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Questions and Answers

Which factors influence the selection of a motor?

  • Size and ratings of motors (correct)
  • Electrical considerations (correct)
  • Application type
  • Mechanical considerations (correct)

    • What is a characteristic feature of analogue controllers?

  • They require minimal safety considerations.
  • They provide flexibility in control functions.
  • They are inflexible. (correct)
  • They are highly configurable.

    • Which of the following best describes passive loads?

  • They are associated with elastic deformation.
  • They are associated with gravitational deformation.
  • They appear as a result of potential energy changes.
  • They always oppose motion. (correct)

    • What are dry friction loads dependent on?

    <p>Torque (B)</p> Signup and view all the answers

    What essential feature is required for the isolation between control and power circuits?

    <p>For safety purposes. (C)</p> Signup and view all the answers

    Which of the following best explains viscous friction loads?

    <p>Torque is linearly dependent on speed. (C)</p> Signup and view all the answers

    What is the role of a Power Electronic Converter (PEC)?

    <p>To regulate the power supply. (A)</p> Signup and view all the answers

    Which of the following is NOT a mechanical consideration in motor selection?

    <p>Initial cost (B)</p> Signup and view all the answers

    What is a primary advantage of AC drive systems compared to DC drive systems?

    <p>Lighter and less expensive (A)</p> Signup and view all the answers

    Before the development of power electronics, in which application were DC drives predominantly used?

    <p>Variable speed applications (A)</p> Signup and view all the answers

    What is one of the components of solid-state drive systems?

    <p>Power source (A)</p> Signup and view all the answers

    Which type of motor is commonly used in AC drive systems?

    <p>Induction motor (A)</p> Signup and view all the answers

    After the introduction of vector control in 1980, which type of drive has become more favored in industrial applications?

    <p>AC drives (D)</p> Signup and view all the answers

    What is one disadvantage of using DC drive systems?

    <p>Limited speed (C)</p> Signup and view all the answers

    What factor is NOT typically considered in the trade-off between classical drive systems and solid-state drives?

    <p>Complexity of control (B)</p> Signup and view all the answers

    Which type of AC motor is characterized by having a magnetic field that rotates at a constant speed?

    <p>Synchronous motor (A)</p> Signup and view all the answers

    What is the mass of the load to be transported by the vehicle?

    <p>400 kg (B)</p> Signup and view all the answers

    In which quadrants does the machine run as a motor?

    <p>1 and 3 (D)</p> Signup and view all the answers

    What is the diameter of the wheel used in the vehicle?

    <p>0.14 m (C)</p> Signup and view all the answers

    How is motor sizing defined in this context?

    <p>Finding the best motor for a specific application (A)</p> Signup and view all the answers

    What is the cycle time given for the vehicle operation?

    <p>7 seconds (C)</p> Signup and view all the answers

    What does the mechanical efficiency (η) equal in this scenario?

    <p>100% (C)</p> Signup and view all the answers

    Which type of electric drive system is characterized by a single motor dedicated to a single load?

    <p>Individual Electric Drive (C)</p> Signup and view all the answers

    What is the gearbox ratio provided in this system?

    <p>10 (C)</p> Signup and view all the answers

    What occurs in quadrants 2 and 4 during the driving cycle?

    <p>The machine operates as a generator or brake (D)</p> Signup and view all the answers

    What is a key advantage of solid-state electric drives?

    <p>Flexible control characteristics (B)</p> Signup and view all the answers

    Which of the following applications would most likely use a multi-motor drive system?

    <p>Robotic systems (B)</p> Signup and view all the answers

    Which of the following is NOT an advantage of solid-state electric drives?

    <p>Inflexible speed control (A)</p> Signup and view all the answers

    What characterizes the torque in applications such as fans and centrifugal pumps?

    <p>Torque is proportional to the square of speed (D)</p> Signup and view all the answers

    What is a potential disadvantage of line shaft or group drives?

    <p>Motor failure causing system shutdown (B)</p> Signup and view all the answers

    Which driving cycle interval follows the acceleration phase?

    <p>Steady-state operation (A)</p> Signup and view all the answers

    Dynamic equations of electric drives are primarily based on which law of motion?

