Origins of SKY INNOVATIVE TECHNOLOGIES go back to early 2014. It is when we realized that there is a lot of scope for improvement in machines. With that vision in mind, we started designing systems to improve efficiency and save power. Initially, we got decent improvements but along the way, we realized a lot more can be done and started solving those new challenges every day. After almost one and half year of our relentless effort, we could get savings in the range of 15%-30%. This is how * POWER SAVER * was born.
By early 2014, though we had solved the technical problems, Ampere was still limited to the laboratory. Hence, we started taking POWER SAVER to the market and experimenting it in various domains. Since needs and working conditions are different in each industry, we had to make sure POWER SAVER works everywhere as expected. It took us almost 2 years to test Ampere in a wide range of industries including Water power plants, Restaurants, Rice mills, Crushers, Cold storages, Factories, Industries etc.
After almost 4 years of development and testing of POWER SAVER, now we are highly confident of our technology and are ready to take it to the market across a huge range of industries and loads. We hope to set up POWER SAVER wherever there is a need and contribute in our way to make our planet earth greener!
What POWER SAVER Does?
Save Energy : POWER SAVER reduces wastage and saves energy by reducing the losses such as Winding Stress, Winding overheating, Voltage Dip, Copper losses, Frictional Loss, Iron loss, Wind age Loss, Sound loss. Addition based on the instantaneous load, POWER SAVER dynamically changes frequency, torque, speed and RPM. This leads to higher efficiency and lower power consumption.
Increase Motor Life : Due to dynamic voltage and frequency control, it offers better protection to the motor from issues such as electro chemical overloads, phase faults, in rush current, spikes and surges in current, over voltage and under voltage. This also helps in greatly reducing wear & tear and extends motor life.
Maintain Power Factor with NO extra Capacitors : POWER SAVER, in addition to saving energy and increasing motor life, it comes with pre-loaded capacitors which maintains high power factor on the live side of the variable frequency. This eliminates the need for expensive capacitor bank.
About “POWER SAVER”:
A large percentage of electrical energy is utilized in running motors in industries. A wide variety of motors are used depending upon the requirement. Star Delta Starters are used with squirrel cage induction motors to reduce the starting current. They operate the motor in star mode at start and after the set time delay, it switches over to Delta mode and continuous to run in delta irrespective of whether the load is low or high. When a motor is running at less than half of rated output, (i.e. 50% of full load current)it is possible to SAVE THE ENERGY by re-connected to star. As such when a motor is re-connected to star from delta it is possible to save energy and ALSO IMPROVE POWER FACTOR OF A MOTOR.AUTO DELTA STAR energy saver is an Electronic Unit. It comes along with current transformer. The current transformer is designed to match the each capacity of full load current. The current transformer (sensing line current) is below 50% of full load current AUTODELTA STAR energy saver unit motor is to operate in star mode and till the line current rises to 48% of full load. There is a fixed time delay of changeover is from delta and there is no time delay of star to delta. The change over from delta to star and star to delta is automatic.
Advantages:
- Reduction in line current
- Energy Saving (Reduction in KW and KWH)
- Reduction in KVA, contributing to reduction in maximum demand
- Improvement in Power Factor
- Running over load current overload protection
- Reduces the motor temperature runs (leading to increase in motor life)
Features:
- Long running life – 25K hours Run in delta if Current transformer is open Overload trip indication and automatic reset Fuse protection and By pass facility 18% to 30% of energy saving
Background– “POWER SAVER”:
Induction motors have five major components of loss; Iron loss, Copper loss, Frictional loss, Wind age loss and Sound loss. All these losses add up to the total loss of the induction motor. Frictional loss, Wind age loss and Sound loss are constant, independent of shaft load, and are typically very small. The major losses are Iron loss and Copper Loss. The iron loss is essentially constant, independent of shaft load, while the copper loss is an I2R loss which is shaft load dependent. The iron loss is voltage dependent and so will reduce with reducing voltage. For a motor with 90% full load efficiency, the copper loss and iron loss are of the same order of magnitude, with the iron loss typically amounting to 25 - 40% of the total losses in the motor at full load. If we consider for example, an induction motor with a full load efficiency of 90%, then we could expect that the iron loss is between 2.5% and 4% of the motor rating. If by reducing the voltage, we are able to halve the iron loss, then this would equate to an iron loss saving of 1-2%of the rated motor load. If the motor was operating under open shaft condition, then the power consumed is primarily iron loss and we could expect to achieve a saving of 30% - 60% of the energy consumed under open shaft conditions. It must be reiterated however, that this is only about 1-2% of the rated motor load. For example, if we take a Toshiba 2 pole 22kW D180M motor, we find a full load efficiency of 90.9%. This motor has a rated iron loss of about 25% of the total loss. This amounts to 22 x .091 x .25 = about 500 watts. At best, I would expect to halve this loss, resulting in a saving of 250 watts at light load. Under open shaft conditions, this may well amount to 30% of the energy consumed by the motor, but it is still only about 1% of the motor rating. If the energy wasted by the motor is small, then there is very little to be saved, irrespective of the technology used.
The POWER SAVER greatly reduces wear to the motor, increase life of the equipment and decrease maintenance costs. Due to optimal voltage and frequency control it offers better protection to the motor from issues such as electro thermal overloads, phase faults, over voltage, under voltage etc. When we start a motor (on load) with help of a POWER SAVER the motor is not subjected to “instant shock” hence there is less wear and tear of belt, gear and pulley system. Power Factor Power converted to rotation, heat, sound, etc. is called active power and is measured in kilowatts (kW). Power that charges builds magnetic fields or charges capacitor is called reactive power and is measured in KVAR. The vector sum of the kW and the KVAR is the Apparent Power and is measured in KVA. Power factor is the ratio of kW/KVA. Typical AC motors may have a full load power factor ranging from 0.7 to 0.8. As the motor load is reduced, the power factor becomes low. The advantage of using POWER SAVER is that it includes capacitors in the DC Bus itself which maintains high power factor on the line side of the Variable Frequency. This eliminates the need of additional expensive capacitor bank.
When POWER SAVER starts the motors, the drawbacks associated with large inrush current i.e. starting current (winding stress, winding overheating and voltage dip on connected bus) is eliminated. This reduces chances of insulation or winding damage and provides extended motor life.
Case Study # 1
For one of the leading tours & travel agency, one of the main concerns was the amount of electricity being consumed in their garage. They have at least two motors that run 8 to 10 hrs a day. Total installed capacity of motors in their garage is 40 HP.
Vital statistics captured from the client during the demo
Total capacity installed - 40 HP
Usage per day - 10 hrs
Average power consumption on a given day - 63 units / hr
Average power consumption with POWER SAVER installed - 51 units / hr
Return of Investment (ROI) realization - 4 months
Case Study # 2
For one of the leading luxury apartment society was looking at reducing their maintenance cost so that funds can be used for other activities / development work. They have installed a 5 HP motor for their swimming pool. The motor runs 8 hrs. a day.
Vital statistics captured from the client during the demo
Total capacity installed - 5 HP
Usage per day - 8 hrs
Average power consumption on a given day - 6 units / hr
Average power consumption with POWER SAVER installed - 4.6 units / hr
Return of Investment (ROI) realization - 5 months
Advantages over similar products in the market:
- Two-year warranty
- Quick realization of ROI (in most cases less than six months)
- Works with Generators as well
- Robust and near 0% failure rate
- Long life – 25K hours
- Cost less than 30% – 35% of similar products