EE 2092 Laboratory Practice III

TEST ON DC MOTORS

CALCULATIONS
Absorption Dynamometer Considering radius of pulley as r; 2 r=11.618cm=0.11618m Armatur4e resistance (Ra) =4.1, series field resistance (Rs) =3.3 Sample Calculation Considering first observation, Weight (W) = 0.4536 x 28lb=12.701kg & Weight (w)= 0.4536 x 14lb=6.350kg Speed (rad s-1) = 2 x x Nr/60= 2 x x 926/60=96.97rads-1 Electrical Input Power = V x I = 202 x 14.4=2.909k W Torque produced (T) = (W-w).g.r = (12.701-6.350) kg x 9.81ms-2 x 0.11618m = 7.238 Nm Mechanical Output Power = Nrad/s .T = 96.97 x 7.238= 701.87W = 100=24.13%

Efficiency=

Copper loss= I2R=14.4A2 x (3.3+4.1)=1534.464W Mech. loss= Elec. Input Mech. output Copper loss=(2908.8-701.87-1534.464)W=672.667W

Observations
Speed(Nr) W(kg)

Calculations
Volt age (V) Curr ent (A)

w
(kg) 6.35 6.35 6.35 6.8 6.8 7.26 7.26 7.26 7.26 7.71 7.71 7.71

rp m 926 940 940 930 910 870 850 840 830 820 790 780

rad/s 96.97 98.437 98.437 97.389 95.295 91.106 89.012 87.965 86.917 85.87 82.729 81.681

12.701 13.608 14.515 15.422 16.33 17.237 18.144 19.051 19.958 20.866 21.773 22.68

202 202 203 203 205 205 203 203 202 201 201 200

14.4 14.2 14.4 14.8 15 16 16.4 16.6 17 17 17.8 18

Elec.i nput Powe r (kW) 2.909 2.868 2.923 3.004 3.075 3.28 3.329 3.37 3.434 3.417 3.578 3.6

Torque (Nm)

Mech.outp ut Power (W)

Efficenc y 24.13% 28.39% 31.34% 31.84% 33.65% 31.59% 33.17% 35.08% 36.64% 37.68% 37.06% 38.71%

copper loss(W) 1534.46 1492.14 1534.46 1620.9 1665 1894.4 1990.3 2039.14 2138.6 2138.6 2344.62 2397.6

Mech.a loss(W) 672.667 561.593 472.481 426.549 375.382 349.451 234.324 148.518 37.276 -9.049 -92.514 -191.16

7.238 8.272 9.306 9.822 10.86 11.37 12.41 13.44 14.48 14.99 16.03 17.06

701.869 814.271 916.055 956.555 1034.618 1036.149 1104.372 1182.338 1258.124 1287.449 1325.898 1393.56

Separately Excited DC Motor Armature Resistance (Ra) = 4.7 Sample Calculation Considering first observation, Speed (rad s-1) = 2 x x Nr/60= 2 x x 1491.8/60=156.22rads-1 Electrical Input Power(Pin) = V2 x I2 = 210 x 1=210W

 Copper loss= I22 .Ra = 12*(4.7) = 20.1W Mechanical loss= P2(0) = V2(0).I2(0) - I22(0).Ra =212x0.5-0.52*4.7=104.825 Mechanical Output Power(Pout) = P2 P2(0) = Mech. Power developed Mech. Loss = (Elec. input power Armature copper loss) Mech. Loss = (Pin - I22.Ra) - P2(0) =[(210-12*4.7)-104.825]=100.475 Torque produced (T)= = = 0.643 Nm

Observation Speed(Nr) I2(A) 1 2 3 4 5 6 7 8 9 10 V2 (V) 210 208 206 206 204 204 204 200 200 198 rpm 1491.8 1482 1480 1474.3 1466.4 1461.4 1455.8 1450.8 1443.1 1435.9 rad/s 156.22 155.2 154.99 154.39 153.56 153.04 152.45 151.93 151.12 150.37 I2(0)(A) 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 V2(0)(V) 212 212 212 212 212 212 212 212 212 212 Pin(W) 210 416 618 824 1020 1224 1428 1600 1800 1980 Copper loss (W) 4.7 18.8 42.3 75.2 117.5 169.2 230.3 300.8 380.7 470

Calculations Mech. Loss (W) 104.825 104.825 104.825 104.825 104.825 104.825 104.825 104.825 104.825 104.825

Pout (W) 100.475 292.375 470.875 643.975 797.675 949.975 1092.88 1194.38 1314.48 1405.18

Torque(Nm)

0.643 1.884 3.038 4.171 5.195 6.207 7.169 7.862 8.698 9.345

1) Series DC motor (i) Speed Vs Torque

speed(rad/s) 96.97 98.437 98.437 97.389 95.295 91.106 89.012 87.965 86.917 85.87 82.729 81.681

