Industrial Motors and Control Means

Industrial Control Systems

Fall 2006

Lecture Industrial Motors

MME 486 Fall 2006

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What is a Motor ?
A motor is a transducer that converts
electrical to mechanical energy.
Electrical
Energy

Motor

Mechanical
Energy

Losses
motor = Mechanical Power
Electrical Power
Lecture Industrial Motors

MME 486 Fall 2006

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DC vs. AC Motors
All motors either create or use alternating currents
internally.
Those which are supplied by a time invariant voltage at
their input and draw close to DC at steady state are
called DC motors.
Those which are supplied by a time variant (typically
sinusoidal) voltage at their input and draw AC current
at steady state are called AC motors.
Both DC and AC motors can be subdivided into brushtype and brushless type.

Lecture Industrial Motors

MME 486 Fall 2006

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Brush Type DC Motors

There are 3 types of brush type DC
motors used in industry:
Shunt field (wound field, separately
excited, or permanent magnet)
Series field
Compound motor (uses both shunt and
series fields)

Lecture Industrial Motors

MME 486 Fall 2006

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Brush Type DC Motors

The speed vs. torque characteristics for each motor type is

different and lend themselves to different applications.
Shunt or Separately Excited

Series Field

Compound Field

no-load
speed
=

no-load
speed

T
stall
torque
Linear Speed Torque Characteristics
Finite No-Load Speed

Lecture Industrial Motors

no-load
speed

stall
torque

Extremely High Starting Torque

Dangerously High Speeds at No-Load Speed

MME 486 Fall 2006

T
stall
torque
Combines Best Features of Shunt and Series Motors
High Stall Torque and Finite No-Load Speed

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Variable Speed Control

of DC Motors
In separately excited (wound field) motors, shunt, or compound
DC motors, the speed of the motor can be controlled by:
1. Changing the field resistance.
2. Changing the armature voltage.
3. Changing the armature current.
In permanent magnet or series field motors, only 2 and 3 apply.

Lecture Industrial Motors

MME 486 Fall 2006

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Variable Speed Control

of DC Motors - PWM

Another means to vary the speed of the motor is to vary the

armature voltage, and hence current, through the use of pulse
width modulation (PWM).

voltage

Average Voltage = Duty Cycle * Vmax

time
toff

ton

tswitch
Duty Cycle =

Lecture Industrial Motors

ton
tswitch

MME 486 Fall 2006

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Variable Speed Control

of DC Motors - PWM
+

Diode

DC Link
PWM Voltage

MOSFET

Lecture Industrial Motors

MME 486 Fall 2006

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DC Motor Loading

Using a permanent magnet motor as an example with a motor

operating at full supply voltage.
n

no-load
speed

no-load
speed

Tfan = nfan2
kfan2

Operational
Speed
nfan
Operational
Speed

T
Constant
Load

stall
torque

T
Fan
Load
Tfan

stall
torque

The operating point of the fan will vary if the supply voltage
changes with this type of motor.
Note, permanent magnet DC motors are typically used for power
levels < 3 hp. Wound field motors are typically used for power
levels > 3hp.

Lecture Industrial Motors

MME 486 Fall 2006

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DC Motor Dynamics

There are 2 equations (an electrical equation and a mechanical equation) that
reflect the behaviour of any motor. As applied to a DC motor:

Electrical equation: Vsupply = Ke motor d/dt Imotor Rarmature

Where:
Ke = Motor electrical constant (V/rad/s)
Mechanical equation: Tgen = Jarmature d motor/dt B motor Tload
Ki Imotor = Jarmature d motor/dt B motor Tload
Where:
Ki = Motor torque constant (Nm / A)

From these equations it may be seen when the motor speed is equal to 0, the
motor EMF = 0.

As a result a need to soft-start the motor may be required depending on the

load. For example, a high inertial load, or a fixed load typically need to be soft
started.

Lecture Industrial Motors

MME 486 Fall 2006

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DC Motor Starters
Purpose:
1. Protect the motor against damage due to
short circuits in equipment
2. Protect motor against damage from long
term overloads
3. Protect motor against damage from
excessive starting currents
4. Provides a convenient manner in which to
control the operating speed of the motor
Lecture Industrial Motors

MME 486 Fall 2006

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Resistive DC Motor Starter

OL

Resistor
DC Motor
Armature

CR1
CR2

DC Motor
Field Winding
Start

Stop

CR1

OL

TD1

CR1
TD1

Lecture Industrial Motors

MME 486 Fall 2006

CR2

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DC Motor Starters
PWM can be used to create a "soft
start" by ramping up the PWM duty
cycle as a function of time, so as to
ramp up the current.

