TYPES OF MOTOR

Motor Types

Industrial motors come in a variety of basic types. These variations are suitable for
many different applications. Naturally, some types of motors are more suited for
certain applications than other motor types are. This document will hopefully give
some guidance in selecting these motors.

 AC Motors
 DC Motors
 Brushless DC Motors
 Servo Motors
 Brushed DC Servo Motors
 Brushless AC Servo Motors
 Stepper Motors
 Linear Motors

AC Motors

The most common and simple industrial motor is the three phase AC induction motor,
sometimes known as the "squirrel cage" motor. Substantial information can be found
about any motor by checking its (nameplate).

Advantages

 Simple Design
 Low Cost
 Reliable Operation
 Easily Found Replacements
 Variety of Mounting Styles
 Many Different Environmental Enclosures
Simple Design

The simple design of the AC motor -- simply a series of three windings in the exterior
(stator) section with a simple rotating section (rotor). The changing field caused by the
50 or 60 Hertz AC line voltage causes the rotor to rotate around the axis of the motor.

The speed of the AC motor depends only on three variables:

1. The fixed number of winding sets (known as poles) built into the motor, which
determines the motor's base speed.
2. The frequency of the AC line voltage. Variable speed drives change this
frequency to change the speed of the motor.
3. The amount of torque loading on the motor, which causes slip.

Low Cost

The AC motor has the advantage of being the lowest cost motor for applications
requiring more than about 1/2 hp (325 watts) of power. This is due to the simple
design of the motor. For this reason, AC motors are overwhelmingly preferred for
fixed speed applications in industrial applications and for commercial and domestic
applications where AC line power can be easily attached. Over 90% of all motors are
AC induction motors. They are found in air conditioners, washers, dryers, industrial
machinery, fans, blowers, vacuum cleaners, and many, many other applications.

Reliable Operation

The simple design of the AC motor results in extremely reliable, low maintenance
operation. Unlike the DC motor, there are no brushes to replace. If run in the
appropriate environment for its enclosure, the AC motor can expect to need new
bearings after several years of operation. If the application is well designed, an AC
motor may not need new bearings for more than a decade.
Easily Found Replacements

The wide use of the AC motor has resulted in easily found replacements. Many
manufacturers adhere to either European (metric) or American (NEMA) standards.
(For Replacement Motors)

Variety of Mounting Styles

AC Motors are available in many different mounting styles such as:

 Foot Mount
 C-Face
 Large Flange
 Vertical
 Specialty

Many Different Environmental Enclosures

Because of the wide range of environments in which people want to use motors, the
AC motor has been adapted by providing a wide range of enclosures:

 ODP - Open Drip Proof

 TEFC - Totally Enclosed Fan Cooled
 TEAO - Totally Enclosed Air Over
 TEBC - Totally Enclosed Blower Cooled
 TENV - Totally Enclosed Non-Ventilated
 TEWC - Totally Enclosed Water Cooled

Disadvantages

 Expensive speed control

 Inability to operate at low speeds
 Poor positioning control
Expensive speed control

Speed control is expensive. The electronics required to handle an AC inverter drive

are considerably more expensive than those required to handle a DC motor. However,
if performance requirements can be met -- meaning that the required speed range is
over 1/3rd of base speed -- AC inverters and AC motors are usually more cost-
effective than DC motors and DC drives for applications larger than about 10
horsepower, because of cost savings in the AC motor.

Inability to operate at low speeds

Standard AC motors should not be operated at speeds less than about 1/3rd of base
speed. This is due to thermal considerations. A DC motor should be considered for
these applications.

Poor positioning control

Positioning control is expensive and crude. Even a vector drive is very crude when
controlling a standard AC motor. Servo motors are more appropriate for these
applications.

DC Motors

The brushed DC motor is one of the earliest motor designs. Today, it is the motor of
choice in the majority of variable speed and torque control applications.