    <p>Newton's second law of motion (D)</p> Signup and view all the answers

    Which inertia ratio is considered typical for most applications?

    <p>5:1 (C)</p> Signup and view all the answers

    What happens when the maximum torque at the application speed falls within the continuous region?

    <p>It indicates an oversized motor. (C)</p> Signup and view all the answers

    How does decreasing the inertia ratio affect control loop tuning?

    <p>It simplifies tuning. (C)</p> Signup and view all the answers

    Which is NOT a key sizing factor for motor selection?

    <p>Environmental factors (A)</p> Signup and view all the answers

    What limitation may arise from using a low inertia ratio?

    <p>Oversized motor requirements. (D)</p> Signup and view all the answers

    Which factor is crucial when considering motor size and rating?

    <p>Heating effects (C)</p> Signup and view all the answers

    What does RMS torque represent in terms of motor performance?

    <p>Steady-state torque (C)</p> Signup and view all the answers

    At a higher inertia ratio, what can be expected regarding the system's performance?

    <p>Increased control complexity (C)</p> Signup and view all the answers

    What can result from using a replacement motor with a lower temperature rating?

    <p>Premature failure of the motor (C)</p> Signup and view all the answers

    What is the main purpose of the IEC 60034-1 standard?

    <p>To classify motor operating conditions (D)</p> Signup and view all the answers

    Which duty type allows a motor to operate at a constant load until thermal equilibrium is reached?

    <p>Duty type S1 (D)</p> Signup and view all the answers

    In duty type S2, how long can the operation take before reaching thermal equilibrium?

    <p>Less than required time (B)</p> Signup and view all the answers

    What is the characteristic of duty type S3?

    <p>A series of identical cycles of operation and pause (A)</p> Signup and view all the answers

    What does the Ingress Protection (IP) rating of a motor indicate?

    <p>The level of protection against water and dust (A)</p> Signup and view all the answers

    Which statement about duty type S4 is correct?

    <p>It includes a significant starting period and a pause. (D)</p> Signup and view all the answers

    What is crucial for ensuring that a motor is suitable for its environment?

    <p>The Ingress Protection (IP) rating (A)</p> Signup and view all the answers

    Flashcards

    DC Drive Systems

    Electric drive systems using DC motors, often preferred for high-performance applications like traction and elevators.

    AC Drive Systems

    Electric drive systems using AC motors, generally chosen for industrial applications due to easier maintenance and lower cost.

    Classical Drive Systems

    Electric drive systems where motors are directly connected to the power source (mains).

    Solid State Drives

    Electric drive systems using power electronics, suitable for variable speed drives (VSDs).

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    Power Source (Electric Drives)

    The energy supplied to the drive system, including DC sources (batteries, fuel cells) or AC sources (utility power).

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    Driving Motor (Selection)

    Selecting a motor based on its power needs and performance requirements (steady-state and dynamic operations) in a specific application.

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    Types of AC Motors

    Induction, Synchronous, Permanent Magnet Synchronous Motors (PMSM), and Brushless DC (BLDC) are common AC motor types.

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    Special Motor Types

    Motors like Universal Motors, Switched Reluctance Motors (SRM), and Stepper Motors, used for specific applications.

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    Driving Motor Selection

    Choosing the right electric motor depends on electrical and mechanical factors, cost, and the load's characteristics.

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    Power Electronic Converter (PEC)

    A device that gives a stable power supply, chosen based on the motor and available power. It may be a single unit or several.

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    Controller Types

    Controllers categorized as analogous, digital (PLCs, DSPs) offering differing flexibility and complexity.

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    Electric Isolation

    A crucial safety measure to prevent control circuit malfunctions when using power circuits.

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    Active Load

    Loads associated with energy changes, like spring actions, due to gravitational/elastic body deformation.

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    Passive Load

    Opposition to motion, mainly friction, shear or deformation in non-elastic bodies. Examples- lathes, fans, pumps.

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    Dry Friction Load

    Torque that remains steady even with speed change.

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    Viscous Friction Load

    Torque is directly proportional to the speed of the load. Ex: eddy current brakes, machine tools.

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    Vehicle Drive System

    Mechanism that moves a vehicle using a toothed belt driven x-axis along a specified path.

