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Home , Home appliance

Efficient Motor for the Home Appliance

By Hans-Jürgen Withopf, ebm-papst

Hans-Jürgen Withopf, Dipl.-Ing. (FH) is product manager home appliance industry of ebm-papst Landshut GmbH.

Legal requirements on energy efficiency of home appliances The conservation of energy in the white goods industry is driven by continuously enhancing legal requirements on minimum efficiency grades. The specific requirements on an international level vary depending on the laws, rules and directives in place.

Situation in Europe which are listed here after: under revision / completion By implementing the directive t Lot 13 / 22nd July 2009: expected within 2016 2005/32/EC the European Commission Regulation (EC) t Lot 16 / 3rd October 2012: Parliament established in July 2005 No 643/2009 ecodesign Commission Regulation (EU) No a framework for the setting of requirements for household 932/2012 ecodesign requirements ecodesign requirements for energy- refrigerating appliances for household tumble driers using products (EuP). In October t Lot 14 / 10th November 2010: t Lot 25 / 22nd August 2013: 2009 it was extended to energy- Commission Regulation (EU) Commission Regulation (EU) No related products (ErP) in general No 1015/2010 ecodesign 801/2013 ecodesign requirements by directive 2009/125/EC. Within requirements for household for standby, off mode electric this so-called ErP process different washing Commission power consumption of electrical product groups became the subject Regulation (EU) No 1016/2010 and electronic household and of an assessment regarding their ecodesign requirements for office equipment – refers e. g. environmental footprint. Already, household since to coffee machines two working plans (2009-2011 and 2014 for non- 2012-2014) have been concluded professional while the study to establish a third use one (2015-2017) has been initiated in January 2014. The final reports of this Ecodesign Working Plan study are in the process of being approved for publication.

Several product groups related to the home appliance industry have been within the scope of the first two working plans. Several regulations of the European Commission have been the result of it setting minimum efficiency grades for the concerned appliances and

BG 15 EC motor with axial blade. Source: ebm-papst

International Appliance 2016 45 NiQ 32 - explosion view. Source: ebm-papst

t Lot 22/Lot 23 / 14th January known by the European consumers. and updating these standards. 2014: Commission Regulation Furthermore it develops test (EU) No 66/2014 ecodesign Situation in the U.S. procedures and executes verification requirements for domestic , One key element of the policy for testing. Like this it supports the hobs (cooktops) and range hoods improving energy efficiency in the Environmental Protection Agency U.S. is the appliance and equipment ENERGY STAR Program and All these regulations are submitted efficiency standards. The first the Federal Trade Commission for revision on a regular basis. standard was set on a state level in ENERGY GUIDE labeling. Actually California in 1974. One year later it 60 products representing 90 precent Requirements on minimum was followed by the Energy Policy of home energy use are part of it. efficiency grades have also been and Conservation Act (EPCA). A The standards program led to gains set for applications dedicated to special focus on energy conservation in energy efficiency of household professional use or are actually in standards was implemented with the appliances as follows: preparation like: amendment in 1979 and minimum t – 75 percent less efficiency standards for household energy at 20 percent more storage t ENTR Lot 1 / 5th May 2015: appliances were established in 1987 capacity since 1973 Commission Regulation (EU) (National Appliance Conservation t clothes washers –70 percent less 1095/2015ecodesign requirements Act). The Department of Energy energy since 1990 for professional (DOE) is in charge of reviewing t dishwashers – 40 percent less refrigerated storage energy since 1990. cabinets, blast cabinets, condensing units and process chillers t Lot 24 draft document of Possible requirements for non-household washing machines, non-household textile dryers and non-household dishwashers Together with the ecodesign requirements the European Union established an energy efficiency labeling system for the respective appliances. These labels with their colored A, B, C classifications and in domestic refrigeration with their A+, A++ and A+++ categories are well-