Advantages

 Easy to understand design

 Easy to control speed
 Easy to control torque
  Simple, cheap drive design

Easy to understand design

The design of the brushed DC motor is quite simple. A permanent magnetic field is
created in the stator by either of two means:

 Permanent magnets
 Electro-magnetic windings

If the field is created by permanent magnets, the motor is said to be a "permanent

magnet DC motor" (PMDC). If created by electromagnetic windings, the motor is
often said to be a "shunt wound DC motor" (SWDC). Today, because of cost-
effectiveness and reliability, the PMDC motor is the motor of choice for applications
involving fractional horsepower DC motors, as well as most applications up to about
three horsepower.

At five horsepower and greater, various forms of the shunt wound DC motor are most
commonly used. This is because the electromagnetic windings are more cost effective
than permanent magnets in this power range.

Caution: If a DC motor suffers a loss of field (if for example, the field power
connections are broken), the DC motor will immediately begin to accelerate to the top
speed which the loading will allow. This can result in the motor flying apart if the
motor is lightly loaded. The possible loss of field must be accounted for, particularly
with shunt wound DC motors.

Opposing the stator field is the armature field, which is generated by a changing
electromagnetic flux coming from windings located on the rotor. The magnetic poles
of the armature field will attempt to line up with the opposite magnetic poles
generated by the stator field. If we stopped the design at this point, the motor would
spin until the poles were opposite one another, settle into place, and then stop -- which
would make a pretty useless motor!
However, we are smarter than that. The section of the rotor where the electricity enters
the rotor windings is called the commutator. The electricity is carried between the
rotor and the stator by conductive graphite-copper brushes (mounted on the rotor)
which contact rings on stator. Imagine power is supplied:

The motor rotates toward the pole alignment point. Just as the motor would get to this
point, the brushes jump across a gap in the stator rings. Momentum carries the motor
forward over this gap. When the brushes get to the other side of the gap, they contact
the stator rings again and -- the polarity of the voltage is reversed in this set of rings!
The motor begins accelerating again, this time trying to get to the opposite set of
poles. (The momentum has carried the motor past the original pole alignment point.)
This continues as the motor rotates.

In most DC motors, several sets of windings or permanent magnets are present to

smooth out the motion.

Easy to control speed

Controlling the speed of a brushed DC motor is simple. The higher the armature
voltage, the faster the rotation. This relationship is linear to the motor's maximum
speed.

The maximum armature voltage which corresponds to a motor's rated speed (these
motors are usually given a rated speed and a maximum speed, such as 1750/2000 rpm)
are available in certain standard voltages, which roughly increase in conjuntion with
horsepower. Thus, the smallest industrial motors are rated 90 VDC and 180 VDC.
Larger units are rated at 250 VDC and sometimes higher.

Specialty motors for use in mobile applications are rated 12, 24, or 48 VDC. Other
tiny motors may be rated 5 VDC.

Most industrial DC motors will operate reliably over a speed range of about 20:1 --
down to about 5-7% of base speed. This is much better performance than the
comparible AC motor. This is partly due to the simplicity of control, but is also partly
due to the fact that most industrial DC motors are designed with variable speed
operation in mind, and have added heat dissipation features which allow lower
operating speeds.

Easy to control torque

In a brushed DC motor, torque control is also simple, since output torque is

proportional to current. If you limit the current, you have just limited the torque which
the motor can achieve. This makes this motor ideal for delicate applications such as
textile manufacturing.

Simple, cheap drive design

The result of this design is that variable speed or variable torque electronics are easy
to design and manufacture. Varying the speed of a brushed DC motor requires little
more than a large enough potentiometer. In practice, these have been replaced for all
but sub-fractional horsepower applications by the SCR and PWM drives, which offer
relatively precisely control voltage and current. Common DC drives are available at
the low end (up to 2 horsepower) for under US$100 -- and sometimes under US$50 if
precision is not important.

Large DC drives are available up to hundreds of horsepower. However, over about 10

horsepower careful consideration should be given to the price/performance tradeoffs
with AC inverter systems, since the AC systems show a price advantage in the larger
systems. (But they may not be capable of the application's performance requirments).

Disadvantages

 Expensive to produce
 Can't reliably control at lowest speeds
 Physically larger
 High maintenance
 Dust
 D.C MOTOR

D.C. MOTOR (PERMANENT MAGNET):

DESCRIPTION OF DC MOTOR
An electric motor is a machine which converts electrical energy to mechanical
energy. Its action is based on the principle that when a current-carrying conductor is
placed in a magnetic field, it experiences a magnetic force whose direction is given by
Fleming’s left hand rule.

