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IE Coverage

Jul 26 2023

Cooling Data Centers Is Costing Our Planet

Cooling Data Centers Is Costing Our Planet

The booming global market for more data centers will require enormous amounts of energy. Sustainable motors will be the key to meeting this demand.

By JUSTIN SCOTT, Applications Engineer, Infinitum

Data centers have become increasingly critical to the world economy. As computing demands rise due to business reliance on cloud computing, the Internet of Things (IoT), AI innovations and Industry 4.0, more data is being generated along with the growing need to capture, store, evaluate and retrieve it. In the U.S alone, the data center market is projected to reach $69 billion by 2024.

And the more we rely on these capabilities, the more energy we require to support our computing needs.

In the U.S., data center energy consumption is expected to double, reaching 35 gigawatts (GW) by 2030, up from 17 GW in 2022. Additionally, with projections stating that by 2030 information and communications technology (ICT) will account for up to 20% of global energy usage, it’s evident that the growing demand for data center computing is becoming a pressing sustainability concern.

While demand is a major factor in energy consumption, higher outdoor temperatures can also play a role.

As external temperatures rise, data center facilities must “work harder” to maintain the required level of cooling. Liquid cooling, air handling units that can leverage free cooling and economizers, as well as precision cooling, are the types of innovative solutions that can increase the energy efficiency of data centers. In addition, HVAC equipment manufacturers are prioritizing sustainable, power-dense equipment that can handle higher levels of heat, while keeping data centers operating at lower temperatures.

Currently, 40% of the energy in data centers is consumed by motors that power cooling equipment, such as fans, pumps, and compressors. A typical data center employs an average of 500 electric motors to drive HVAC systems alone. Many of the motors powering today’s data centers are heavy and inefficient.

New advancements in motor designs that replace traditional heavy iron core stators with innovative materials, such as PCBs, have led to motors that are smaller, lighter, more efficient and power-dense. Some motors can also be precisely matched to the cooling application’s specific horsepower, speed and torque requirements, allowing data center designers to optimize and reduce the supporting electrical infrastructure, while achieving performance targets to reduce energy consumption by 10-15%.

As data center cooling equipment manufacturers continue to innovate with more efficient HVAC designs, there are three main considerations for sustainable data center cooling that begin with the motor. Below, I’ll explain why each should be considered when introducing a motor into the data center environment:

High-Efficiency Levels Across a Wide Range

Traditional motors that feature an iron core with copper windings will often experience eddy currents that result in motor losses. Replacing the iron core and copper windings with a PCB stator eliminates these losses, resulting in a higher efficiency motor not just at the rated power and speed, but across the entire operating range (including partial load conditions). In motors that use PCB stators, copper can be etched directly into the PCB, which also increases the reliability and life of the stator, and significantly reduces the amount of copper material needed.

In a data center, where loads can vary widely depending on the time of day, it’s important to identify a motor that has a flat efficiency curve across a wide range of load conditions to optimize overall HVAC system efficiency and operations. Doing this will ensure the system will benefit from optimum efficiency under a variety of operating conditions.

Advanced air core motors that leverage PCB stators can run at variable speeds with partial load efficiency, saving energy at off peak times, while maintaining high levels of efficiency across a wide range of loads and speeds. For example, air core motors used together with an efficient fan can improve wire-to-air efficiency, and create a fan with a flat efficiency curve across full and partial load conditions.

Precise Controls and Intelligence

Improvements to motor efficiency and demand-based variable speed controls can save upwards of 65% of energy use depending on the application. Control capabilities for motors range from basic speed control options to more sophisticated speed control features and capabilities. Variable frequency drives (VFDs) that use silicon carbide can operate at higher switching frequencies and temperatures, with fewer losses, and can provide precise control in overall power and energy savings for the motor system.

Having more intelligence built into motors can also allow data centers to require fewer motors for redundancy on fan systems, while also running them at their most efficient operating speeds. Today’s motors can integrate MODBUS, BACnet and SCADA connectivity to communicate motor performance and health data back to a controller or centralized control system. IoT connectivity can also be used to monitor critical equipment to optimize building operations, and alert operators to high temperatures or other system parameters that are out of pattern or range so they can proactively address issues before something fails.