Radial blower for evaporator use with BG15 EC motor. Source: ebm-papst

46 International Appliance Manufacturing 2016 Since 2005 the DOE started to 2012 publication status focus on different rulemakings / residential dishwashers up-dates to enhance necessary 77 FR 65942 – final standard In conclusion it could be recognized test procedures. In 2013 the residential that the energy conservation President‘s Climate Action Plan clothes washers standards will continue to tighten in was announced. It foresees a 77 FR 59719 – final standard the coming years. reduction of carbon pollution by a compliance mandatory as of 2015 minimum of 3 billion metric tons respectively 2018 Like in the European Union a label cumulatively by 2030. This leads to was also introduced in the US to an acceleration of the rulemaking 2013 provide consumers information process. A goal was set to reach a microwave ovens about energy consumption, total of 26 standards rulemakings 78 FR 36316 – final standard / efficiency and operating cost. This between 2014 and 2016 covering 2016: 81 FR 7965 – correction label is called ENERGYGUIDE. Its 30 products and 10 more between notice development was mandated by the 2017 and 2020 covering an consumer clothes dryers Energy Policy and Conservation Act additional 12 products. 78 FR 49608 – final standard of 1975 and it was introduced for all compliance mandatory as of 1st products since 1980. Besides that The following examples are among July 2015 another voluntary one exists with these rulemakings for energy ENERGY STAR label. It sets more conservation standards: stringent requirements on energy 2014 saving than the ENERGYGUIDE. 2011 commercial clothes washers 79 FR 74492 – final standard residential refrigerators Usage of Efficient 76 FR 57516 – final standard compliance mandatory as of 1st compliance mandatory as of 15th January 2018 Electronically September 2014 conventional Commutated Motors products Driven by a continuously tightened first standard set energy conservation policy EC 1990 / rulemaking motors are in the meantime started and in widely used in large white goods progress equipment. With its high electrical efficiency (typically between 45 2015 percent to 80 percent compared to residential low efficiency shaded-pole motors refrigerators - ice (typically between 15 percent to making final standard 20 percent which transform the compliance mandatory main part of its power consumption as of 1st January 2018 in dissipated heat and with a 2016 significantly reduced usage of miscellaneous resources (copper, electric sheets residential etc.) for their production they not refrigeration only have a positive effect on the rulemaking in progress CO2 foot print but also on the including wine sustainable usage of resources also chillers final shown as ecodesign in general. determination, pre- Refrigerators and Freezers The prime example of the successful

Radial blower with BG 19 EC motor. Source: ebm-papst

International Appliance Manufacturing 2016 47 implementation of EC technology BG43 sensorless BLDC motor. and of small EC Source: ebm-papst motors in white goods applications are the refrigerators and freezers. As these appliances are permanently operated to store perishable goods for a reasonable time they are the most energy consuming domestic major appliances. Thus it has been clear that they have been in primary focus of energy conservation policies.

As a consequence gaskets, compressors, controllers and other components have been improved to maximize efficiency. Vacuum panels started to be used as an alternative insulation, LED lighting was introduced in high-end and premium products and especially EC motors became very popular increasing significantly the efficiency of evaporator and condenser fan units whereupon mains supply driven ones permitted an easy drop-in replacement of the commonly used C-frame shaded-pole motors with engineers are in the position to their axial impellers. Dishwashers control its operational behavior in The main process of a detail and to adjust it according to Another step forward to reduce is carried out by the spray arm the process requirements. energy consumption and additional operation; it moistens dried food noise emissions has been the residues and cleans the dishes. This development of smart radial blowers Kitchen Hoods is an energy consuming process. in EC technology to be fit into Variable speed capabilities make EC The usage of EC technology optimized air ducts. technology a perfect choice for such reduces the power consumption. kind of appliances which require a Furthermore, an adjustable Ovens correct setting to different working speed leads to further process But not only its energy saving conditions at any time to provide the optimization. capabilities makes EC technology highest comfort for the consumer. so smart. It offers a broader Besides a nice appearance in the Space is extremely limited in functionality and options for either kitchen due to some exceptional dishwashers. Therefore, drying fans the appliance design or its mode design features a range hood has to or process fans with AC motors of operation. While standard AC provide sufficient suction capability are limited in their power density as shaded-pole motors could only to fulfill its operational duties and at these motors are restricted by the be operated in a single direction an acceptable noise level. By using barrier of the synchronous speed EC motors could be operated in the signal-in of the motor interface limits from the mains supply. EC clockwise or counterclockwise the speed could be adjusted in technology supports in breaking direction. Furthermore EC different steps or even continuously. down these barriers. Small and motors with variable speed Combined with an optimized powerful fans could be built with capability allow the motor speed aerodynamics and assembly high speed motors. The reduced to be adjusted via sensors or concept of such an exhaust fan dimensions of an EC motor also following specific programs for the sound level could be kept at enable its integration into the fan its operation. Therefore, design comfortable levels. unit itself. The drive motor thus