Torque(Nm) 7.238 8.272 9.306 9.822 10.857 11.373 12.407 13.441 14.475 14.993 16.027 17.061

100

95

90 speed(rad/s) 85 80 75 5 7 9 11 13 Torque(Nm) 15 17 19

(ii) Torque Vs Armature current

Torque(Nm) 7.238 8.272 9.306 9.822 10.857 11.373 12.407 13.441 14.475 14.993 16.027 17.061 Armature current(A) 14.4 14.2 14.4 14.8 15 16 16.4 16.6 17 17 17.8 18

18

17

16

15

14 Torque(Nm)

13

12

11

10

8 12 13 14 15 16 Armature current(A) 17 18 19 20

(iii) Speed Vs Armature Current

speed (rad/s) 96.97 98.437 98.437 97.389 95.295 91.106 89.012 87.965 86.917 85.87 82.729 81.681 Armature current(A) 14.4 14.2 14.4 14.8 15 16 16.4 16.6 17 17 17.8 18

100

95

Speed(rad/s)

90

85

80 14 14.5 15 15.5 16 16.5 17 17.5 18 18.5 19 Armature current(A)

(iv) Efficiency Vs Armature current

Efficiency 0.241 0.284 0.313 0.318 0.336 0.316 0.332 0.351 0.366 0.377 0.371 0.387 Armature current(A) 14.4 14.2 14.4 14.8 15 16 16.4 16.6 17 17 17.8 18

39.0%

37.0%

35.0%

33.0% Efficency

31.0%

29.0%

27.0%

25.0%

23.0% 14 14.5 15 15.5 16 16.5 17 17.5 18 18.5 19 Armature current(A)

(v) Copper loss Vs Armature current

Copper loss(W) 1534.464 1492.136 1534.464 1620.896 1665 1894.4 1990.304 2039.144 2138.6 2138.6 2344.616 2397.6 Armature current(A) 14.4 14.2 14.4 14.8 15 16 16.4 16.6 17 17 17.8 18

2450

2350

2250

2150

2050 copper loss

1950

1850

1750

1650

1550

1450 14 14.5 15 15.5 16 16.5 17 17.5 18 18.5 19 Armature current(A)

(vi) Mechanical loss Vs Speed

Mechanical loss(W) 672.667 561.593 472.481 426.549 375.382 349.451 234.324 148.518 37.276 -9.049 -92.514 -191.16 Speed(rad/s) 96.97 98.437 98.437 97.389 95.295 91.106 89.012 87.965 86.917 85.87 82.729 81.681

680

580

480

380 Mechanical loss(W)

280

180

80

-20 80

82

84

86

88

90

92

94

96

98

-120

-220

Speed(rad/s)

2) Separately excited DC motor (vii) Speed Vs Torque

sep. ex. DC motor Speed(rad/s) Torque(Nm) 156.221 0.643 155.195 1.884 154.985 3.038 154.388 4.171 153.561 5.195 153.037 6.207 152.451 7.169 151.927 7.862 151.121 8.698 150.367 9.345 series DC motor Speed(rad/s) Torque(Nm) 96.97 7.238 98.437 8.272 98.437 9.306 97.389 9.822 95.295 10.857 91.106 11.373 89.012 12.407 87.965 13.441 86.917 14.475 85.87 14.993 82.729 16.027 81.681 17.061
Series DC motor

Sep. ex Dc motor

175

155

Speed(rad/s)

135

115

95

75 0.5 2.5 4.5 6.5 8.5 10.5 12.5 14.5 16.5 Torque(Nm)

(viii) Speed Vs Armature current

sep. ex. DC motor speed(rad/s) Armature current(A) 1 156.221 2 155.195 3 154.985 4 154.388 5 153.561 6 153.037 7 152.451 8 151.927 9 151.121 10 150.367 series DC motor Speed(rad/s) Armature current(A) 96.97 14.4 98.437 14.2 98.437 14.4 97.389 14.8 95.295 15 91.106 16 89.012 16.4 87.965 16.6 86.917 17 85.87 17 82.729 17.8 81.681 18

sep. ex DC motor

Series DC motor

175

155

Speed(rad/s)

135

115

95

75 0.5 2.5 4.5 6.5 8.5 10.5 12.5 14.5 16.5 18.5 Amature current(A)

(ix) Pin Vs Pout

sep. ex. DC motor Pin(W)
210 416 618 824 1020 1224 1428 1600 1800 1980

series DC motor Pin(W) 2909 2868 2923 3004 3075 3280 3329 3370 3434 3417 3578 3600 Pout(W) 701.869 814.271 916.055 956.555 1034.618 1036.149 1104.372 1182.338 1258.124 1287.449 1325.898 1393.56
Series DC motor