Sustainable Design

With data center space at a premium, design is an important consideration. Motors that take advantage of more compact, axial-flux designs and thin PCB stators (versus heavier iron-core motors) can result in 50% smaller and lighter form factors and reduce overall space required in data center air handling, chillers, coolers and liquid cooling applications.

This can allow for closer proximity to data center equipment and for more effective, efficient cooling and removal of heat. Smaller, lighter motors can also allow for ease of installation and make access easier for maintenance.

Sustainable design that minimizes the use of raw materials and incorporates end of life management can support initiatives to reduce waste. Today, the majority of motors end up in landfills after 10 to 20 years, but advances in circular motor design are allowing for extended component life and reuse. Data centers have hundreds to thousands of motors with valuable materials, such as aluminum, steel, magnets that can benefit from refurbishment and reuse, rather than being thrown into a landfill. Motors that take advantage of modular design can make the motor easy to maintain and allow for components to be reused multiple times.

In conclusion, responsible design in data center cooling equipment is increasingly becoming a priority as data centers continue to grow in number and energy usage. Advanced motors that operate with high efficiency across a wide range of speeds, have precise control and intelligence capabilities, and those that are built with sustainable design in mind can play a major role in reducing the carbon footprint of HVAC systems and data centers overall.

Read the full article at HPAC Engineering.

Written by Mandy Chalman · Categorized: Coverage, IE Coverage · Tagged: Data center, electric motors, HVAC, Sustainability, sustainable

Jun 19 2023

HVAC Solutions Help Data Centers Achieve Sustainability

HVAC Solutions Help Data Centers Achieve Sustainability

The right equipment can reduce energy consumption, as well as the carbon footprint

By Joanna R. Turpin

SUSTAINABLE SOLUTIONS: Adopting sustainable HVAC solutions can reduce a data center’s environmental impact and energy consumption. (Courtesy of Danfoss)

Data center growth has exploded in recent years; however, this increased demand for data processing comes at a cost, as data centers are notorious for their massive energy consumption and carbon footprint. In fact, according to the Department of Energy (DOE), data centers consume 10 to 50 times the energy per floor space of a typical commercial office building, accounting for approximately 2% of the total U.S. electricity use.

To tackle this problem, there has been more of an emphasis on promoting sustainability in data centers. HVAC systems play a large role in achieving sustainability, as this equipment is responsible for ensuring that the temperature and humidity levels in a data center remain within the acceptable range 24 hours a day, seven days a week. By implementing sustainable HVAC solutions, data center operators can significantly reduce their energy consumption and environmental impact.

“A sustainable data center actively works to reduce power usage, energy, water, and carbon emissions.”

– Michael Strouboulis
Director of business development, data centers
Danfoss

Sustainable Strategies

A sustainable data center aims to balance the need for reliable and effective data processing with the need to minimize its environmental impact. To achieve that objective, a sustainable data center actively works to reduce power usage, energy, water, and carbon emissions, said Michael Strouboulis, director of business development, data centers, at Danfoss.

“Lowering power usage effectiveness (PUE), which measures the ratio of the total power coming into the data center to the power consumed by the information technology equipment (ITE), as well as water usage effectiveness (WUE), carbon usage effectiveness (CUE), and increasing energy reuse (ERE), are key to meeting sustainability and net-zero carbon targets,” said Strouboulis. “The transition to all four of these metrics naturally involves looking at the entire data center infrastructure, including the mechanical systems that support data center cooling and ITE thermal management, which account for as much as 30% to 40% of the power into the facility.”

Sustainable data centers also strive to attain carbon neutrality targets and lower carbon emissions by utilizing renewable energy sources and adopting energy-efficient HVAC equipment and monitoring technologies, all while ensuring reliable and effective power supply, said Mukul Anand, global director of business development, applied HVAC global products at Johnson Controls.