48 International Appliance Manufacturing 2016 becomes an integral part of it. BG 22 respectively BG 36 BLDC combined with its open mechanical motor platform design this platform provides to Motor Platforms These internal rotor BLDC motors the appliance engineer high design EC motor platforms are available are widely used to drive crossflow, flexibility. The functional aspect in the market to satisfy the diverse axial and radial blowers. The stays in the foreground. The motor smaller EC motor provides a and specific requirements of becomes an integral part of a fan power consumption of up to 20 refrigerators, dishwashers, ovens unit. or kitchen hoods. Depending on its W. Its speed range includes up to purpose either one-phase or three- 15,000 rpm. The bigger EC motor BG 32-3 BLDC motor platform phase BLDC motors are available. is available in different stack sizes covering power consumption up to This is a three-phase motor One-Phase 350 W. Its speed range reaches up platform which fits to the specific to 9,000 rpm. BLDC Motors requirements of cooling fans or hot air convection fans providing BG 15 respectively BG 20 BLDC In the area of professional food a maximum possible power motor platform processing equipment such motors consumption P1 of 20 W and a These motors are widely used in are operating (e.g. radial blowers) speed range up to maximum 4,500 domestic refrigeration. As single in dishwashers which require a rpm. The motor provides a modular motors with up to 3 W power powerful but quick drying cycle. consumption and typical set Another application is food storage design with open mechanical speeds of e.g. 1,800, 2,100, or equipment where the EC motors interfaces similar to the before 2,500 rpm they provide retro-fit serve to provide a constant flow of mentioned BG 19 motor platform. capabilities to easily up-grade well-tempered air. Its assembly concept permits the existing appliance platforms from usage of the same core module AC to EC. Depending on their BG 32-1 BLDC motor platform for different applications. With its design they are used either as an respectively NiQ 32 motor small dimensions it targets build-in evaporator, compartment ventilation BG 32-1 platform is the core of situations with limited space. or condenser fan motor. the NiQ 32 motor. This is a new EC motor design to replace AC BG 43 sensorless BLDC motor BG 15 motor platform furthermore Q-motors (4 pole shaded pole platform works with constant speed. This motors) with a drop-in replacement. means that the motor has an It operates in its standard design This is a sensorless BLDC motor. internal speed control adjusting with either 1,550 rpm (catalog It is available in different motors the speed according to the load version in 110-120 V 50/60 Hz) or sizes with a power consumption of situation to its set point. 1,300 rpm (catalog version in 220- maximum 50 W, 80 W or 220 W. Integrated into a complete blower 240 V 50/60 Hz) at constant speed Its maximum speed range covers assembly they even serve to reduce (similar to BG 15 motor platform up to 4,000 rpm. It provides EC complexity of parts, as to ease the mentioned above). assembly process as to optimize technology while having comparable intralogistics (in-house logistic) mechanical interfaces as the Due to its modular design it could processes on the customer side. ebm-papst PSC motor series. A be easily adjusted to other speed separate electronic box which is settings like 1,800 or 2,200 rpm. Apart from their usage as evaporator part of the motor and contains the or condenser fans for refrigerators Three-Phase commutation is attached other versions of such EC motors either to the motor itself or placed are used to drive e. g. cross flow BLDC Motors outside of it and connected to blowers or radial blowers for diverse BG 19 BLDC motor platform the motors cable. The driver box applications. Depending on the This is a versatile motor platform provides a VSD interface to control working point required they perform especially designed to be integrated with power consumption up to 20 into diverse products like fans or the speed either by a 0-10 V analog W and cover a speed range up to pumps. With maximum possible or PWM signal. As a sensorless 7,000 rpm. power consumption P1 of 20 W, a BLDC motor it provides a calculated speed range up to 12,000 rpm, and speed signal. IAM

International Appliance Manufacturing 2016 49 Discover ebm-papst in household appliances. You can discover innovative solutions for household appliances at discover.ebmpapst.com/household_appliances

Christian Oberpriller, Key Account Manager at ebm-papst

Did you know that up to 20 products from ebm-papst can be hidden in one single home? Whether in the dish- washer, oven hood or , our fans and small motors can handle any “household chore” reliably, qui- etly, and in an energy-saving manner. You can’t see it. But you can feel it!