Combined winding "Slavyanka"

Revolution in the field of electric motors

About the combined winding technology "Slavyanka"

The combined winding technology "Slavyanka" is applicable for most types and kinds of electrical rotating machines, both single-phase and three-phase ones. In their classic version, these motors are designed with either a "star" or "delta" winding.

The peculiarity of "Slavyanka" is combining two winding types in one electric motor. "Star" and "Delta" are combined in parallel with a 30-electrical-degree shift of the resultant electromagnetic induction vectors.

The combined winding was named "Slavyanka". Motors with this winding type have unique performance features and outperform all the world rivals available in the market.

More about the technology — at the "Sovelmash" website.

Advantages of electric motors with "Slavyanka"

The data is based on the results of conducted tests

Energy saving up to 40%

Reducing production cost

Reliability (service factor 2.5)

Increasing starting torque

Reducing starting currents

Reducing noise and vibration 1.5-2 times

Scope of application

Electric motors with the "Slavyanka" technology have been acknowledged in various areas

Electric bicycles
Electric mopeds
Electric motorcycles
Electric cars
Public transport
Electric locomotives

Machine tools
Lifting equipment
Pumps
Ventilation
Crane equipment
Conveyor belt lines

Wind turbines
Hydroelectric power plants
Thermal power stations
Nuclear power plants
Mobile power generating units
Renewable energy industry

Fridges
Washing machines
Vacuum cleaners
Dishwasher
Ventilators
Microwave oven

Agricultural equipment and machinery
Construction equipment and machinery
Medical equipment
Ships, yachts, motor boats
Military equipment
Aviation

Patents

The validity of all the documents can be checked in the official sources by following the link

Studies of electric motors with "Slavyanka"

The technology efficiency has been confirmed by independent tests

The "Slavyanka" technology has proven its efficiency in the course of tests conducted at different times by experts of various scientific institutions and industrial enterprises. The testing results for the induction electric motors with combined winding supplemented by the official test reports are presented in this section.

University Düsseldorf, 2016

Comparative tests of the general purpose industrial motor rewound by applying the "Slavyanka" technology. University Düsseldorf

Independent tests of general purpose industrial motors were conducted in the Higher School at University Düsseldorf.

The task was to test the original motor and then rewind it using the "Slavyanka" technology, test the modernized motor and compare the results.

A 7.5 kW motor was provided for the tests. The tests demonstrated that after the "Slavyanka" technology modernization it: - had a 30% bigger torque, - consumed up to 30% less electrical energy.

You can view the test reports here - https://clck.ru/G7VX9
University of Bologna, September 2013

Comparative tests of the "Slavyanka"-rewound motor. University of Bologna, September 2013

The task of the test was creating a combined winding motor for electric buggies based on the "Slavyanka" technology and conduct comparative testing of it against the standard motor.

The standard motor made specially for the buggy weighed 54 kg and had a copper rotor. A general purpose industrial motor weighing 27 kg with an aluminium rotor was chosen for testing the "Slavyanka" technology.

Its performance characteristics: 4 polar size-100 AEG motor, 3 kW, with 86% efficiency and IE2 energy efficiency class. For the tests, the controller developed at the University was used that synchronized perfectly well with the motor rewound using Duyunov's technology.

The tests were conducted in three different modes: • nominal 135 A, • 270 A, • 350 A.

As a result, the modified motor fell short by 1 kW of the nominal power and by 1 kW of the maximum power. The previous motor for electric buggies produced the power of 20 kW at 350 Amperes, and 19 kW - with the combined winding.

There were differences in the efficiency values too: the electric buggy motor - 91%, the modified general-purpose industrial motor with "Slavyanka" – 89%.

Victor Arestov, who was running the tests, admitted that the choice of motor for the tests was not fully correct. To achieve the planned results, a size 112 motor should have been chosen instead of a size 100 one to, with a higher power of 4 kW.

However, it should be taken into consideration that the weight difference of the motors was almost twofold, and the special motor for electric buggies had a copper rotor while the modified motor had an aluminium one (by replacing the aluminium rotor with a copper one, you can increase efficiency by 2-3%).

At the same time, the 27-kg combined winding motor demonstrated almost the same performance as the specially developed original motor weighing 54 kilograms!