“Digitally equipped BMS and optimization software provide insights and control that help facility managers run buildings as efficiently as possible,” said Anand. “Some facility managers are also working with HVAC manufacturers to find ways to use waste heat in other building areas, which minimizes fossil fuel use. In response, HVAC engineers are developing products that can very efficiently use this waste heat.”

Sustainability in a data center extends beyond just its power sources, encompassing its construction and design as well. For example, the materials and components employed must be durable and minimize waste by avoiding unnecessary repairs and replacements, said Rachel (Ray) Larimore, project manager at Ruskin.

“The design should also maximize the space while allowing for ease of maintenance,” said Larimore. “HVAC systems are generally difficult to access for maintenance, since they are most often built into walls and in high ceilings. However, data center owners are taking particular care to design their facilities with maintenance schedules and longevity in mind.”

Finally, sustainable data centers have an end-of-life strategy that limits waste and environmental pollutants, which is a key aspect of these types of facilities, said Justin Scott, applications engineer at Infinitum.

“Operators must responsibly dispose of refrigerants and other fluids, and work with partners to recycle or remanufacture components and subcomponents,” said Scott. “Data centers also have thousands of motors with valuable materials, such as aluminum, steel, and magnets that would benefit from refurbishment and reuse, rather than being thrown into a landfill.”

HVAC Solutions

Achieving sustainability in a new or existing data center can be a challenge, as it can be difficult to balance design conditions with energy efficiency. Uptime is absolutely critical to data centers, so the HVAC equipment has to be designed to keep the facility operational in the most extreme conditions it will face, said Anand.

OPTIMAL UPTIME: Data centers are running processes 24/7, so uptime and operational efficiency are paramount. (Courtesy of Danfoss)

“Yet a data center may only experience extreme conditions a handful of times — if ever — and this can result in a trade-off when it comes to sustainability,” said Anand. “This is because equipment typically operates in conditions for which it wasn’t originally selected, and that can result in decreased energy efficiency.”

One technology that is widely used to increase sustainability and reduce energy consumption in data centers is free cooling. Free cooling refers to the use of cooler outdoor air to reduce the temperature of the facility’s cooling water or air without the need for mechanical cooling. By using free cooling, HVAC systems can significantly reduce energy consumption and operating costs, especially in regions with mild climates.

“Data centers have used direct evaporative cooling to achieve cooling, which can be water and energy intensive,” said Anand. “We see a shift there. Advances in air-cooled chillers make it possible to use economization instead. Some air-cooled chillers feature additional free cooling coils that generate free cooling when ambient conditions are milder or colder. The latest air-cooled chillers operate at inverted conditions, which means they can provide free cooling even in the absence of free cooling coils, providing excellent efficiency at low ambient conditions. These lighter chillers also allow for a smaller carbon footprint.”

COST SAVINGS: Using efficient motors — such as the Infinitum motors used in this data center fan array — can translate to 10% savings in energy consumption and costs. (Courtesy of Infinitum)

Utilizing energy-efficient motors and variable-speed drives (VSDs) is also essential for optimizing the energy consumption of cooling system components such as compressors, fans, and pumps. The VSD allows the motor’s output to match the computing demand and saves energy by delivering the exact amount of power required at any given time, said Strouboulis.

“The effect that VSDs have on energy consumption is huge,” he said. “Chillers with oil-free, magnetic bearing, VSD compressors are some of the most efficient pieces of equipment used in data centers, because they offer efficient heat transfer and reliable cooling throughout their life cycle without the maintenance requirements and performance degradation experienced with other types of compressors.”

Utilizing efficient components in HVAC equipment to enhance sustainability is important, agrees Scott, especially in data centers that experience usage cycles. He cites Netflix as an example, noting that their data centers may experience a peak load at 8 p.m. when users stream content, and a smaller load at 8 a.m. Given this usage profile, it would make sense to decrease the load on the HVAC system during the morning hours.

“EC motors used together with an efficient fan creates a highly efficient EC fan with a flat efficiency curve across full and partial load conditions,” said Scott. “EC motors can run at variable speeds with partial-load efficiency, saving energy at off-peak times. Some are able to maintain high levels of efficiency across a wide range of loads and speeds. Using more efficient motors, like EC motors, can translate to 10% savings in energy consumption and costs overall.”