Pout(W)
100.475 292.375 470.875 643.975 797.675 949.975 1092.88 1194.38 1314.48 1405.18

sep. ex DC motor 3650

3150

2650

2150

Pin(W)
1650 1150 650 150 0.5 200.5 400.5 600.5 Pout(W) 800.5 1000.5 1200.5

DISCUSSION
(1) Types of materials employed in construction

High grade steel: -Mainly there two advantages of using high graded steel. One is to keep hysteresis loss low, which is due to cyclic change of magnetization caused by rotation of the core in the magnetic field and the other one is to reduce the eddy currents in the core which are induced by the rotation of the core in the magnetic field Cupper (Cu): -Cu is used to make Field windings and Armature windings Carbon/Carbon graphite/ Graphite/Metal graphite: -Those are used to make brushes due to its reluctance for deterioration Insulating Material: -Insulating materials are used to provide electrical insulation between parts at different potentials. An insulating material should have high resistivity, high dielectric strength, low dielectric loss, good heat conductivity, sufficient mechanical strength to withstand vibrations etc. These materials begin to deteriorate at relatively small temperatures. For reliable operation, it is essential that the temperature rise in electrical machines and equipment do not exceed the permissible temperature of the insulating materials used therein.Some of the most important insulating materials used for insulation in electrical machines and apparatus are mica, cotton, asbestos, paper and glass Cast iron/Cast steel/Fabricated steel: -Cast iron yokes are preferred in smaller machines; because of its cheapness but yoke fabricated steel yokes are preferred in larger machines due to its high permeability. Because weights of large machines are the main considerable fact. As the permeability of cast steel is nearly twice of cast iron, the weight of cast steel required will be only half of the cast iron if used for the same reluctance. Pole cores are usually not laminated and made of cast steel.

(2) Part of the DC machine

Armature: -This is the rotating part of a DC motor and is built up in a cylindrical shape. The purpose of the armature is to rotate the conductor in the uniform magnetic field. It consists of coils of insulated wires wound around an iron and so arranged that electric currents are induced in these wires when the armature is rotated in a magnetic field. It provide a path of very low reluctance to the magnetic flux. The armature core is made from high permeability silicon-steel stampings, each stamping, being separated from its neighbouring one by thin paper or thin coating of varnish as insulation. Due to this the eddy currents in the core induced by the rotation of the core in the magnetic field, is cut into several. The laminations should be perpendicular to the paths of eddy currents and parallel to the flux. Stator: -The stator is the stationary part of a rotor system. It mainly consists with stator poles pole shoes field windings (winding that produces main magnetic flux.), etc. Shaft: -The shaft is made of mild steel with a maximum breaking strength. The shaft is used to transfer mechanical power from or to the machine. The rotating parts such as armature core, commutator, cooling fan etc. are keyed to the shaft.

Brushes: -The brushes are rectangular in shape and rest on the commutator.The function of brushes is to collect current from the commutator and supply it to the external load circuit (the armature of the machine being connected to the external load circuit via the commutator and brushes). The brushes are rectangular in shape and rest on the commutator. Brushes are manufacture in a variety of compositions and degrees of hardness to suit the commutation requirements. Commutator: -The commutator is a cylindrical structure and is built up of wedge shaped segments of high conductivity hard drawn copper and the segments are insulated from each other. Commutator provides the electrical connections between the rotating armature coils and the stationary external circuit, keeps the rotor or the armature mmf stationary in space, when the rotor rotates perform switching action reversing the electrical connections between the external circuit and each armature coil in turn so that the armature coil voltage add together and result in a DC output voltage. So this is a main part of motor.

(3) Types of armature windings and their applications

There are several types of armature windings called Lap winding, wave winding, Non lap winding. The difference between lap winding and wave winding is different arrangement of the end connections at the front or commutator end of armature. Each winding can be arranged progressively or retrogressively and connected in simplex, duplex and triplex. Commonly for windings these things should be considered The number of commutator segments is equal to the number of slots or coils because the front ends of conductors are joined to the segments in pairs. The winding must close upon itself Both pitches should be odd, otherwise it would be difficult to place the coils properly on the armature. As windings should be full-pitched the front and back pitch are each approximately equal to the pole-pitch. This results in increased e.m.f round the coils Lap Winding In the case of lap winding, the end of a wire conductor is connected to the commutator, and then the other wire end is connected to the beginning of the next coil segment. This winding configuration refers to the fact that the wire "laps over" each segment as the winding structure reaches its terminus.