You can view the test reports here - https://clck.ru/GQgTM
Belgorod University, 2016

Comparative tests of induction electric motors. Belgorod University, 2016

Belgorod State Technological University hosted comparative tests of two induction electric motors AIR 71V4.

The goal of the procedure was checking the stated performance of the motor AIR 71V4 modernized using the "Slavyanka" technology as compared to a similar factory-manufactured motor with the standard three-phase winding.

In the course of the tests, reduced noise level and heating temperature of the modified motor was noted. The tests demonstrated considerable performance improvement of the modified electric motor in virtually all operational modes as well as improved efficiency in a wider load range.

It was concluded that in the process of real-life operation, the combined winding motor would enable significant reduction of power consumption by 14-20%. The largest saving amount could be achieved in the electric drive operation modes with the motor load lower than nominal. Besides, reducing starting and nominal currents, decreasing the operational temperature of the stator winding, reducing the internal conductor vibration in the coils and stator slots would considerably slow down the rate of conductor insulation wear.

The researchers recommended the "Slavyanka" technology for repairing induction electric motors at industrial enterprises with the purpose of considerable energy saving.

The test report is available here https://drive.google.com/file/d/1e6RKjKRkJq28NUDDz8i216c6ES_5HbIB/view
Belgrade quarry, 2015

Testing the motor with "Slavyanka". Belgrade, October 7, 2015

The goal of the tests was to determine how the electric motor performance changed after replacing the traditional winding with the "star-delta" combination.

The Serbian company D.O.O. «Savian» received a 15 kW induction electric motor with a burnt winding for modernization. The motor had been used in a rock quarry. The motor owner, the company D.O.O. Kuevo, ordered a full-fledged repair that included changing the winding type.

As a result of applying the energy-saving "Slavyanka" technology, the modernized motor performance changed as follows.

The nominal power increased from 15 kW to 19 kW, i.e., by 26.6%.

No-load currents were not detected before the repair, since the motor was inoperable. According to the motor certificate, the value was 27 A, and after modernization it decreased to 13.4 A.

The conducted tests graphically demonstrated the energy efficiency of the "Slavyanka" technology. Chief Technology Officer at D.O.O. Kuevo confirmed the operational reliability of the modernized motor.

You can view the test report here https://drive.google.com/drive/u/0/folders/1H5tQwSIQX9siP_J_-t9zf6bCMGaQ9Nq5?ths=true
Russian plant, July 2016

Tests of the modernized motor for a drain pump. Russia, July 2016

Engineers of the Russian plant modernized the induction electric motor 5AI160M2U2 with the power of 18.5 kW installed in a drain pump. During the repair, the blown old winding was replaced by burning, and the motor was rewound using the patented "Slavyanka" technology.

The goal of the tests is to identify changes in the motor performance characteristics after modernization.

Before the repair, the 5AI160M2 motor was designed to operate at the voltage of 660V, after modernization it was powered from 380V mains electricity. At 500V supplied in the laboratory conditions, the no-load current reduced on average by 12% (from 27.3 A to 24.0 A). When operating at 380V, the no-load current reduced by 3%, and under load — by 2%.

After rewinding, the pump productivity increased (duration of the pump operation cycle reduced by 39 seconds). It resulted in reduction of the required motor operation time by 8%. The total energy saving per one motor switch-on amounted to 12 %. The consumed power when draining the tank before rewinding was 2.573 kW, after rewinding it decreased to 2.3368 kW. The saving was 10%.

The test results confirmed the efficiency of the combined winding technology "Slavyanka".

The test reports and explanations for them are available here https://drive.google.com/drive/u/0/folders/1a1fglrN6zxjGJ1b7o3DLrUbMPJgn13PJ?ths=true
The Saint Petersburg Metro, October 2015

Tests of the motor modernized using the "Slavyanka" technology. The Saint Petersburg Metro, October 2015

At the request of the production technology department of the Saint Petersburg Metro, the workers of electromechanical service modernized an inoperable electric motor of a ventilation unit in a powerful tunnel ventilation system by applying the energy-saving "Slavyanka" technology.

The goal of the tests was to identify the changes in the performance characteristics of the motor after modification.

