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Trial motors and compressors
Panasonic uses a new type of magnetic material to prototype motors for home appliance compressors, which can improve the energy efficiency of home appliances. The magnetic material used was “NANOMETâ€, a low-loss soft magnetic material developed by Tohoku University in Japan. By using this material, the energy efficiency of the cooling and heating equipment such as air conditioners and refrigerators equipped with compressors, ie, COP (performance coefficient), increased by 2.9%. Panasonic will strive to start production of home appliances using new materials by 2018.
Panasonic and Tohoku University had successfully developed motors using new materials before December 2014. However, the diameter of the motor at that time was 70mm, which was only for trial use and could not be applied to home appliances. This time, both used new materials for 125mm diameter motors that are widely used in home appliances. By making the main loss of the motor - iron loss of magnetic material is reduced by approximately 60%, etc., the energy efficiency of the motor is increased by 3.1% compared to the use of existing materials.
This time, the motor was inserted into the compressor, and the COP was actually used to detect the refrigeration capacity of 1 kW. It was found that the COP was increased by 2.9% compared with the existing material.
Panasonic hopes to build this technology to improve the "energy-saving performance" of air conditioners and refrigerators. Statistics show that refrigerators and air conditioners account for approximately 1/4 of the total household electricity consumption (the Japan Resources and Energy Agency released in 2009). Since the 2000s, the efficiency of the motor has been improving slowly. Between 2000 and 2015, it only increased by 2%. The company believes that a 3% increase in efficiency has a huge impact on the difference in energy performance.
Core thickness reduced to 1/10
The new material "is a ferroalloy that does not use rare earths and therefore can reduce material costs" (Professor Makino Makino, professor of Tohoku University's Institute of Metal Materials that led development of the material). A part of Fe of the Fe (iron)-Si-BP-Cu material is substituted with Ni (nickel), and the iron content is 94 to 95%. When used as a magnetic material for a motor coil, not only iron loss can be significantly reduced, but also the saturation magnetic flux density that determines the ease of miniaturization of the coil is large. In various types of iron loss, the eddy current loss can be reduced by thinning the coil core. If the thickness of the iron core is extremely thin, the new material has a better effect of reducing the loss than the existing material.
Panasonic currently manufactures cores for coils using production technology that enables the use of new materials. Generally speaking, once the stress is generated in the magnetic material, the characteristics will be deteriorated. For this reason, the company has newly adopted a processing method that is not easy to cause stress. The core is made of a superimposed metal plate made of a new material. This time, no stress or stress remains in each step of cutting, laminating, and heat treatment of the metal plate. In particular, the heat treatment has been meticulously improved.
However, difficult processing of new materials may result in complicated processes. This is because the texture of the new material is hard. In order to reduce the eddy current loss of the core, the thickness of the metal plate is reduced to 35 μm, which is only 1/10 of the present, and the number is increased to 10 times. In order to prevent the advantages of low material cost being offset, the company will continue to implement improvements in production technology before it is put into practical use.
In addition, the new material's magnetic material properties are different from existing materials, so the optimal design of the circuit, including coils, will change. Although a reasonable circuit design has also been adopted in the trial production stage, there is still room for further optimization. Motors using new materials may also continue to increase efficiency. (Reporter: Mitsui often)
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