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    Machine's Four-Quadrant Operation

    The capability of a machine to switch between motor and generator/brake modes based on the applied torque and speed.

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    Motor Sizing

    The selection of a suitable motor for a particular application based on various factors.

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    Load Parameters

    Essential attributes of the transported load, including mass (M), and travelling distance (S).

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    Cycle Time

    Duration for one complete cycle of the vehicle's movement.

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    Mechanical Efficiency

    Percentage of input energy converted into useful output work/energy by the system.

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    Quadrant 1 and 3

    Two quadrants where the machine runs as a motor (Speed and torque have the same directions).

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    Quadrant 2 and 4

    Two quadrants where the machine acts as a generator or brake (Speed and torque have opposite directions).

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    Torque vs. speed (fans/pumps)

    Torque varies with the square of speed for fans, pumps, and propellers.

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    Torque vs. speed (machines)

    Torque decreases as speed increases for milling, lathes, and boring machines.

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    Solid-state drive advantages

    Flexible control, wide torque/speed ranges, adaptable to conditions, fault detection, four-quadrant operation, energy saving, high efficiency, high power factor, remote control, compact, and quiet.

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    Individual Electric Drives

    A single motor connected to a single load (e.g., household appliances).

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    Line Shaft Drives

    A single motor is used to drive multiple loads via a common shaft or belts.

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    Multi-Motor Drives

    Multiple motors drive a single mechanical load (e.g., airplane systems, cranes).

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    Driving Cycle Intervals

    Driving cycles involve acceleration, steady-state operation, and deceleration.

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    Dynamic Equations of Electric Drives

    The dynamic equations of an electrical drive are based on Newton's second law of motion, focusing on a motor coupled to a rotating load.

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    Motor Duty Cycle S1

    Continuous operation at a constant load, allowing the motor to reach thermal equilibrium.

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    Motor Duty Cycle S2

    Constant load for a period, less than needed for full thermal equilibrium, followed by a cool-down period.

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    Motor Duty Cycle S3

    Repeated identical cycles of operation and rest; starting current is insignificant

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    Motor Duty Cycle S4

    Identical repeating cycles with a significant starting period, followed by constant load and rest.

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    Motor Nameplate

    A label on the motor providing essential information, including IP ratings.

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    IP Rating

    Ingress Protection rating that signifies the protection level of a motor from foreign objects and water.

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    Motor Failure (Temperature)

    Replacing a motor with a lower temperature rating can lead to early motor failure

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    IEC 60034-1

    International standard for classifying motor duty cycles.

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    Inertia Ratio

    The ratio of load inertia to motor inertia, typically 5:1, but can vary from 2:1 for high performance to 10:1 for less critical applications

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    Motor Rating - RMS Torque

    Motor rating's steady-state torque, calculated as the root mean square (RMS) of the torque profile. It should fall in the continuous operating region.

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    Speed-Torque Curve

    A graphical representation showing the relationship between motor speed and torque output. Crucial for motor selection.

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    Maximum Torque

    The highest torque the motor can produce at a specified speed.

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    Load Inertia

    The total inertia of the mechanical load to be driven. Often calculated.

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    Torque profile

    The variation of torque with time or speed during operation. Used to determine RMS torque and maximum torque.

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    Inertia Ratio (Performance)

    Lower inertia ratios (2:1 or less) allow for superior dynamic performance and easier control loop tuning.

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    Motor Selection Factors

    Factors like heating, load conditions, duty type and load inertia are considered when selecting a motor.

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    Study Notes

    Electric Drives EEP 436 Course Contents

    • Components and properties of electric drive systems
    • Types of loads and four-quadrant operation
    • Motor sizing
    • Thermal considerations and duty types
    • DC Drives
      • Fundamentals of DC machine speed control
      • Open-loop and closed-loop speed control
    • Induction Motor (IM) Drives
      • Fundamentals of IM speed control
      • Three-phase voltage source inverters (VSIs)
      • Three-phase AC voltage controllers
      • Open-loop V/f speed control
      • Closed-loop V/f speed control
      • Braking techniques
      • Vector control

    Text Books

    • Fundamentals of Electrical Drives, Mohamed El-Sharkawy, Brooks/Cole, 2000
    • Electric Drives: An Integrative Approach, Ned Mohan
    • The Induction Machine Handbook, I. Boldea, S. Nassar

    Assessment

    • Projects: 20%
    • Lab: 20%
    • Midterm: 25%
    • Final Exam: 50%

    Motion Control and Servo Systems

    • A servomechanism is an automatic device using error-sensing negative feedback to correct a mechanism's action. It has a built-in position/speed feedback mechanism to ensure the output matches desired position/speed.
    • Drive systems employing electric motors as prime movers are called electric drive systems. The combination of electric motor, transmission, and control equipment is an electric drive system.

