
control, and it seems likely that control techniques
that take account of motor non-linearity caused
by magnetic saturation will enter practical use in
order to combine controllability with small size and
light weight (10) . In the field of design technology,
meanwhile, it is anticipated that integrated design
Fig. 14—Prototype Motor on Show at Hitachi uVALUE methods will be adopted using techniques based on
Convention 2010 held in Japan.
overall optimization instead of designing the inverter,
The prototype motor was included in the 100th Anniversary
Exhibit and was made using a design prepared by Hitachi’s
motor, and control separately as in the past and then
Design Division. having to tune their combined operation.
CONCLUSIONS
the volume of current 5-HP induction motors) (see Motors and generators are examples of products
Fig. 13). The motor development also drew on the that utilize magnetism in their operation. This article
leading-edge materials of the Hitachi Group including has reviewed the historical evolution and future
the use of neodymium magnets from Hitachi Metals, outlook for these machines along with the inverter-
Ltd. in the rotor, enameled wire from Hitachi Cable, based control systems used to drive them.
Ltd., and organic chemical materials from Hitachi As with the relationship between motors and
Chemical Co., Ltd. control and motors and inverters, it is anticipated that
An example of the prototype motor produced electric drive will continue to make rapid advances
using a design from Hitachi’s Design Division was in the future through the ability to produce designs
unveiled to the public at the “Hitachi uVALUE that are even better at balancing reliability, structural
Convention 2010” held in July 2010 in Japan where it design, and value by designing motors and inverters
was included in an exhibit celebrating the company’s as a single unit.
100th anniversary (see Fig. 14).
Hitachi Review Vol. 60 (2011), No. 1 45
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Waves of the Synchronous Machine Considering Positive- Core to Permanent Magnet Synchronous Motors,” The
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(5) K. Siohata, “A Method for Analyzing Electromagnetic-Force- (10) H. Nagura, “New Vector Controller for PM Motors Which
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Hideaki Seki
Joined Hitachi, Ltd. in 1979, and now works at the
Motor Power Systems Division. He is currently
engaged in a project to strengthen motor and inverter
development.