Power consumption in a data center can also be reduced through the use of energy-efficient controls and careful planning to reduce the energy required to operate HVAC systems, said Larimore. For example, she said that it may be possible to reduce the number of actuators used to modulate airflow by reducing the number of sections or optimizing installation locations to power multiple sections of dampers from a single actuator. This can reduce the overall power needs in the design.

“Airflow design needs to be taken into consideration as well,” said Larimore. “Keeping electronics cool to avoid failure is of great importance in a data center. Rather than overcompensating by bringing in extra air, HVAC equipment should be designed to optimize airflow and circulation to keep the building at the required temperature and with enough clean air without being wasteful.”

Looking Ahead

The sustainable data center trend will likely continue, given the rising demand for digital services and growing awareness of the impact of these types of facilities on the environment. As such, the HVAC equipment designed for data centers will continue to evolve. For example, today’s primary way for cooling data centers is precision air, and that will be around for the “low rack power density” data centers for some time, said Strouboulis.

“However, with the proliferation of high-performance computing (HPC), artificial intelligence (AI), machine learning (ML), IoT, and other evolving computing technologies, rack power densities are rising, and liquid cooling is becoming essential to ensuring reliability and performance,” he said. “For example, CRAC/CRAH and row-based containment cooling solutions are ideal up to 15 to 20 kW, but there is a point, maybe around 20 kW, past which they are no longer cost-effective or efficient. At that point, you start to look at other techniques that are cooling closer to the source of heat and are located very close to the rack doors or even closer than that, as these techniques will be cooling microchips directly by direct-to-chip or immersion liquid cooling.”

Compared to traditional air cooling, liquid cooling is more efficient at transferring heat away from electrical components, said Scott. That is because liquid’s heat-carrying capacity can be up to 3,500 times greater than that of air.

“There are a few ways to apply liquid cooling and each has challenges,” he said. “One approach is to bring fluid to the chip set to remove heat, but while this is great for the processor, it doesn’t cool other components. A second approach is bringing liquid cooling to the rack where air supplements the cooling. A third approach is immersion cooling of server racks in a tank, where the fluid surrounds server boards and removes heat. The challenge is moving parts in and out of fluid and potentially contaminating/damaging other components. With liquid cooling, you still need traditional air coolers, chillers, and evaporative cooling.”

PEAK EFFICIENCY: The York YVAM air-cooled magnetic bearing centrifugal chiller can reduce the full-load power consumption of the chiller and deliver peak efficiency beyond typical industry standards. (Courtesy of Johnson Controls)

Speaking of chillers, new technology is available that can help contractors design more sustainable data center systems. Specifically, low-friction, air-cooled, magnetic-bearing centrifugal chillers can reduce the full-load power consumption of the chiller and deliver peak efficiency beyond typical industry standards, said Anand. In addition, the electrical infrastructure that powers the chiller — including transformers, uninterruptible power supplies (UPS), generators, automatic transfer switches, and switchgear — can all be sized lower, leading to first-cost savings.

“Cooling products that use low-GWP refrigerants are also available to further minimize resource consumption and reduce community and planet impact,” said Anand. “In addition, HVAC engineers are working on quieter products that consume less natural resources and have the maximum amount of recyclable content.”

Another factor that will influence the future design of HVAC equipment is the increasing price of real estate.

“Because land is so valuable in key locations, including Ashburn, Phoenix, Dallas, and Silicon Valley, data centers are now growing vertically rather than horizontally,” said Anand. “When a data center grows vertically, the interior square footage that must be cooled gets larger, but the amount of rooftop space to place chillers doesn’t. Multistory data centers are one of the challenges that continue to drive innovation in the design of HVAC equipment.”

Identifying Improvements

Contractors can help their data center customers identify ways to improve their sustainability by evaluating their operating conditions from three different perspectives, said Mukul Anand from Johnson Controls:

  • Is any equipment operating outside of its parameters that could indicate a potential issue in the near future?
  • Is the HVAC equipment operating at optimal energy efficiency given the ambient conditions?
  • Are there spikes in the system that are reducing efficiency and reliability?

