Ceiling Fan Motor Analysis

Ceiling Fan Motor Analysis

December, 2010

Energy Star Program -- Residential

Ceiling Fans (Version 2.3)

� Residential ceiling fan is defined as a non-portable device

designed for home use that is suspended from the ceiling for

circulating air via the rotation of fan blades.

• Some ceiling fans also have an integral or attachable light kit.

� Key Requirements

• Minimum CFM and CFM/watt requirements

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• Minimum CFM and CFM/watt requirements

• Pin based option in light kits

• Minimum 30-year motor, 1-year component, and 2-year light kit

warranty requirements

Fan Speed Minimum Airflow Efficiency Requirement

Low 1,250 CFM 155 CFM/watt

Medium 3,000 CFM 100 CFM/watt

High 5,000 CFM 75 CFM/watt

Other Ceiling Fan-Related Trends

� Energy efficient

� Quiet

� Designer

� Incorporating light fixture


Type of Motor used in Ceiling Fans and Salient

Feature of the Conventional Motor

� Ceiling Fans are direct driven mostly using single-phase Induction motor.

• Split-phase permanent capacitor

• Capacitor start, capacitor run

• Shaded pole motor

� Motors have windings wound for 18, 20 or 22 poles, resulting in to loweroperating speeds (Most common: 18 pole).

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operating speeds (Most common: 18 pole).

� The rotor resistance is very high for wide speed control range using thestator voltage control.

� The operating speed range for the ceiling fans are

• 180 rpm to 380 rpm for countries like India

• 110 rpm to 220 rpm for Developed World

• Low Speed is approx. half of high speed

Type of Motor used in Ceiling Fans and

Salient Feature of the Conventional Motor

� High speed motor efficiency of about 20%.

� In India the minimum air delivery to achieve 5-star energy rating is210 m3/min, i.e. If the Fan draws 52.5 W or less then it is qualifiedfor 5-star energy rating.

� The hub diameter is about 15% of the tip diameter.

� The blade angle is about 10° to 15° and constant from hub to tip.


� The blade angle is about 10° to 15° and constant from hub to tip.

� Between low and high speeds three to five operating speed at equal interval is achieved using the variable speed control.

Improvement in Ceiling Fan

Performance by Motor Design

� Replacing the conventional 1-phase induction motor with energyefficient 1-phase induction motor

• Higher efficiency compared to the conventional motor

• Rotor bars are made up of copper instead of aluminium

• Increase in copper

• Increase in Iron


• Increase in Iron

• Higher Cost compared to conventional 1-ph. Induction Motor

• Example: 70 W input power can be reduce to 50-55 W.

� Replacing the conventional 1-phase induction motor with 1-phase /3-phase PMBL DC motor

• Higher efficiency compared to the energy efficient 1-phase induction

motor at all the speeds

• Higher Motor Cost due to the presence of Magnet, Electronics and

Sensors

Improvement in Ceiling Fan

Performance by Motor Design

� Small pay back period for the additional cost

� Difficulty in achieving the sensorless operation due to low operating speed

� Single phase PMBL DC motor should have a non-uniform airgap to achieve starting torque at all rotor positions.

� In case of fan with 1-ph. PMBL DC motor, when the fan is switched


� In case of fan with 1-ph. PMBL DC motor, when the fan is switched off, Jerky motion of rotor due to preferred parking position of the rotor.

Benchmarked Ceiling Fans

No.Fan

ManufacturerSupply Motor Magnet Controller Fan Model

1 Emerson120 VAC,

60 Hz

PSC type single

phase InductionNone

Using Different value of

Capacitances

2 Emerson120 VAC,

60 Hz

3-Phase PMBL

DC

Rubber

Ferrite

Rhine Electronics Co. Ltd.

Model No. RH-165M

120 V AC, 60 Hz, 0.65 A,

40 W, 210 rpm

CF955 Midway

Eco 54” Dia.

(CF9550RB)


40 W, 210 rpm

3 Regency120 VAC,

60 Hz

3-Phase PMBL

DC

Rubber

Ferrite

Model No. RH 787 RX

FR-7871-SS-02

120 V, 60 Hz, Motor:35

Wmax

Regency Gladiator

III

4 Monte Carlo120 VAC,

60 Hz

3-Phase PMBL

DC

Sintered

Ferrite Arc

Youngo Ltd., Model

BJX1514AST, 120 V AC,

60 Hz, 3 A

MonteCarlo Avanti

52”

5 Amasco240 VAC,

50 Hz

3-Phase PMBL

DCRubber

FerriteFR-7872LL-01

Amasco Coaster

54” (Model AMC-

333)

