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 Pin based option in light kits Minimum 30-year motor, 1-year component, and 2-year light kit warranty requirements
Fan Speed Low Medium High Minimum Airflow 1,250 CFM 3,000 CFM 5,000 CFM Efficiency Requirement 155 CFM/watt 100 CFM/watt 75 CFM/watt

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Other Ceiling Fan-Related Trends

Energy efficient Quiet Designer Incorporating light fixture

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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 lower operating speeds (Most common: 18 pole). The rotor resistance is very high for wide speed control range using the stator 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

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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 is 210 m3/min, i.e. If the Fan draws 52.5 W or less then it is qualified for 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. Between low and high speeds three to five operating speed at equal interval is achieved using the variable speed control.

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Improvement in Ceiling Fan Performance by Motor Design

Replacing the conventional 1-phase induction motor with energy efficient 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 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

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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 off, Jerky motion of rotor due to preferred parking position of the rotor.

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Benchmarked Ceiling Fans

No.

Fan Manufacturer Emerson

Supply 120 VAC, 60 Hz

Motor PSC type single phase Induction

Magnet

Controller Using Different value of Capacitances Rhine Electronics Co. Ltd. Model No. RH-165M 120 V AC, 60 Hz, 0.65 A, 40 W, 210 rpm Model No. RH 787 RX FR-7871-SS-02 120 V, 60 Hz, Motor:35 W max Youngo Ltd., Model BJX1514AST, 120 V AC, 60 Hz, 3 A FR-7872LL-01

Fan Model

None

Emerson

120 VAC, 60 Hz

3-Phase PMBL DC

Rubber Ferrite

CF955 Midway Eco 54 Dia. (CF9550RB)

Regency

120 VAC, 60 Hz

3-Phase PMBL DC

Rubber Ferrite

Regency Gladiator III MonteCarlo Avanti 52 Amasco Coaster 54 (Model AMC333)

Monte Carlo

120 VAC, 60 Hz 240 VAC, 50 Hz

3-Phase PMBL DC 3-Phase PMBL DC

Sintered Ferrite Arc Rubber Ferrite

Amasco

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Testing Methodology

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Testing of PSC Single Phase Induction Motor from Emerson Ceiling Fan

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Aluminum die cast in rotor

Testing of PSC Single Phase Induction Motor from Emerson Ceiling Fan
V (Volts) 119.46 110.12 100.15 90.10 80.13 V (Volts) 140.59 130 120.13 110.22 100.16 90.62 80.74 I (A) 0.84 0.78 0.71 0.64 0.57 Pin (W) 100.05 85.07 70.65 57.29 45.42 I (A) 0.95 0.8956 0.8257 0.7616 0.7013 0.6306 0.5631 PF 1.00 1.00 1.00 0.99 0.99 Pout (W) 16.14 12.75 9.46 6.74 4.67 (%) 16 15 13 12 10 N (rpm) 212 197 176 165 149 132 116 N (rpm) T (mN-m) 175.70 165.00 149.20 132.10 116.10 877.21 737.96 605.30 486.85 383.77

Pin (W) 133.28 117.01 98.93 83.71 70.74 56.97 45.32

f (Hz) 59.96 59.96 59.96 59.96 59.96 59.96 59.96

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Testing of PMBL DC Motor from Emerson Ceiling Fan

Summer Use (CCW from bottom)
Speed setting 1 2 3 4 5 6 Supply Volt (V) 120 120 120 120 120 120 I (A) 0.044~0.048 0.055~0.06 0.075~0.09 0.12~0.15 0.19~0.22 0.33~0.38 Pin (W) 2.2~2.9 3.2~3.8 5~5.8 8.5~9.5 11~13.5 22~24 N (rpm) 52 83 116 148 170 213

Winter Use (CW from bottom)

Speed setting 1 2 3 4 5 6 Supply Volt (V) 120 120 120 120 120 120 I (A) 0.043~0.05 0.053~0.057 0.065~0.075 0.095~0.105 0.145~0.165 0.22~0.245 Pin (W) 2.2~2.7 3.1~3.6 4.3~5.0 6.2~7.1 9.4~10.3 13.5~14.8 N (rpm) 50 72.5 95 118 141 165

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Benchmarking of PMBL DC Motor from Emersion Ceiling Fan

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Testing of PMBL DC Motor from Monte Carlo Ceiling Fan

Summer Use (CCW from bottom)
Speed setting 1 2 3 4 Supply Volt (V) 120 120 120 120 I (A) 0.03~0.037 0.12~0.14 0.17~0.195 0.35~0.39 Pin (W) 1.7~2.1 6.9~7.8 10.5~11.8 21.5~23.5 N (rpm) 40 86 101 132

Winter Use (CW from bottom)

Speed setting 1 2 3 4 Voltage 120 120 120 120 Current (A) 0.031~0.037 0.11~0.13 0.17~0.19 0.35~0.38 Pin (W) 1.7~2.2 6.9~7.9 10.1~11.3 21.5~23.3 N (rpm) 40 87 102 134

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Benchmarking of PMBL DC Motor from Monte Carlo Ceiling Fan

42

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Benchmarking of PMBL DC Motor from Ceiling Fans Motor Details

Parameter No. of stator slots / Magnet poles No. of laminations on stator Thickness of stator lamination (mm) No. of turns/ coil Overall diameter of motor (mm) Winding conductor diameter (mm/ AWG) Outer diameter of the magnet (mm) Inner diameter of the magnet (mm) Thickness of the magnet (mm) Axial length of the magnet (mm) Outer diameter of the stator (mm) Axial length of the stator (mm) Length of airgap (mm) Thickness of the rotor back iron (mm) Axial length of the back iron (mm) Shaft diameter (mm) Weight of copper (gm) Weight of magnet (gm) Weight of iron in stator laminations (gm) Weight of rotor back iron (gm) * Based on back iron OD and axial length of magnet Fan Manufacturer Emersion 9 / 12 49 0.51 450 140.9 0.47/ 26 137.3 121.76 7.77 34.5 120.00 25.00 0.88 1.80 56.74 17~18 442.8 392 997.30 338.20 Monte Carlo 12 / 8 36 0.50 550 162.0 0.34/ 29 156.00 143.90 6.05 19.90 142.20 18.00 0.85 3.00 29.20 17.00 358.40 202.40 1441.20 334.43 Regency 9 / 12 60 0.51 499 100.6 0.34/29 96.83 86.43 5.20 44.60 84.80 30.34 0.82 1.88 57.00 17.23 258.20 243.90 581.30 250.40 Amasco 9 / 12 49 0.50 800 140.9 0.42/ 27 137.30 122.00 7.65 34.62 120.00 25.00 0.95 1.80 56.71 17.20 655 389 995.10 341.71

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