When a motor is in operation, it develops torque. This torque can produce

mechanical rotation. DC motors are also like generators classified into shunt wound
or series wound or compound wound motors.

FLEMING’S LEFT HAND RULE:

Keep the force finger, middle finger and thumb of the left hand mutually
perpendicular to one another. If the fore finger indicates the direction of magnetic
field and middle finger indicates direction of current in the conductor, then the thumb
indicates the direction of the motion of conductor.

PRINCIPLE OF OPERATION OF DC MOTOR:

Figure I show a uniform magnetic field in which a straight conductor carrying

no current is placed. The conductor is perpendicular to the direction of the magnetic
field.

In figure II the conductor is shown as carrying a current away from the viewer,
but the field due to the N and S poles has been removed. There is no movement of the
conductor during the above two conditions. In figure III the current carrying
conductor is placed in the magnetic field. The field due to the current in the conductor
supports the main field above the conductor, but opposes the main field below the
conductor.

Movement of

Conductor

N S

Magnetic flux current carrying

Conductor

The result is to increase the flux density in to the region directly above the
conductor and to reduce the flux density in the region directly below the conductor. It
is found that a force acts on the conductor, trying to push the conductor downwards as
shown by the arrow. If the current in the conductor is reversed, the strengthening of
flux lines occurs below the conductor, and the conductor will be pushed upwards
(figure-IV).
 Now consider a single turn coil carrying a current as shown in the above figure.
in view of the reasons given above, the coil side A will be forced to move downwards,
whereas the coil side B will be forced to move upwards. The forces acting on the coil
sides A and B will be of same magnitude. But their direction is opposite to one
another. As the coil is wound on the armature core which is supported by the
bearings, the armature will now rotate. The commutator periodically reverses the
direction of current flow through the armature. Therefore the armature will have a
continuous rotation.

A simplified model of such a motor is shown in figure VI. The conductors are
wound over a soft iron core. DC supply is given to the field poles for producing flux.
The conductors are connected to the DC supply through brushes

Let's start by looking at the overall plan of a simple 2-pole DC electric motor. A
simple motor has 6 parts, as shown in the diagram below.

 An armature or rotor
 A commutator
 Brushes
 An axle
 A field magnet
 A DC power supply of some sort
 An electric motor is all about magnets and magnetism: a motor uses magnets to
create motion. If you have ever played with magnets you know about the fundamental
law of all magnets: Opposites attract and likes repel.

So if you have 2 bar magnets with their ends marked north and south, then the
North end of one magnet will attract the South end of the other. On the other hand, the
North end of one magnet will repel the North end of the other (and similarly south will
repel south). Inside an electric motor these attracting and repelling forces create
rotational motion.

In the diagram above and below you can see two magnets in the motor, the
armature (or rotor) is an electromagnet, while the field magnet is a permanent magnet
(the field magnet could be an electromagnet as well, but in most small motors it is not
to save power).

Electromagnets and Motors:

 To understand how an electric motor works, the key is to understand how the
electromagnet works. An electromagnet is the basis of an electric motor. You can
understand how things work in the motor by imagining the following scenario. Say
that you created a simple electromagnet by wrapping 100 loops of wire around a nail
and connecting it to a battery. The nail would become a magnet and have a North and
South pole while the battery is connected.

Now say that you take your nail electromagnet, run an axle through the middle
of it, and you suspended it in the middle of a horseshoe magnet as shown in the figure
below. If you were to attach a battery to the electromagnet so that the North end of the
nail appeared as shown, the basic law of magnetism tells you what would happen: The
North end of the electromagnet would be repelled from the north end of the horseshoe
magnet and attracted to the south end of the horseshoe magnet.

The South end of the electromagnet would be repelled in a similar way. The
nail would move about half a turn and then stop in the position shown.
 You can see that this half-turn of motion is simple and obvious because of the
way magnets naturally attract and repel one another. The key to an electric motor is to
then go one step further so that, at the moment that this half-turn of motion completes,
the field of the electromagnet flips. The flip causes the electromagnet to complete
another half-turn of motion.