Testing Methodology


Testing of PSC Single Phase Induction

Motor from Emerson Ceiling Fan


Speed and direction controller Aluminum die cast in rotor

V (Volts) I (A) Pin (W) PF Pout (W) η (%) N (rpm) T (mN-m)

119.46 0.84 100.05 1.00 16.14 16 175.70 877.21

110.12 0.78 85.07 1.00 12.75 15 165.00 737.96

100.15 0.71 70.65 1.00 9.46 13 149.20 605.30

90.10 0.64 57.29 0.99 6.74 12 132.10 486.85

80.13 0.57 45.42 0.99 4.67 10 116.10 383.77

Testing of PSC Single Phase Induction

Motor from Emerson Ceiling Fan


80.13 0.57 45.42 0.99 4.67 10 116.10 383.77

V (Volts) I (A) Pin (W) N (rpm) f (Hz)

140.59 0.95 133.28 212 59.96

130 0.8956 117.01 197 59.96

120.13 0.8257 98.93 176 59.96

110.22 0.7616 83.71 165 59.96

100.16 0.7013 70.74 149 59.96

90.62 0.6306 56.97 132 59.96

80.74 0.5631 45.32 116 59.96

Summer Use (CCW from bottom)

Speed setting

Supply Volt (V)

I (A) Pin (W) N (rpm)

1 120 0.044~0.048 2.2~2.9 52

2 120 0.055~0.06 3.2~3.8 83

3 120 0.075~0.09 5~5.8 116

4 120 0.12~0.15 8.5~9.5 148

5 120 0.19~0.22 11~13.5 170

Testing of PMBL DC Motor

from Emerson Ceiling Fan


6 120 0.33~0.38 22~24 213

Winter Use (CW from bottom)

Speed setting

Supply Volt (V)


1 120 0.043~0.05 2.2~2.7 50

2 120 0.053~0.057 3.1~3.6 72.5

3 120 0.065~0.075 4.3~5.0 95

4 120 0.095~0.105 6.2~7.1 118

5 120 0.145~0.165 9.4~10.3 141

6 120 0.22~0.245 13.5~14.8 165

Benchmarking of PMBL DC Motor

from Emersion Ceiling Fan


Summer Use (CCW from bottom)

Speed setting

Supply Volt (V)


1 120 0.03~0.037 1.7~2.1 40

2 120 0.12~0.14 6.9~7.8 86

3 120 0.17~0.195 10.5~11.8 101

4 120 0.35~0.39 21.5~23.5 132

Testing of PMBL DC Motor

from Monte Carlo Ceiling Fan


4 120 0.35~0.39 21.5~23.5 132

Winter Use (CW from bottom)

Speed setting

Voltage Current (A) Pin (W) N (rpm)

1 120 0.031~0.037 1.7~2.2 40

2 120 0.11~0.13 6.9~7.9 87

3 120 0.17~0.19 10.1~11.3 102

4 120 0.35~0.38 21.5~23.3 134

Benchmarking of PMBL DC Motor

from Monte Carlo Ceiling Fan


42

ParameterFan Manufacturer

Emersion Monte Carlo Regency Amasco

No. of stator slots / Magnet poles 9 / 12 12 / 8 9 / 12 9 / 12

No. of laminations on stator 49 36 60 49

Thickness of stator lamination (mm) 0.51 0.50 0.51 0.50

No. of turns/ coil 450 550 499 800

Overall diameter of motor (mm) 140.9 162.0 100.6 140.9

Winding conductor diameter (mm/ AWG) 0.47/ 26 0.34/ 29 0.34/29 0.42/ 27

Outer diameter of the magnet (mm) 137.3 156.00 96.83 137.30

Inner diameter of the magnet (mm) 121.76 143.90 86.43 122.00

Thickness of the magnet (mm)

Benchmarking of PMBL DC Motor from

Ceiling Fans – Motor Details


Thickness of the magnet (mm) 7.77 6.05 5.20 7.65

Axial length of the magnet (mm) 34.5 19.90 44.60 34.62

Outer diameter of the stator (mm) 120.00 142.20 84.80 120.00

Axial length of the stator (mm) 25.00 18.00 30.34 25.00

Length of airgap (mm) 0.88 0.85 0.82 0.95

Thickness of the rotor back iron (mm) 1.80 3.00 1.88 1.80

Axial length of the back iron (mm) 56.74 29.20 57.00 56.71

Shaft diameter (mm) 17~18 17.00 17.23 17.20

Weight of copper (gm) 442.8 358.40 258.20 655

Weight of magnet (gm) 392 202.40 243.90 389

Weight of iron in stator laminations (gm) 997.30 1441.20 581.30 995.10

Weight of rotor back iron (gm) 338.20 334.43 250.40 341.71

* Based on back iron OD and axial length of magnet

Ceiling Fan Motor Analysis

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