Wave Winding With wave winding, one wire conductor is wrapped under one pole, and then connected to the back of the next pole. In this case, the series of wire conductors do not directly overlap, but when it's completed, the structure looks like a series of copper "waves" wrapped around the commutator.

Non-Lapped Winding Non-lapped winding refers to a wire process that does not employ overlapping at any point across the commutator but employs a linear side-by-side configuration from the front to the rear of the structure.

(4) Performance characteristics of the DC Series Motor

Rated load

EFFICIENCY IN PERCENTAGE ARMATURE CURRENT IN A SPEED IN rpm TORQUE IN Nm

In the above figure, four important characteristics of a DC series motor, namely torque, speed, current and efficiency, each plotted against useful output power, are shown. Components of a series motor include the armature and the field. The same current is impressed upon the armature and the series field. The coils in the series field are made of a few turns of large gauge wire, to facilitate large current flow. This provides high starting torque, approximately 2 times the rated load torque. Series motor armatures are usually lap wound. Lap

windings are good for high current, low voltage applications because they have additional parallel paths for current flow. Series motors have very poor speed control, running slowly with heavy loads and quickly with light loads. A series motor should never drive machines with a belt. If the belt breaks, the load would be removed and cause the motor to over speed and destroy itself in a matter of seconds. Common uses of the series motor include crane hoists, where large heavy loads will be raised and lowered and bridge and trolley drives on large overhead cranes. The series motor provides the starting torque required for moving large loads. Traction motors used to drive trains are series motors that provide the required torque and horsepower to get massive amounts of weight moving. On the coldest days of winter the series motor that starts a car overcomes the extreme cold temperatures and thick lubricant to get the car going. (5) Performance characteristics of the separately excited DC motor Mainly there are two methods to control the speed in safe operate region which are called armature control and field control. In armature control there is a constant torque while constant power in the field control

Armature control

Field Control

The separately excited DC motor is probably the most common dc motor used in industry today. Components of the separately excited DC motors are the armature and the field. The coils in the shunt field are composed of many turns of small wire, resulting in low shunt field current and moderate armature current. This motor provides starting torque that varies with the load applied and good speed regulation by controlling the shunt field voltage. If the separately excited DC motor loses its field it will accelerate slightly until EMF rises to a value sufficient to shut off the torque producing current. In other words, the shunt motor will not destroy itself if it loses its field, but it wont have the torque required to do the job it was designed for. Some of the common uses of the shunt motor are machine shop lathes, and industry process lines where speed and tension control are critical.

When comparing the advantages of the series and separately excited DC motor, the series motor has greater torque capabilities while the separately excited DC motor has more constant and controllable speed over various loads.

(6)

Difference between performance characteristics of series DC motor and separately excited DC motor.

Torque
Series DC motor Separately excited DC motor

Speed ()

When you increase the load, Speed of Separately excited DC Motors will nearly remain constant where as speed of series DC Motors will drastically decrease. Therefore shunt DC Motors is more suitable for traction applications. Separately excited DC meter has good speed controllability, safe no load speed and good speed controllability. In series DC motor it can give high torque at starting without demanding similar high power. Series DC motor has high torque capability and reasonable good power cushioning ability. But Unlike Separately excited DC motors, series DC motors can produce high starting torques. Therefore series DC motors are more suitable for starter applications.

(7) Applications of motors with limitations

1. Shunt excited dc motors These have fairly constant speeds against a varying load or torque. Therefore applications include situations where a constant speed is required. (E.g. Lathes, Conveyors, Fans, Machine tool drives ) 2. Compound excited dc motors These have Combine characteristics of both shunt and series wound motors. The series winding gives good starting torque and shunt winding ensures a comparatively constant speed. (E.g. Planers, Shears, Guillotines, Printer machines, Power presses which needs peak loads at certain instances) 3. Permanent magnet motors These are used for low power applications. (E.g. Automobiles, Starter motors, Wiper motors, Lowering windows, Toys, Electric tooth brushes)

4. Adjustable speed DC shunt motor

Starting torque should be medium. Usually limited to 250% by a starting resistance but may be increased. Maximum momentary operating torque-usually limited to about 200% by commutation. Speed regulation-10-15%. Speed control-6:1 range by field control, lowered below normal speed by armature voltage control. Used for constant speed applications which require medium starting torque & which require adjustable speed control, either constant torque or constant output. 5. Differential compound wound DC motor with relatively weak series field It has almost constant torque, constant speed and tendency towards speed instability with a possibility of motor running away and strong possibility of motor starting in wrong direction. Applications are mainly for experimental and research work

REFERENCES Electrical Machines and Drive Systems, by C.B.Gray Electrical Machines, by Draper Machine Elements in Mechanical Design, by Robert L. Mott. http://electricalandelectronics.org/2009/04/29/types-of-armature-windings/,