The type of the repaired electric motor produced in 1975 — 5AM280S8Y3. Its power before the breakdown was 55 kW, current — 108 A, speed — 740 revolutions per minute, voltage — 380 V.

After the repair, the experimental motor was installed in V-1 unit. As a result of the tests, the commission determined the following performance characteristics of the modernized motor with the "Slavyanka" winding: the running current was 48 A; the starting current amounted to 359 A.

The tests confirmed that modernizing electric motors using Duyunov's technology increased their energy efficiency.

The document clarifying the course and results of the tests is available here https://drive.google.com/drive/u/0/folders/1ful8GH2DhtwOOA8p2cGIc3J3OxRrXRkd?ths=true
Russian plant producing ventilation systems, 2016

Comparative tests of electric motors. Plant producing ventilation systems, Russia, October 2016

The goal of the tests is to compare the performance of two induction electric motors AIR80A4 with the winding types "Star" and "Delta".

The test results of the modernized combined winding motor compared to a regular motor demonstrated a reduction of the consumed motor power due to almost complete absence of the reactive component.

As a result of applying the energy saving technology "Slavyanka" the electric motor performance
changed in the following way:
- the power factor increased from 0.77 to 0.99;
- with the shaft load increased, the consumed power grew from 1.1 to 2.23 kW;
- the maximum temperature of the "Slavyanka" motor frame was 74°С
with the admissible temperature for thermal resistance of class "F" winding insulation equal to 105°С.

The recorded 2.2 kW power of the modernized motor is nominal for similar-type motors with 4 pairs of poles and rotation axis length of 90 mm, i.e., the next step of the size scale.

Test report is available here https://drive.google.com/file/d/1ImngEFWJFqXGn_FZh2rvYCgemDfrve_S/view
"Sovelmash" Laboratory, Zelenograd, 2019

Testing DA-90S and DA-100S L electric motors. "Sovelmash" laboratory, Zelenograd, 2019

The "Sovelmash" laboratory conducted bench tests of motors modernized at AS & PP Weihai: DA-90S and DA-100S L (extended).

The goal of the tests was to confirm the stated performance of electric motors.

The tests returned expectably good results.

Both motors demonstrated the efficiency of up to 90% in the nominal mode, and within a wide torque range the efficiency was 85-88%. The motors successfully withstood long-term overloads of up to 60 N·m.

Test report for DA-90S motor - https://clck.ru/FVG4q
University Düsseldorf, 2016

Testing the Siemens motor modernized by applying the "Slavyanka" technology. University Düsseldorf, January 2016

The test was conducted in a Düsseldorf laboratory and was commissioned by the Saint Petersburg company "SPBEK"

The goal of the tests was to see how the "Slavyanka" winding would impact the performance of a motor produced by a well-known company. Siemens electric motors were chosen for rewinding: the original motor and the one rewound using the combined winding technology.

During the tests, the second motor demonstrated higher efficiency throughout the whole range. The test proved that even motors with initially good efficiency could be improved by replacing a regular winding with the combined one.

The test reports can be found here https://drive.google.com/file/d/1qBVDfIh_8Ehh2H65T8SLchvhZOW44OFC/view

Practical application of the "Slavyanka" technology

The technology has been successfully applied since 1995

KAMAZ with the modernized generator

KAMAZ with the modernized generator

In summer 2017, the generator of "KAMAZ" from the "KAMAZ-Master" sports team was rewound using the "Slavyanka" technology. The rewinding made it possible to increase the generator power almost by 30%.

The modernized "KAMAZ" with Anton Shibalov's team took part in the 2017 Dakar Rally in South America with the route running through Paraguay - Bolivia - Argentina.

The "KAMAZ-Master" team was happy with the improvement, later the generators of the other cars were rewound for the 2018 Dakar Rally!

Besides, it was decided to apply the "Slavyanka" technology for the windscreen wipers motor of the racer KAMAZ cars.

The "KAMAZ-Master" generators were modernized by the company OOO "Electrocomplex", the licensee of OOO "ASiPP".
"ZAZ" electric car

Electric car ZAZ-966 with Duyunov's motor

A Zaporozhets car was equipped with a motor modernized by applying the "Slavyanka" technology, specially for the Kiev - Monte Carlo Electric Marathon 2015.