Lecture Industrial Motors

MME 486 Fall 2006

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Brush Type DC Motors

Protection Considerations
Many DC motor drives include a "Loss of Field" relay
interlocked to the E-Stop circuit.

In series with
E-Stop chain

Lecture Industrial Motors

CR1

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Brush Type DC Motors

Protection Considerations

An bimetallic temperature sensor can also be placed in the field

windings.
If the temperature exceeds a certain temperature, the switch will click
open. This switch can also be placed in series with the E-Stop chain.

In series with
E-Stop chain

In series with
E-Stop chain

Lecture Industrial Motors

CR1

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Brush Type DC Motors

Protection Considerations
Other protection means include:

Fusing of armature to protect the motor against short circuits,

or extended, excessive loads (typically a slow-blow fuse).
Magnetic relays used to shut down the motor if the
instantaneous armature current exceeds 300% of its rated value
for example.
An Undervoltage Relay Used to shut down the motor if the line
supplying the motor drops by a certain percentage (20% for
example

Lecture Industrial Motors

MME 486 Fall 2006

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3 Phase AC Motors
In a 3 phase induction motor, a rotating magnetic field is
created in the stator windings of the machine by three
supply voltages that are 120 degrees apart.
A current is induced in the rotor bars from the rotating
magnetic field.
The rotor bars have a magnetic field surrounding them
that pushes against the magnetic field produced by the
stator.
The rotor, therefore, follows the rotating magnetic field
produced by the stator.

Lecture Industrial Motors

MME 486 Fall 2006

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3 Phase AC Motors
The speed in (RPM) at which the magnetic field rotates in
the stator equals:
nmotor= 120 f
p
Where: f = the motor supply frequency (typically 60 Hz)
p = the number of poles in the motor (dim.)
The speed of the magnetic field in the stator is called the
synchronous speed

Lecture Industrial Motors

MME 486 Fall 2006

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3 Phase AC Motors
The rotor will rotate at a lower speed than the synchronous
speed:
The difference between the rotor speed and synchronous
speed divided by the synchronous speed is known as slip.
% slip = synchronous speed rotor speed x 100
synchronous speed

Lecture Industrial Motors

MME 486 Fall 2006

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3 Phase Motor Speed-Torque Characteristics

The speed-torque characteristics of a 3 phase motor
varies with rotor slip.
Speed
Note: Most motors operate under 3 5%
slip at full-load torque (almost constant
speed operation)

Pull-out Torque
(Torque at which motor speed begins to
decrease until motor stalls)

Torque
100%
150%
Full-Load Full-Load
Torque Torque

Lecture Industrial Motors

250%
Full-Load
Torque

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3 Phase Motor Torque-Speed

Characteristics Different Types of Motors

There are 4 classes of standard induction machines,

namely A, B, C, and D.

Each motor has its own speed-torque characteristics.

Each motor type is used for different applications.

Lecture Industrial Motors

MME 486 Fall 2006

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Class A Induction Motors

This is a standard motor design.

Full load slip must be 5% or less.
Pull-out torque is 200 - 300% of full-load torque and occurs at less than 20% slip.
A drawback of this design is extremely high inrush current typically 500 800% rated current.
Applications include: fans, blowers, centrifugal pumps and compressors where starting requirements are low.

Speed

3-5%
Slip
20%
Slip

Torque
100%
Full-Load
Torque

Lecture Industrial Motors

250%
Full-Load
Torque

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Class B Induction Motors

Normal starting torque.

Lower starting current.
Low slip operation.
Produces same starting torque at 25 % less current.
Pullout torque is 200% of full-load torque but is less than Class A design (higher rotor resistance).
Rotor slip < 5% at full-load.
Applications same as Class A, however, is preferred due to lower starting current.
Speed

<5%
Slip
20%
Slip

Torque
100%
Full-Load
Torque

Lecture Industrial Motors

200%
Full-Load
Torque

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Class C Induction Motors

High starting torque.

Low starting current.
Rotor slip < 5% at full-load.
Pullout torque is up to 250% of full-load torque but is less than Class A design (higher rotor resistance).
Motors are constructed of double cage rotors so they are more expensive.
Applications are typically high starting torque loads such as loaded pumps, compressors, and conveyors
Speed

<5%
Slip
20%
Slip

Torque
200%
250%
Full-Load Full-Load
Torque Torque

Lecture Industrial Motors

MME 486 Fall 2006

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Class D Induction Motors

Very high starting torque (275 % or more of rated torque).

