Selection Of Crane Duty Motors (Part 2)

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Ashok Parikh

S e l e cti o n O f Cr a n e Du ty Mo to r s ( o n p h o to : El e ctr i c wi r e r o p e h o i s t fo r LNG ( l i q u i fi e d n a tu r a l g a s ) - S TAHL Cr a n e S ys te m s G m b H b y

Di r e ctIn d u s tr y)

Continued from first part: Selection Of Crane Duty Motors (Part 1)

Crane Dut y Mot ors

Types of Crane Duty Motors

Following two types of motors are widely used for crane duty applications.

Squirrel Cage Crane Duty Motors

Slip ring and Wound Rotor Crane Duty Motors

The crane motors are duty type rated for developing high starting torque with low starting current. The motors are
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designed to withstand stresses due to frequent starts/stops and reversals. Also, a rapid acceleration is achieved by
high pull out torque/rotor inertia ratio.

Generally, the motors assigned duty type S3, S4 and S5 are considered for crane applications.

The crane duty motors are specially designed to offer satisfactory performance and long lives for service on the
cranes and hoists.

These motors may also be used for similar applications such as material handling, sluice operation on dams/weirs,
lifts of all types and in rolling mills as auxiliary motors or wherever operating drives are required for intermittent
services.

Applicable St andards
The crane duty motors should generally comply with Indian Standards provided in Table.3 below:

Table.1 Standards applicable to motors

Indian St andard Tit le Applicabilit y

IS:1231- 1974 Dimension of Three Phase Foot Mounted Induction Motors For dimensions of
motor

IS :2223- 1983 Dimension of Flange Mounted AC Induction Motors For dimensions

motor

IS:325- 1996 Three Phase Induction Motors – Specification For specification

and performance of
motor

IS:1271- 985 Specification for Thermal Evaluation and Classification of For insulation of
Electrical Insulation stator and rotor
windings

IS:12824- 1989 Types of Duty and Classes of Rating Assigned to rotating Electrical For duty class and
Machines assigned rating for
motors

IS:4691- 1985 Degrees of Protection Provided by Enclosures for Rotating Electric For protection to
Machines enclosures

IS:6362- 1995 Designation of Methods of Cooling for Rotating Electrical Machines For cooling of
motors

IS:2253- 1974 Designations for Types of Construction and Mounting Arrangements of For type of mounting
Rotating Electrical Machines and frame siz e

IS:12065- 1987 Permissible Limits of Noise Levels for Rotating Electrical Machines For noise level

IS:12075- 1987 Mechanical Vibration of Rotating Electrical Machines with Shaft Heights For vibration level
56 mm and Higher – Measurement, Evaluation and Limits of Vibrations
Severity

IS:4029- 1967 Guide for Testing of Three Phase Induction Motors For testing of motors

IS :3177–1977 Code of Practice for Electric overhead Travelling Cranes and Gantry For understanding
Cranes other than Steelworks Cranes requirements of
cranes

St andard operat ing condit ions

In accordance with the provisions made in the applicable Indian Standard, the motors should be able to perform
satisfactorily for the power supply parameters, site conditions and insulation class as provided in Table.2, unless
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specific parameters are furnished.

Table.2 – Power supply parameters, site conditions and insulation class for AC motors

Supply voltage 415 volts ±10%, 3 phase

with permissible
variation

Supply frequency 50 Hz + 5%
with permissible
variation

Combined voltage ±10% (absolute sum)

and frequency
variation

Unbalance Standard motors capable to operate under unbalance supply conditions, wherein negative
and z ero sequence voltage components not to exceed individually 2% of positive phase
sequence component

Ambient - 10°C to 40°C

temperature

Altitude Up to 1000 m

Humidity Up to 100%

Insulation Class “F” in Squirrel cage motors

Class “F/F” for both stator and rotor in slip ring motors

Ambient temperature

The rated output of motor specified by the vendor is generally at 40°C ambient temperature. For temperatures other
than 40°C, a duration factor should be applied as indicated Table.3.

Table.2 – Ambient temperature and deration factors for AC motors

Ambient temperature Deration factor

45°C 0.95

50°C 0.88

55°C 0.83

60°C 0.75

Salient t echnical and const ruct ional f eat ures of crane dut y mot ors
The technical and constructional features of crane duty motors as follows are more or less similar to that are
found in the standard continuous duty motors.