In Odessa, the founders of the "Ecofactor" project fully modernized the car within 3 weeks by changing the internal parts and leaving only the bodyshell intact.

In the race, the Odessan team crossed 10 countries and covered the distance of almost 3000 kilometres. At one of the route legs, ZAZ managed to overtake the Tesla electric car. There were no troubles with the electric car on the route, except for some minor loose ends that were quickly eliminated.

Zaporozhets was the fifth overall to arrive to the finish line and the second among the modernized electric cars. The Odessan electric car also won the people's choice award. Besides, the founder of the race, prince of Monaco Albert, paid attention to ZAZ, noting a very authentic exterior of the Ukrainian car.

Promo video about modernizing ZAZ — https://www.youtube.com/watch?v=m8uGFK2H-H8&t=40s
Mining electric locomotive "Era"

Mining electric locomotive Era

Electric locomotive Era is a vehicle used for freight transportation in the mines on a narrow-gauge railway.

In 2013, in Donetsk Era was equipped with a size-112 motor modernized using the "Slavyanka" technology instead of the original factory-supplied DRT-13, as well as a Сurtis controller.

The running tests demonstrated the following performance of the mining electric locomotive: it pulled 11 cars with coal while the previous one pulled 5, the speed was 12 km/h on a flat level surface and 7 km/h uphill, when transporting 100 tons of coal, the motor didn't overheat, despite the load increased two times.

Duyunov's development increased labour productivity of Donetsk miners twice alongside a considerable decrease in power consumption. The specialists also noted considerable reduction of high-frequency harmonics and reactive component in mains electricity that powered the traction step-down substations.
"Tavria" with Duyunov's motor

Tavria with Duyunov's motor

In 2014, the citizen of Belgorod region Igor Korkhov modernized the general purpose industrial motor in size 100 by rewinding it using the "Slavyanka" technology. As a result, the motor became 10 times more powerful with a comparatively light weight of 29 kilograms.

Before modernization, the motor power was 4 kW, and after - increased up to 12-13 kW, with the maximum of 50 kW.

"Igor Korkhov equipped the Tavria car with a modernized motor. The heavy car started quite vigorously in both first and third gear, while running very quietly. The maximum speed of the car amounted to 110 km/h, and it could run about 100 kilometres on a single charge ."

Igor Korkhov started modernizing Tavria back in the beginning of 2000s. The car had already been equipped with an electric motor, but the engineer wasn't satisfied with the speed that didn't exceed 50 km/h. So, he first equipped Tavria with an American commutator electric motor, and then - with a combined winding motor completed with a Curtis controller.

Tavria is still in operation today, already with its new owner. And Igor Korkhov is now a member of Duyunov's team and works at "Sovelmash" in Zelenograd.

Video about Tavria on Life News - https://www.youtube.com/watch?v=RhPMZyUspeI
Trolleybus in Kiev

Trolleybus in Kiev

In 2014, in Kiev at the premises of "KyivPasTrans", a trolleybus with a motor modernized using the "Slavyanka" technology was tested.

The modified drive increased the trolleybus speed and reduced power consumption. The project was terminated due to the unfavourable events in Ukraine.
Citroёn with Duyunov's motor

Citroёn with Duyunov's motor

In 2017, Dmitriy Duyunov's partner, Victor Arestov, in Germany installed a motor rewound using the "Slavyanka" technology in an old Citroën electric car.

The modernized electric car impressed the audience with fast start from rest, fast run and maneuverability. The car charge is enough for one hour.

Citroën performance after modernizing the motor:

Weight — 750 kg
Battery — 14 kWh
Controller Curtis 1238 96 V
Average charge consumption — 9.6 kWh per 100 km
Consumption in urban areas — 7.2 kWh per 100 km
Single charge range — up to 180 km
Maximum speed — 130 km/h

Modernizing the electric motor by applying the "Slavyanka" technology for Citroën resulted in considerable enhancement of the key performance features.

Video from Victor Arestov engaged in modernizing the electric car https://www.youtube.com/watch?v=RDdM2bclpKg&t=5s

One of the reports about Citroën in German https://www.youtube.com/watch?v=WtVqu0rLADw
Denzel Pickman truck

Denzel Pickman truck

Pickman electric car is a vehicle with a payload capacity of up to 500 kg. It is used for short-distance trips over small areas: in farming, tourism or production.