You flip the magnetic field simply by changing the direction of the electrons
flowing in the wire (you do that by flipping the battery over). If the field of the
electromagnet flipped at just the right moment at the end of each half-turn of motion,
the electric motor would spin freely.

The Armature:

The armature takes the place of the nail in an electric

motor. The armature is an electromagnet made by coiling thin
wire around two or more poles of a metal core. The armature
has an axle, and the commutator is attached to the axle. In the
diagram above you can see three different views of the same
armature: front, side and end-on. In the end-on view the
winding is eliminated to make the commutator more obvious.
You can see that the commutator is simply a pair of plates attached to the axle. These
plates provide the two connections for the coil of the electromagnet.
The Commutator and brushes:

The "flipping the electric field" part of an electric motor is accomplished by

two parts: the commutator and the brushes. The diagram at the right shows how the
commutator and brushes work together to let current flow to the electromagnet, and
also to flip the direction that the electrons are flowing at just the right moment. The
contacts of the commutator are attached to the axle of the electromagnet, so they spin
with the magnet. The brushes are just two pieces of springy metal or carbon that make
contact with the contacts of the commutator.

Putting It All Together:

When you put all of these parts together, what you have is a complete electric motor:
 In this figure, the armature winding has been left out so that it is easier to see
the commutator in action. The key thing to notice is that as the armature passes
through the horizontal position, the poles of the electromagnet flip. Because of the
flip, the North pole of the electromagnet is always above the axle so it can repel the
field magnet's North pole and attract the field magnet's South pole. If you ever take
apart an electric motor you will find that it contains the same pieces described above:
two small permanent magnets, a commutator, two brushes and an electromagnet made
by winding wire around a piece of metal. Almost always, however, the rotor will have
three poles rather than the two poles as shown in this article. There are two good
reasons for a motor to have three poles:

It causes the motor to have better dynamics. In a two-pole motor, if the

electromagnet is at the balance point, perfectly horizontal between the two
poles of the field magnet when the motor starts; you can imagine the armature
getting "stuck" there. That never happens in a three-pole motor.

Each time the commutator hits the point where it flips the field in a two-pole
motor, the commutator shorts out the battery (directly connects the positive and
negative terminals) for a moment. This shorting wastes energy and drains the
battery needlessly. A three-pole motor solves this problem as well.

It is possible to have any number of poles, depending on the size of the motor
and the specific application it is being used in.
 DESIGN OF D.C. MOTOR

1. P.M.D.C MOTOR:-

Power = 90 Watts
Voltage = 12 Volt
Output Speed = 60 RPM
Speed in rotor = 2800 RPM
Type = Permanent Magnet Type

2. TORQUE IN A MOTOR:

By the term torque, it is meant the turning or twisting moment of a force about
an axis. It is measured by the product of the force and the radius at which this force
acts.

For an armature of a motor, to rotate about its centre, a tangential force is

necessary. This force is developed with in the motor itself.

Torque (T) = ½ ( Ia / A ) BDC Z Newton meters

Using the relation,
B = φ/a
= φ/(ΠD/P)ł
= φ x P / ( Π Dł )
T = ½ x (Ia / A) x Z x φ x {P/ (ΠDł) } x Dł
 = φ Z P Ia / ( 2ΠA ) Newton meters
= 0.159 x φ x Z x Ia X (P/A) Newton meters
= 0.162 x φ x Z x Ia x (P/A) Kg-m

The torque given by the above equation is the developed torque in the machine.
But the output torque is less than the developed torque due to friction and windage
losses.

DESIGN OF SPUR GEAR

SPEEDS IN GEAR BOX:

Measured Specifications:

N1/N2 = D2/D1
Where,
N1 = Motor speed in RPM---40 RPM
N2 = Output speed
D2 = Diameter of the roller gear wheel
= 88 mm
D1 = Diameter of the motor gear wheel
= 35 mm

∴ N2 = (D1/D2) x N1

= (35 / 88) x40 = 16 rpm