“While the first two are pretty self-explanatory, the third relies on understanding facility trends,” said Anand. “For example, if a data center typically ramps up in heat generation at 8 a.m., it can be automated to gradually ramp up capacity starting at 7 a.m. rather than going at 100% capacity at 7:59 a.m. This can minimize system spikes, improve energy efficiency, and extend equipment life.”

It can sometimes be difficult for contractors to obtain this type of information, as some data centers — due to concerns over cybersecurity and privacy — have developed their own real-time, AI-assisted monitoring and tracking systems used for optimizing operations, predictive and service maintenance, energy consumption optimization, capacity management, and planning, said Michael Strouboulis from Danfoss.

“However, there are third-party SaaS packages that offer additional insights, such as predictive analytics, to service enterprise and edge data centers,” he said. “Energy audits and installing smart devices such as energy metering can help identify areas of improvement. Contractors can also install sensors that feed information to cloud-based monitoring of essential components of the cooling system in order to ensure systems are running at peak performance and thereby reducing carbon emissions.”

Read the full article at ACHR News.

Written by Mandy Chalman · Categorized: Coverage, IE Coverage · Tagged: Data center, electric motors, HVAC, Sustainability, sustainable

Jun 13 2023

How advances in industrial motors and controls can boost the bottom line

How advances in industrial motors and controls can boost the bottom line

Sheila Kennedy says revolutionary approaches in design and technology yield unique benefits.

By Sheila Kennedy

Motor and drive providers are moving forward with new solutions for persistent challenges. Thinking out of the box, they are embracing business, technological, and environmental opportunities to help their customers improve operations and maintenance and boost the bottom line.

Innovative motor designs

Sustainability, reliability, and maintainability are common aspirations for motor designers. The Aircore EC motor from Infinitum, designed for efficiency, reliability, and performance, delivers reduced energy consumption, extended life, and minimal waste. For instance, the integrated motor and drive is smaller and lighter than traditional iron core motors and its printed circuit board stators use 66% less copper than conventional wire-wound stators.

“Fewer raw materials and modular design simplify maintenance for industrial plant professionals and allow for remanufacturing and reuse, while an integrated VFD made with silicon carbide technology results in unparalleled control of the motor, and can save upwards of 65% of energy use, depending on the application,” says Ramon Guitart, vice president of engineering at Infinitum.

Download “Designing Electric Motors for Intrinsic Reliability”

AC motors, like Infinitum’s Aircore EC are more energy-efficient compared to other types of motors, such as DC motors. They convert electrical energy into mechanical energy more effectively, resulting in reduced energy consumption. Lower energy usage leads to decreased operating costs and improved overall efficiency.

Advanced motor controls allow for precise control of motor speed, acceleration, and deceleration. This feature is particularly useful in applications where varying loads and speeds are required. By adjusting the motor speed to match the specific task requirements, businesses can optimize energy consumption and reduce wear and tear on machinery, thereby extending their lifespan.

Motor control systems enable businesses to implement sophisticated automation and process control strategies. These systems can integrate with other industrial control systems, such as programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) systems, and distributed control systems (DCS). The precise control and monitoring of motors in conjunction with these systems result in better overall process efficiency, reduced downtime, and improved product quality.

Industrial motor controls often incorporate condition monitoring capabilities. These systems can collect data on motor performance, temperature, vibrations, and other key parameters. By continuously monitoring motor health, businesses can identify potential issues before they cause significant downtime or catastrophic failures. Predictive maintenance based on real-time data allows for proactive maintenance scheduling, reducing unplanned downtime and avoiding costly repairs.

Many advanced motor control systems offer remote monitoring and control capabilities. This feature allows businesses to monitor motor performance and make necessary adjustments from a centralized location. Remote access to motor controls enables faster troubleshooting, reduced response times, and minimizes the need for on-site personnel, resulting in cost savings.

Compliance with Efficiency Standards: AC motors and motor controls that meet or exceed energy efficiency standards, such as those established by organizations like the International Electrotechnical Commission (IEC) or the National Electrical Manufacturers Association (NEMA), can help businesses comply with regulations. Compliance with energy efficiency standards may lead to financial incentives, rebates, or tax benefits.