    Reasons for Using Variable Speed Drives (VSDs)

    • VSDs are used for applications like paper-making machines that can't operate without them, and for centrifugal pumps that benefit from energy savings.
    • VSDs match motor speed/torque to the process requirement.
    • VSDs save energy and improve efficiency.

    Ward Leonard System for Variable Speed

    • Introduced by Henry Ward Leonard in 1891.
    • Disadvantages: very costly, low efficiency, large size, and weight.

    Types of Electric Drives

    • Based on motor type:
      • DC drive systems
        • Pros: simple control
        • Cons: regular maintenance, heavy, expensive, limited speed
        • Suitable for applications needing high performance (tractions, elevators, servos).
      • AC drive systems
        • Pros: less maintenance, lighter, less expensive, wide speed range.

    Types of Electric Drives (Before power electronics development)

    • DC drives were used in variable speed and High Performance Applications.
    • AC drives were used in Fixed Speed Applications.
    • Vector control of AC drives introduced in 1980, making AC drives the more preferred choice in most industrial applications.

    Types of Classical Drive Systems

    • Classical Drive Systems: Motors are directly fed from mains.
    • Solid State Drives: Best suitable for VSDs applications.
    • Trade-off between the two types depends on technology, application, performance capabilities, motor cost, and additional system component costs.

    Components of Solid-State Drive Systems

    • Power Source
    • Power Converter
    • Driving Motor
    • Gating Signals
    • Controller
    • Measurements

    Power Source

    • Available supplies are commonly:
      • DC: Batteries, fuel cells, photovoltaic systems
      • AC: Single- or three-phase utility.
    • Power sources may also be unregulated or fixed voltage/frequency.

    Driving Motor

    • Electric motors exhibit variations in torque-speed characteristics for varying mechanical loads.
    • The basic selection criterion is meeting the required power level and performance during both steady-state and dynamic operations
    • Motor types: DC motors (permanent magnet or wound field), AC motors (induction, synchronous, PMSM, brushless DC), and special motors (universal, switched reluctance, stepper).

    Driving Motor (Considerations)

    • Electrical Considerations: Running characteristics, Starting characteristics, Speed control characteristics, and Braking characteristics
    • Mechanical Considerations: Type of enclosure, Type of bearings, Transmission, and Noise
    • Sizing and Ratings: Load duty cycle, Heating and cooling time constants, and Overload capacity
    • Cost Considerations: Initial cost and Running cost

    Power Electronic Converter PEC (or Power Modules)

    • Function: Regulates power supply depending on the motor type and available supply.
    • May be a single converter or a combination.

    Controller

    • Controller complexity depends on performance requirements. Controller types: Analog (inflexible) and Digital (configurable)
    • PLCs, DSPs, and microprocessors perform complex control functions. – Electric (or Galvanic) isolation between control and power circuits is mandatory for safety and avoiding control circuit malfunction or damage.

    Mechanical Loads

    • Active loads: Associated with gravitational or elastic deformation (change in potential energy), e.g., springs.
    • Passive loads: Due to friction, shear, or deformation in non-elastic bodies (opposes motion). Examples: lathes, fans, and pumps.
    • Load torque (TL) is empirically represented by various relationships (e.g., proportional to speed, proportional to square of speed, independent of speed).

    Basic Types of Passive Loads

    • Dry friction load (torque independent of speed)
    • Viscous friction load (torque linearly dependent on speed)
    • Torque proportional to the square of the speed
    • Torque inversely proportional to the speed

    Advantages of Solid-State Electric Drives

    • Flexible control characteristics for shaping steady-state and dynamic load requirements.
    • Wide range of torque and speed.
    • Adaptable to various operating conditions (normal and hazardous).
    • Automatic fault detection and ride-through capability.
    • Four-quadrant operation.
    • Energy saving and high efficiency.
    • High power factor operation.
    • Facility for remote control.
    • Compactness and less floor space.
    • Quiet operation.