In September 2017, the truck was equipped with an electric motor modernized using the "Slavyanka" technology, smaller in size and weight than the standard operating motor. Thanks to the new motor:

the vehicle speed increased; the battery cycle increased.

Later on, Denzel Pickman was equipped with more powerful combined winding motors, modernized by ASPP Weihai using the "Slavyanka" technology.

In 2018 the truck was tested with a DA-90S motor.

In 2019 — with a DA-100S motor and a new lithium battery (84 Ah) instead of a lead one (100 Ah). The electric car demonstrated the following performance with them:

speed — 65 km/h, distance-to-empty — 100 km at an average speed of about 50 km/h.

Video of the Pickman tests — https://www.youtube.com/watch?v=dLcZMtuVOjI&t=9s
Electric scooter Irbis Grace with size-318 hub motor

Electric scooter Irbis Grace with size-318 hub motor

The Irbis scooter was modernized in 2016. The vehicle was equipped with one of the first prototype models developed by Duyunov, a 318-size hub motor. Besides, the rear float lever was replaced, and the steering system was supplied with a lever for regenerative braking. All the original factory-supplied electrics and control systems of the electric scooter remained intact.

The first test rides demonstrated better maneuverability of Irbis, it started easier and developed excellent speed. During a country road test ride, the scooter managed to develop the speed of up to 70 km/h.

Climax of the tests: Irbis Grace moved Niva (1500 kg) from rest and dragged it, thus demonstrating its power and endurance.

The video of Evgeniy Duyunov talking about the Irbis Grace scooter with size-318 hub motor - https://www.youtube.com/watch?v=WH3vAeIRElE&t=39s
Electric car Renault Kangoo

Electric car Renault Kangoo

In 2015, the member of Duyunov's team Victor Arestov applied the "Slavyanka" technology to rewind the motor of Renault Kangoo the electric motor of which had been prone to overheating. As a result, the motor stopped heating and the electric car distance range increased by 20%.

Later, an even more enhanced version of Renault Kangoo participated in 7 exhibitions in Monaco and in the south of France having amazed the visitors and specialists by: accelerating from rest in third or forth gear and a mountain trip in forth gear.

Renault E-Kangoo performance:

Car weight: 1560 kg
Controller: Curtis 1238-7601 650 A
Batteries: 33 x WINSTON WB-LYP200AHA 3.2 V (33 x 3.2 V x 200 AHA = 21.120 kWH)
"Slavyanka" motor: size 112, weight 60 kg
Power: max 57 kW (controller restricted); nominal: 35 kW
Motor revolutions: up to 9000 (Curtis controller restricted up to 8000 rev/min)
Maximum speed: up to 150 km/h
Maximum distance range: up to 210 km at 50 km/h
Consumption at 50 km/h: 5.7-6.2 kWh; at 80 km/h: 12.7 kW (four-wheel drive 4x4)
Acceleration time 0-100 km/h: 14 sec.

The electric car has been in running order up to the present day outperforming the Renault and Citroёn cars of the same type.

Renault Kangoo in action - https://www.youtube.com/watch?v=6bgLduo-xWs&t=1s
Electric car Renault Twizy

Electric car Renault Twizy

The original motor of Renault Twizy electric car was rewound using the "Slavyanka" technology in 2017 in Germany.

Testing Twizy started with an outdated 5-year battery that, however, didn't become an obstacle for enhancing the vehicle performance.

After modernization, the electric car could boast the following performance enhancements:

- distance range increased by over 20 %,
- motor power increased up to 18 kW,
- the motor didn't overheat remaining slightly warm.

The electric car was presented at the EVER and Top Mark exhibitions in Monaco in April 2017. The audience were amazed by its free maneuvering in the traffic and distance range.

Today, Twizy is kept at "Sovelmash" in Zelenograd and awaits further improvement of its specifications. It is planned to equip the electric car with a new battery weighing only 60 kg (instead of 120 kg old Li-Phosphate battery) and twice as powerful as the previous one.
Electric car Zetta

Electric car Zetta

One of the high-profile developments with Duyunov's hub motor was Zetta.