Material and construction of stator frame and end shields

Material and construction of stator and rotor cores
Bearings at non- drive and drive ends
Material of construction of shaft
Earthing to stator frame and terminal box
Mounting of motor – foot mounted or flange mounted
Material, construction and position of terminal box

Specific technical and constructional features required to be incorporated in the specification for the crane duty
motors are listed hereunder so that the motors provide desired trouble free, predetermined and optimum
performance.

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The motor rating should be decided based on its thermal capability taking into consideration few or all factors listed
hereunder as per duty requirements.

1. Optimised nos. of starts and frequency of starts for all the motors should be specified for the design purpose
(Starting class);
2. Percentage of time during each operating cycle the motor is energised, i.e. Cyclic duty factor (CDF);
3. The intermittent duty type S3, S4 or S5 should be defined correctly based on exact operational requirements
of cranes. The number and type of cycle per hour should be (Duty class) should be considered;

It is vital to specify the correctly calculated “Cyclic Duty Factor” (CDF) for crane duty motors. Calculations for
deriving CDF for type duty S3, S4 and S5 are given in succeeding paragraphs for reference.

The motors should have higher than normal pullout torques. As the motors are supposed to experience large no. of
starts, it is necessary that the accelerating time of the system should be as small as possible. The higher pull out
torque ensures rapid acceleration irrespective of drop in effective torque due to stepped rotor resistance.

Moreover for minimiz ing acceleration time, total inertia of the system, comprising of moment of inertia of motor plus
moment of inertia of load, should be minimum. This can be achieved by keeping lower than normal rotor inertia in
comparison to standard continuous duty motors.

The torque available from the motor varies as the square of the motor terminal voltage, an allowance for voltage
drop in long cables, live rails and collectors must be considered. The voltage drop is significant when the motor is
operated at pull out torque point, since current at this point is much higher than the rated current.

The motors should be able to withstand 1.5 times the rated current for 2 minutes without suffering damage. This
feature makes the motor suitable for intermittent and severe duties experienced on the crane or similar applications.

All 4, 6, 8, and 10 pole motors should be designed for withstanding an overspeed of 2.5 times rated synchronous
speed or minimum 2000 rpm, whichever is less.

The squirrel cage motors should be provided single cylindrical shaft extension and the wound rotor (slip ring) motors
should be provided double cylindrical shaft extension.

The stator and rotor windings should be impregnated with Class ‘F’ thermosetting varnish insulation. In stringent
cases, Class ‘H’ insulation may also be considered.

Additionally, the rotor windings should be braced with resin- glass banding to give protection against centrifugal
forces experienced by overhang during overspeed and frequent reversals. Gel- coat may be painted on the winding
overhang for better consolidation and protection from vibration.

Siz e of the terminal box should be adequate for to facilitate splitting of power cables cores and terminate
comfortably. In slip ring motors, the cables for main power supply and from slip rings are usually accommodated in
the same terminal box for simplifying wiring and maintenance.

Hence in case of slip ring as well as squirrel cage motors, if required, the cable box siz e may be increased by
providing an attachment of cable splitter box (generally of trapezoidal shape) to the main terminal box.

The rotors of squirrel cage and wound rotor motors should be dynamically balanced to ensure lowest possible
vibration.

It should be preferred to use the metallic cooling fans in the wound rotor motors. PVC or plastic fans are likely to be
deformed due to high temperature in housing due to slip rings and get damaged.

As the motor would generate more heat due to intermittent switching operations, the painting should be heat
resistant, specifically able to withstand higher temperatures.

The standard crane duty motors should be provided IP55 Degree of protection as per IS:4691. The cooling code of
motor should be IC411 as per IS:6362.

The insulation resistance of the slip- ring unit should be high enough ensuring minimum wear and breakdown. The
brush holders, made as a complete unit, should be easily replaceable. The slip- ring should be large enough to
encounter starting currents and for proper installation of brushes in slip ring motors.

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The enclosure for slip- rings should be dustproof and easily accessible for inspection.

For higher rated would rotor motors, separate disc should be provide between the slip- ring and rotor windings to
prevent ingress of carbon dust from brushes into windings.

Will be continued in 2 days…

Re f e re nce s :

1. Efficient Electric Motor Systems Handbook, by Todd Litmann

2. IS:12824- 1989; Types of Duty and Classes of Rating Assigned to Rotating Electrical Machines
3. The Technical Literature of Indian Motor Manufacturers

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