    Forms of Electric Drive Systems

    • Individual Electric Drive (Single-motor, single-load drives):
      • Most common form
      • Dedicated to a single load
      • Higher initial cost
      • Applications include household equipment (washers, dryers), drills, fans, hard disks.
    • Line Shaft or Group Drives:
      • Single motor drives multiple loads through a common line shaft and/or belts
      • Low initial cost
      • Motor rating sums less than individual loads
      • Disadvantages: motor failure shuts down whole system, inflexible speed control, high noise, and high mechanical losses.
    • Multi-Motor Drives:
      • Several motors drive a single load
    • Application examples: airplane actuation systems, cranes, robots

    Driving Cycle Intervals

    • Composed of acceleration, steady-state operation, and deceleration intervals.

    Dynamic Equations of Electric Drives

    • Governed by Newton's second law of motion.
    • Simplest drive system comprises a rotating load directly coupled to the motor.
    • Key variables: Motor torque (Te), Equivalent load torque (TL), Equivalent inertia (Jeq = Jm + JL), Equivalent friction (beq = bm + bL), and Equivalent stiffness (Keq).

    Steady-State Stability

    • Stability depends on friction and shaft stiffness.
    • Operating point A is stable; point B is unstable.

    Gear Input/Output Relations

    • Assuming 100% gear efficiency, input and output speeds and torques are related.
    • Gear ratios are important in relating input to output.

    Gear Transmission

    • Spur gear set
    • Straight gear set
    • Spiral bevel gear
    • Worm gear set
    • Helical gear set
    • Planetary gear set
    • Herringbone gear
    • Hypoid gear

    Equation of Motion

    • Translational motion (Newton's law)
    • Rotational motion
    • Combination of rotational and translational motions

    How To Refer System to Motor Side

    • Load is coupled to the motor through a gearbox with ratios.
    • Kinetic energy and power transfer are equivalent between motor and load sides despite the gearbox.

    Translational to Rotating Motion

    • For equivalent kinetic energy, relationships exist between translation and rotation with respect to gearing and radius.

    Example (Equivalent Motor Torque, Inertia, and Friction)

    • Includes cylindrical loads, winch loads, dry friction loads, viscous friction loads, and fan loads.

    Motion Profiles

    • Trapezoidal velocity profile (for analysis).
    • S-curve velocity profile (practical). This profile leads to smoother motion.
    • Jerk (jolt) of trapezoidal profile is infinite at four points resulting in discontinuities, while S-curve motion reduces discontinuous abrupt acceleration changes.

    Example (Single-Axis Conveyor Vehicle)

    • Defined parameters include mass, wheel diameter, speed, acceleration/deceleration, distance traveled, cycle time, gearbox ratio, and mechanical efficiency.

    Load Side (Linear and Angular Motion)

    • Defined parameters include time (t), velocity (v(t)), acceleration (a(t)), and displacement (s(t)) for linear motion.
    • Parameters include time (t), angular velocity (ω(t)), angular acceleration (a(t)), and angular displacement (θ(t)) for angular motion.

    Effect of Gearing-Equivalent System Inertia

    • Motors designed for high speed, low speed applications use a gear to reduce the high speed.
    • Gearing ratio (n = n₁/n₂) affects equivalent system inertia.

    Load and Motor Steady-State Torque

    • Pushing force, motion, friction, and relationships between torque and forces

    Total Torque

    • Rated torque (RMS) of the torque curve
    • Trms (based on the torque curve)
    • Tmax (based on the torque curve)

    Four-Quadrant Operation

    • During a driving cycle, the machine may act as a motor in either direction of rotation, or as a generator or brake depending on the terminal conditions.

    Four-Quadrant Operation (Under Different Conditions)

    • The machine operates in different quadrants based on the direction and magnitude of torque and speed (T and N).
    • Specific diagrams show these relationships.