In summary, AC motors, like Infinitum’s Aircore EC, contribute to increased energy efficiency, improved process control, optimized maintenance strategies, and enhanced automation. These benefits collectively lead to cost savings, increased productivity, reduced downtime, and improved overall operational efficiency, ultimately boosting the bottom line for businesses.

Read the full article at Plant Services.

Written by Mandy Chalman · Categorized: Coverage, IE Coverage · Tagged: electric motors, Sustainability, sustainable

Jun 01 2023

5 Ways to Maximize Energy Conservation in Circulator Pumps With Electronically Commutated Motors

5 Ways to Maximize Energy Conservation in Circulator Pumps With Electronically Commutated Motors

Choosing the right EC motor can aid sustainability efforts.

By Anthony Lou


IMAGE 1: Fan efficiency curve comparing EC motors (with and without air core architecture) to super premium alternating current (AC) induction motor and variable frequency drive (Images courtesy of Infinitum)

The United States Department of Energy (DOE) recently proposed new energy conservation standards for circulator pumps, prompting manufacturers to design them for increased efficiency.

Circulator pumps are ubiquitous, and the opportunity to reduce their energy consumption is enormous. An Electric Power Research Institute (EPRI) report estimated the energy savings potential for the approximately 30 million installations of circulator pumps is greater than 50%.

Circulator pumps are found in a variety of commercial building applications, such as air handling units (AHUs), cooling coil booster pumps, small radiant systems, ground source heat pumps and domestic hot water (DHW) recirculation loops.
To date, circulator pumps have been overlooked for energy efficiency upgrades, in part due to the lengthy, capital-intensive design cycles inherent to pump design, but new technologies are making it worthwhile.

Currently, more than 90% of circulator pumps in the U.S. are constant volume pumps powered by standard induction motors, according to the U.S. General Services Administration. To achieve energy conservation goals, the DOE recommends using more advanced motor technologies.

The DOE’s analysis finds that electronically commutated (EC) motors are generally much more efficient than induction motors and can improve overall pump system efficiency. Most EC motors use a traditional iron-core stator with copper windings, but new air core motor topologies are using an innovative printed circuit board (PCB) stator, which has the benefit of eliminating core losses and increasing efficiency. As circulator pump manufacturers consider new EC motor technologies in their designs, there are several factors to consider for optimization.

Efficiency

EC motors are generally 30% more efficient than induction motors because their construction minimizes losses between the rotor and stator components. In EC motors, the lamination and copper heat loss is reduced by 50%, making it more efficient. EC motors that meet international efficiency (IE) 5 standards offer some of the highest efficiency levels possible, but it is important to note that EC motors can vary in efficiency over different speeds and loads. When choosing an EC motor, identify a motor that has a flat efficiency curve across a wide range of load conditions to optimize overall pump system efficiency and operations (Image 1). Doing this will ensure the pump system will benefi t from optimum efficiency under a variety of operating conditions.

Advanced EC motors that use PCB stators can increase efficiency further and eliminate core losses. The copper in PCB stators is etched directly into the PCB, increasing reliability and reducing the amount of copper material. Motors that feature a stator composed of a steel core with copper windings will experience eddy currents that result in motor losses. Replacing the core and copper windings with the PCB stator eliminates these losses, resulting in a higher efficiency motor at the rated power and speed, as well as across the entire operating range.

Controls

The DOE recommendation indicates that improvements to motor efficiency and demand-based variable speed controls can yield greater energy savings than those from improved hydraulic efficiency, saving upwards of 65% of energy use depending on the application. Pumps that vary speed can reduce their energy consumption by reducing pump speed to match load requirements. Integrated variable speed controls can also eliminate the need for throttling downstream valves to match demand, saving both energy and infrastructure wear and tear. In addition, this can be done without having to install, wire and commission a separate, conditioned air space for a conventional variable frequency drive (VFD), which can be cost prohibitive.