Low starting current.
Rotor slip 7 11 % at full-load.
Peak torque is shifted to a very low speed. Maximum torque could occur at 300% slip (0 speed)
Applications fix weights and very large inertial loads.
Speed

7-11%
Slip

100%
Slip

100%
Full-Load
Torque

Lecture Industrial Motors

300%
Full-Load
Torque

MME 486 Fall 2006

Torque

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Starting AC Motors

The most common means for starting an induction motors is an

across the line motor starter that applies full voltage to the stator
windings.
If the rotor is connected to a high inertial load, resistive or
semiconductor starting may be employed to limit current to the motor
windings on start-up.

Lecture Industrial Motors

MME 486 Fall 2006

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3 Phase Resistive Starter

CR1

CR2

OL

ph. A
CR1
CR2

OL

ph. B

3 Phase
Motor
CR1
CR2

ph. C

OL

Start

CR1

Stop

OL

TD1

CR1

Lecture Industrial Motors

TD1

MME 486 Fall 2006

CR2

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3 Phase Semiconductor Starter

Increasing
Conduction Angle
=
Decreased
Power

Run

SCR A
Start

OL
Voltage

ph. A

SCR B

SCR B

Run

Time

SCR A
Start

OL
3 Phase
Motor

ph. B
Run

Conduction
Angle
Start

OL

ph. C

Lecture Industrial Motors

MME 486 Fall 2006

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3 Phase Motor Speed Control

A wound rotor induction motor controls rotor resistance,
and hence motor speed.
Stator

Rotor

Slip Rings

Variable frequency drives.

Lecture Industrial Motors

MME 486 Fall 2006

Variable
Resistance

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Synchronous Motors

Permanent magnet
Trapezoidal Back EMF
Sinusoidal Back EMF
Speed-Torque Characteristics

Lecture Industrial Motors

MME 486 Fall 2006

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Single Phase AC Motors

Types Include:
Resistance-Start Split Phase Motor
Capacitor-Start Motor
Permanent-Split Capacitor Motor
Two-Value Capacitor Motor
Shaded Pole Motor

Lecture Industrial Motors

MME 486 Fall 2006

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Single Phase AC Motors

Run Winding
(Low Resistance)

Resistance-Start Split Phase Motor

Rotor
Starting
Switch

Start Winding
(High Resistance)

Typical power levels up to 0.33 hp

Low starting torque
Used to drive fans, woodworking tools, grinders, furnaces
Lecture Industrial Motors

MME 486 Fall 2006

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Single Phase AC Motors

Run Winding

Capacitor-Start Motor

Rotor
Starting
Switch

Start Winding

Typical power levels up to 0.125 to 0.75 hp, however sizes up to 2 hp available

High starting torque (up to 450 % of full-load). Capacitor is electrolytic
Used for heavy duty drives such as refrigerator compressors, pumps and AC

Lecture Industrial Motors

MME 486 Fall 2006

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Single Phase AC Motors

Permanent-Split Capacitor Motor

Run Winding

Rotor
Starting / Running
Capacitor

Auxillary
Winding

Typical power levels up to 0.33 hp

Compromise design. Very low starting torque but quieter and more efficient than capacitor start
motor. Capacitor for running conditions much smaller that that required to give good starting
torque. Capacitor is oil filled or mylar film.
Used for fans and blowers where the motor is used for fans and blowers where motor can
be matched to load.
Lecture Industrial Motors

MME 486 Fall 2006

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Single Phase AC Motors

+

Two-Value Capacitor Motor

Run Winding

Rotor

Starting
Capacitor

Running
Capacitor
Starting
Capacitor
Switch

Auxillary
Winding

Typical power levels up to 0.33 hp

Excellent starting torque, better running torque than capacitor start motor.
Cap for running conditions much smaller that that required to give good starting torque. Start
capacitor is electrolytic. Run capacitor is oil filled or mylar film.
Used for applications where high starting torque is required.
Lecture Industrial Motors

MME 486 Fall 2006

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Single Phase AC Motors

Shaded Pole Motor

Shading Pole

Lecture Industrial Motors

Shading Pole

MME 486 Fall 2006

Shading Pole

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Other Motors
Other types of motors in use in industrial applications
include:
Hysteresis motors
Universal motors
These are typically used in low power applications.

Lecture Industrial Motors

MME 486 Fall 2006

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