    Four-Quadrant Operation Using Hoisting System

    • The counterweight weight is adjusted to be greater than the unloaded cage and less than the loaded one (typically half the weight of the loaded cage).
    • The machine runs as a motor (speed and torque have the same direction) in quadrants 1 and 3. –The machine acts as a generator or brake (Speed and torque are in opposite directions) in quadrants 2 and 4.

    Motor Sizing

    • Finding the best motor for a certain application.
    • Motor selection depends on many factors: motion profile, inertia, speed, acceleration, torque, regenerative capacity, overload capacity, cost, resolution requirements, environment, power requirements, and physical size limitation.

    Four Key Sizing Factors

    • Inertia Ratio
    • Speed
    • Max torque at rated speed
    • RMS torque at rated speed
    • Motor inertia (Jm)
    • Load inertia (Jl)

    Inertia Ratio Specification

    • 5:1 is typical
    • 2:1 or less for high dynamic performance
    • 10:1 or more for applications where performance is not critical
    • Ease of control loop tunning and machine dynamic performance go up as inertia ratio goes down
    • Low inertia ratio may entail an oversized motor, which can be avoided by using gear transmission.

    Speed-Torque Curve

    • Shows the relationship between speed and torque. A speed-torque curve shows possible torque values at different RPMs.
    • Continuous versus Intermittent operating regions on the curve.

    Motor Rating

    • Rated torque is the maximum continuous torque at or below rated speed.
    • Maximum speed and maximum torque are also determined.
    • RMS torque should fall within the continuous region.

    Max and RMS Torques

    • Maximum torque at the application speed ideally falls in the intermittent region.
    • RMS torque is equivalent to steady-state torque (for design purposes).

    YASKAWA SigmaSelect

    • Software package for selecting motor types.
    • Allows load, motor, and gear designs parameters to be set and evaluated.

    Selection of Motor Rating and Thermal Considerations

    • Motor size and rating depend on heating effects, load conditions, duty type, and environmental conditions.
    • A motor is selected such that the temperature rise (θ) is less than the permissible temperature rise (θp).

    Motor Heating and Cooling

    • General information.

    Motor Thermal Model

    • Heating/cooling equation—related to losses (Q, Watts), temperature rise (Δθ), and thermal time constants.

    Heating and Cooling Time Constants

    • Heating time constant (Th) and cooling time constant (Tc).
    • Tc is generally two to three times larger than Th.

    Insulation Classes for Electric Motors

    • Insulation classes (A, B, F, H) specify allowable winding temperature rise with ambient temperature (40°C).
    • Temperature rises in the motor windings as soon as the AC motor starts. Hot-spot temperatures are higher than ambient.
    • Classes B and F are common. Specific temperature allowances exist for certain conditions and classes.

    Insulation Classes for Electric Motors (Cont.)

    • Operating at higher temperatures reduces service life. A 10°C increase in temperature can halve the expected life of the insulation.
    • Hot-spot temperature allowances are provided to account for higher temperatures in hot-spot regions within windings. Insulation replacements should use equivalent or higher classes.

    Example (Transformer)

    • A 10KVA transformer has a normal load overload of 25KVA. Heating time constants are dependent on copper losses ignoring iron losses.

    IEC 60034-1 Electric Motor Duty Cycles

    • IEC standards for describing motor operating conditions. Duty cycles are important for selecting appropriate motors due to their impact on internal temperatures.

    Duty Type S1 (Continuous running)

    • Constant load, sufficient time for thermal equilibrium.

    Duty Type S2 (Short-time duty)

    • Constant load for a specific time period (less than time for reaching thermal equilibrium)
    • Cycle includes pause for thermal equilibrium.

    Duty Type S3 (Intermittent Periodic Duty)

    • Series of identical cycles—operation followed by a pause
    • Starting current is not significant for heating concerns.

    Duty Type S4 (Intermittent Periodic Duty With Significant Starting Periods)

    • Series of identical cycles with significant starting periods followed by constant load operation and pauses.

    Motor Nameplate

    • Contains information about the motor, including its specifications
    • Examples shown on some of the nameplates.

    Electric Motor Ingress Protection (IP) Ratings

    • IP ratings indicate protection against water and solid foreign objects (dust).
    • These ratings are provided on the nameplate.

    IP Ratings (Solids and Liquids)

    • IP ratings for solids and liquids, showing different levels of protection against these types of foreign matter.

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