Smart industrial motor with AC-AC converter needs no VSD - Drives&Controls

Key parts of the Vidar motor including: (1) a bidirectional, non-sparking, corrosion-resistant fan made of a conductive plastic; (2) the terminal box; (3) the IP66-protected AC-Link converter and terminal box; (7) an EMC filter that meets EN55011 Class A (industrial) C3; (8) motor and converter temperature sensors; (9) Nema TEFC cast-iron frame; (10) Class H insulation; (11) severe-duty exterior paint; (12) the SynRM magnet-assisted motor; (13) anti-corrosion coated internal rotor and stator surfaces; and (15) a drive-end bearing isolator.

The US engineering manufacturer ITT has entered the industrial motors market with a first-of-its-kind smart, variable-speed motor with a patented AC-to-AC converter technology that does away with the need for an external AC-to-DC-to-AC VSD/VFD (variable-speed / variable-frequency drive). It says that its Vidar motor is 60% smaller than conventional motor-drive combinations and will cut energy use, CO2 emissions and costs, and increase equipment lifespans in industrial pump and fan applications, especially in harsh environments.

The motor – previously marketed as the Embedded Motor Drive (EMD) – can be used as a drop-in replacement for existing motors, initially in Nema frame versions. Unlike conventional motor-and-drive set-ups, it does not need special inverter-duty cabling, additional enclosures, or extra floor space. Vidar says it can be installed in less than an hour.

The motor is based on a high-efficiency synchronous reluctance motor with permanent magnet assistance. It complies with CSA Class 1 Division 2 for hazardous areas, and IEEE-519 power quality standards for reduced harmonic distortion. The design eliminates rotor-induced currents for higher efficiencies and power densities. It is said to operate 10-25% cooler than induction motors, cutting energy losses, extending component lives and enhancing reliability.

The motor’s advanced magnetic design is claimed to deliver high efficiencies, torque levels and power factors.

Vidar’s patented AC-Link technology replaces conventional AC–DC–AC converter technology with a streamlined AC-to-AC approach. The technology is based on work done at the University of Nottingham in the UK on a novel AC-to-AC power conversion technology, small enough to be embedded in the motor housing. During a multi-year collaboration between the university and Vidar, prototypes were iterated and the technology was refined and tested to prepare it for real-world applications.

By removing the DC stage, the new design eliminates bulky and failure-prone capacitors, shrinking the converter size by 60%, and allowing it to be combined with the motor in a single, compact package. Long cable runs between a motor and its drive are eliminated, the VFD and motor, and the motor’s insulation life is said to be extended. There is a single cooling fan for both the motor and the converter circuitry.

Vidar says the technology has undergone thousands of hours of testing in harsh industrial environments. In one example, it replaced a single fixed-speed motor on an industrial pump, allowing a control valve to open to 100%, up from 35%, and slowing the pump to around 75% of its maximum speed. This cut power consumption by 52%, while delivering the same flow as before.

“Vidar’s innovative design unlocks energy and cost savings potential by addressing common barriers to efficiency and reliability that have impacted the industry in the past,” says Dan Kernan, vice-president and general manager of ITT’s Vidar business. “Vidar makes the advantage of adjustable-speed over fixed-speed motors available to more customers of pumps, fans, and fluid process systems through a simplified, combined solution that’s easy to install and simple to operate.”

“Vidar is a game-changing innovation,” adds ITT’s president and CEO, Luca Savi. “With it, we are entering a new addressable market for industrial motors. The opportunity for sustainable value creation ahead of us is significant. We are proud of the work that Dan and his team in Syracuse, New York have done over the past six years to make Vidar a reality, and I cannot wait to see this technology succeed for our customers, for ITT and for our shareholders.”

ITT is entering a global market for industrial motors estimated to be worth around $6bn. Each year, it points out, around $300bn is spent globally on moving fluids in critical applications such as energy production, water purification and food and beverage processing. An estimated 85% of industrial pumps and fans still rely on fixed-speed motors and mechanical controls, resulting in high energy usage and low reliability. Current technologies such as VFDs/VSDs need costly installation and take up a lot of space.

Vidar expects the first shipments of its motor to start in the third quarter of 2025, ramping up considerably in 2026. Initially the motor will be available in ratings from 15–75hp (11.2–55.9kW) at 460V. There will be 3,600 rpm models that operate from 360-4,500 rpm and 1,800 rpm versions that operate from 180–2,500 rpm.

The motors will be rated for use in Class 1 Division 2 Groups A, B, C, D T4 hazardous areas, will have built-in STO (safe torque off) functions, and will comply with SIL2, Category 3PL d6.

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