While all EC motors have some level of built in variable speed technology, it is important to be aware that their control capabilities range from basic speed control options to more sophisticated control features found in typical VFDs, such as MODBUS connectivity and capabilities to communicate motor performance and health data back to a controller or centralized control system. These advanced EC motors enable the remote monitoring of vibration, temperature, speed and efficiency, which feeds back to pump controllers and allows motors to adjust and protect themselves on demand.

Reliability

Compared to induction and other asynchronous motors, EC motors generate less heat, which avoids stress on components and results in longer service life. However, in all motors with copper-wound iron cores, the coefficients of thermal expansion of the iron, copper windings, insulation materials and varnish are all different, leading to expansion and contractions at various rates across the materials, which ultimately leads to the failure of the motor. The PCB stators in advanced axial flux EC motors only consist of two primary materials, the etched copper and the glass-epoxy laminate, both of which have the same coefficients of thermal expansion. This means thermal stresses are minimized and allow the copper to maintain its original form and protection within the PCB material. In a multiyear accelerated life test program where PCB stator coils were tested alongside conventional preformed copper coils under similar conditions to determine the robustness and reliability, results indicated that PCB stator life is at least 10 times longer and is 10 times more reliable than a form wound coil stator.

IMAGE 2: Space comparison for AC induction motor and axial flux EC motor

Design
The design of an EC motor is an important factor, as space is often at a premium. Most motor designs for pumps require infrastructure for foot mounts and allotted space around the pumps for servicing and the motor itself. EC motors that take advantage of more compact, axial-flux designs and thin PCB stators can result in 50% smaller and lighter form factors and reduce overall space required for a pump system (Image 2). These smaller, lighter EC motors can also simplify design processes for pump manufacturers and make installation easier.

Sustainability
Highly efficient EC motors can reduce energy use and operating costs over the lifetime of the motor and, in some cases, can pay for themselves within the first year of operation. In addition to reduced energy demand, sustainable design that minimizes the use of raw materials and incorporates end of life management can support initiatives to reduce waste. The majority of motors end up in landfills after 10 to 20 years, but advances in circular motor design are allowing for extended component life and reuse. Consider a motor that takes advantage of modular design to make the motor easy to maintain and allows components to be reused multiple times to serve future generations, keeping the motor in service and out of landfills.

As circulator pump manufacturers plan for the DOE’s new energy conservation standards and select EC motors for new equipment, efficiency, controls, reliability, design and sustainability should all be factored into decision making for optimal operations and lifetime. Selecting the right EC motor can help systems achieve the maximum energy efficiency and conservation of energy today, while contributing to a more sustainable future for the next generation.

Read the full article at Pumps & Systems.

Written by Mandy Chalman · Categorized: Coverage, IE Coverage · Tagged: electric motors, PCB Stator, Pump Applications, Sustainability

Apr 26 2023

Infinitum acquires Circuit Connect to scale up production of motors with PCB stator technology

Infinitum acquires Circuit Connect to scale up production of motors with PCB stator technology

by Nikola Potrebic & filed under Newswire, The Tech.

Electric motor manufacturer Infinitum has completed the acquisition of printed circuit board (PCB) manufacturer Circuit Connect.

Circuit Connect has supplied Infinitum with PCB stators for more than five years. The acquisition will allow Infinitum to scale up its production of PCB stators and provide a framework for continuous volume growth.

Infinitum’s air core motors replace heavy iron found in traditional electric motors with a lightweight PCB stator. They are 50% smaller and lighter, use 66% less copper, and consume 10% less energy than standard iron core stator motors, according to the company. Their modular design allows the housing, rotors, and stators to be reused multiple times, giving parts a second and third life.

“Circuit Connect has worked side by side with us, advancing and improving how PCB stators are made. Their acquisition will help us ensure consistent delivery of stator components as we execute on our hypergrowth phase and scale up manufacturing to meet the demand for our motors,” said Ben Schuler, founder and CEO of Infinitum. 

Read the full article at Charged Electric Vehicles Magazine.

Written by Mandy Chalman · Categorized: Coverage, IE Coverage · Tagged: electric motors, PCB Stator

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