Zetta (back then - El-Panda) was first introduced in September 2017 at an exhibition in Ulyanovsk where it was noted by the President of Russia.

Size-318 hub motors were used in the electric car design with the maximum power of up to 18.1 kW, the torque of about 200 Nm. I.e., in total the hub motors develop the power of 72.4 kW (98 hp) and the torque of 800 Nm.

Every motor has its own controller, therefore the electric car can go both in four-wheel drive mode and in front-wheel or rear-wheel drive mode. The controllers are torque-synchronized together, which contributes to the travel quality.

Li-ion batteries of Zetta have the capacity of 10 kW*h, provide power enough for 200 km without recharging, meanwhile, the consumption is 40 W*h per kilometre.

The frame design is universal, which means that it can be applied for different kinds of bodyshells.

Evgeniy Duyunov's interview about Zetta - https://www.youtube.com/watch?v=z0RYgIYIzOc&t=1s

Presentation of Zetta - https://www.youtube.com/watch?v=V8GnFw87bAk&t=5s
Size-186 hub motor

Size-186 hub motor

The world's first induction hub motor is one of the most popular developments of Dmitriy Duyunov's team. This is a motor installed in the wheel of an electric vehicle, be it a bicycle, scooter, motorcycle or car. Duyunov's hub motor employs the combined winding technology "Slavyanka".

The analogues of Duyunov's hub motor are BLDC motors with magnets. To produce them, the rare-earth metals are needed that only China can provide in the required amount. Taking into consideration the progressively growing popularity of electric transport worldwide, the induction hub motor is not simply an analogue, but a fully functional, more effective and affordable substitute to the Chinese BLDC motors.

Work on size-186 hub motor ("Kolobok") started on February 4, 2015. Initially, it was designed for a wheelchair scooter: a piece of equipment that provides more mobile transportation for disabled people. Later, size-186 "Kolobok" was tested on a bicycle.

The hub motor doesn't overheat, withstands external impact, is resistant to water, dust and dirt, vehicles equipped with it demonstrate high speed.

Motor performance:

weight — 8 kg, maximum efficiency — 94 %, maximum speed of the bicycle with the hub motor — 101 km/h, starting torque at the start - 52 Nm, torque — 200 Nm maximum torque — 76 Nm. maximum power — 20 kW,

Duyunov's hub motor is distinguished by durability and long service life, its production cost is 30% lower, it's also cheaper to maintain. Vehicles with the hub motor demonstrate increased travel distance.

Later, a size 318 hub motor was designed weighing 18 kg. Sizes 186 and 318 are the minimum and maximum ones, Duyunov's team are working on the intermediate size. Over the course of testing and running, the hub motors have been tested on various bicycles: "Gran", "Versiya", El Moto, Denzel Sparta, Denzel Escort
Angle grinder

Angle grinder

The "Sovelmash" engineers modernized the angle grinder UShM 230/2100M by equipping it with an induction short-circuited drive designed by applying the combined winding technology.

Then the "Sovelmash" laboratory conducted comparative performance tests for the standard and modified machines. The tests showed that the angle grinder with Duyunov's motor operated more smoothly: it was evident in rotation, noise level, and cutting quality.

Besides, the following peculiarities have been noted:

- the no-load speed of the classic angle grinding unit is higher than of the induction drive angle grinder, but under the load, the difference between them gets completely eliminated; - the "Slavyanka" model has much fewer constituent parts which leads to faster cutting and increasing service life of the angle grinder; - weight and noise level of the induction drive angle grinder are lower than the rival's.

Enhanced performance of the "Slavyanka" angle grinder improves productivity and comfort level of operating it.

Dmitriy Duyunov about developing a specialized induction drive designed for power tools - https://youtu.be/ltLRWSdZBIo

View the comparative tests of the angle grinder with "Slavyanka" and classic angle grinder here - https://youtu.be/oiavBAL9OXo

Small-scale production

Purchase the electric motors with "Slavyanka" to experience the efficiency of the innovation first-hand

The small-scale production of motors implemented by applying the modernization potential of standard electric motors through changing the classic winding to combined winding is carried out by ASPP Weihai. The enterprise operates in China under license issued by OOO "ASiPP". The company produces various modifications of traction motors for electric vehicles.