INDUSTRIAL DRIVES AND CONTROL
) SWITCHING CIRCUITS -- Switching operations in motor’s
1. MOTION CONTROL-- is widely used in all types of
industries including packaging, assembly, paper, printing,
food processing, wood products, machinery, electronics, and
semiconductor manufacturing.
-Motion control is focused on moving a load from one place
to another.
2.ELECTRICAL DRIVE--Systems employed for motion control
are called drives and may employ any of the prime movers for
supplying mechanical energy for motion control.
3. Prime Mover - an initial source of motive power designed
to receive and modify force and motion applied by some
natural source to drive machinery.
EXAMPLE:
Windmills, Turbines, Steam Engines, Internal Combustion
Engines, Hydraulic Motors, Electric Motor
4. Drives employing electric motors are called Electrical
Drives.
5. Power modulators-- regulate the power flow from source
to the motor to enable the motor to develop the torque
speed characteristics required by the load.
PARTS OF ELECTRICAL DRIVES – POWER MODULATOR
A.) CONVERTERS-- When a power modulator performs the
function of electrical energy conversion, it can be classified as
a converter.
 AC to DC Converters - used to get DC supply of fixed
voltage from the AC supply of fixed voltage
 AC Voltage controllers or AC Regulators - are
employed to get variable AC voltage of the same
frequency from a source of fixed AC voltage.
 Choppers or DC-DC Converters - are used to get
variable voltage DC from a fixed voltage DC.
 Inverters - are employed to get a variable frequency
AC supply from a DC supply.
 Cycloconverters - converts fixed voltage and
frequency AC to variable voltage and variable
frequency AC.
B.) VARIABLE IMPEDANCES
-- Variable resistors are used for the control of low cost DC
and AC drives and are also needed for dynamic braking of
drives.
C.
power circuit are carried out by high power electromagnetic
relays known as contactor.
6. ELECTRIC MOTOR -- is an electrical machine that converts
electrical energy into mechanical energy.
7. ELECTRIC GENERATOR -- is mechanically identical to an
electric motor, but operates with a reversed flow of power,
converting mechanical energy into electrical energy.
8. MOTOR LOAD-- The burden placed on the motor due to
this mechanical activity is referred to as the motor load.
Properly matching the motor load to the motor is important
to prevent damage to the motor or inefficient and needlessly
costly operation.
9. CONTROL UNIT -- power modulator are provided in the
control unit.
DYNAMICS OF ELECTRICAL DRIVES
10. MOTOR-- generally drives a load (machine) through some
transmission system. while the motor always rotates, the
load may rotate or may undergo a translational motion.
11. STEADY STATE—When the torque of the motor and load
is equal the drive is said to be at steady state.
12. MOTOR SPEED -- is considered positive when rotating in
the forward direction.
13. POSITIVE MOTOR TORQUE
- defined as the torque which produces acceleration
- positive rate of change of speed in forward direction.
14. POSITIVE LOAD TORQUE --is opposite in direction to
positive motor torque.
15. MOTOR TORQUE-- is considered negative if it produces
deceleration.
A MOTOR OPERATES IN TWO MODES:
16. MOTORING – converts electrical energy to mechanical
energy (supports its motion).
17. BRAKING – works as generator converting mechanical
energy to electrical energy (opposes the motion).
Electrical Motor Control
18. MAGNETIC CONTACTOR --is a device that is powered by
magnetism. Used to open and close the contacts in the motor
control circuit, may also be called a magnetic switch or a
contactor. -A magnetic contactor is a device that is very often
used in industry. Commercial, large industries are very much
dependent on this device. Through it, we can easily control
heavy loads such as high-capacity motors.
19. AUXILIARY CONTACT-- is the contact in the auxiliary
circuit that is operated mechanically.
--It is physically linked to the main contacts and activated at
the same time. It does not carry so much current.
--Auxiliary contact is also referred to as supplementary
contact or control contact.
28. MOTOR CIRCUIT PROTECTOR (MCP)
--This type of protection does not have thermal protection in
order to ignore the Inrush in motors. Eaton has a nice line of
High-Interrupting Motor Circuit Protector (HMCP) circuit
breakers.
29. When you pair a contactor with an overload relay, it is
called a STARTER or MOTOR STARTER.

--It is used for auxiliary functions on a contactor, relay, or

circuit-breaker.

--Auxiliary contact is available in various versions as normally

open (NO), normally closed (NC), or changeover (C/O). It can
be available internally on a device or can be mountable.

--Multiple auxiliary contacts can be mounted to electrical

devices.

20. The hazards that come with motors are SHORT CIRCUITS
and OVERLOAD / OVERCURRENT.

A short circuit can be caused by two things:

21. PHASE TO PHASE SHORT – This is when one phase goes

into another (two phases with no insulation accidentally
touch each other). They create an unrestricted path for
current to flow and a huge amount of current goes through
them very quickly. This heats up the wire and burns down the
insulation. Needless to say, the heat burning down the
insulation can potentially cause fire.
22. Phase to ground short – This is when a phased wire
unintentionally touches a ground phase, such as a metal rail
in a garage. This creates a path to ground from the phased
wire. Again, the same problem occurs as the phase to phase
short and can potentially cause fire.
23. MOTOR OVERLOAD / OVERCURRENT-- is when the motor
draws too much current. Motors have specific speed, load
capacity, and current ratings. The motor will eventually
overheat if it draws more current that its normal rating range.
24. A popular and most common way to protect a motor is by
using a MOLDED CASE CIRCUIT BREAKER.
Motor Selection
30. WOUND ROTOR INDUCTION MOTORS --are useful in
some applications (above 250 kW) because the resistance of
the rotor circuits can be altered to give the desired starting or
running characteristics.
• More expensive and more maintenance
Synchronous motor selection
31. Speed --Synchronous motors operate at synchronous
speed with no speed drop over the load range. They should
be selected if exact speed is required.
32. Power Factor Correction-- Synchronous motors can
generate reactive power to correct poor supply system power
factor while delivering mechanical power. When supplying
reactive power, they are said to be

The breaker has two different circuit protection inside. operating at a leading power factor.

25. One is MAGNETIC CIRCUIT PROTECTION, which protects
against short circuits.
26. The other is BI-METALLIC THERMAL CIRCUIT
PROTECTION, which protects against overload / overcurrent.
33. Lower Operating Costs --Synchronous motors are often
more energy efficient than induction motors, especially in the
very large horsepower ranges (above 1000 hp).
Direct Current Motor Selection

27. ELECTRIC MOTOR – INRUSH AND FULL LOAD AMPS • DC motors are often selected where precise speed control
is required, as DC speed control is simpler, less costly and
--The problem with molded case circuit breakers’ thermal spans a greater range than AC speed control systems.
protection lies with the amount of current it takes to turn on
a motor. To get a motor up and running from a dead stop, a • Where very high starting torque and/or high over-torque
huge rush of current must occur at the very beginning. After capability is required, DC motors are often selected.
this rush of current, the motor levels out and runs at about a
•They are also appropriate where equipment is battery
100% speed. At 100% speed, the motor will pull a
powered.
certain amount of continuous current until the operator turns
34. Load -- Motors must be sized to accommodate the
the motor off. This current at 100% full speed is called “Full
running load’s speed and torque requirements. Load types
Load Amps” (FLA). The big rush of current at the beginning is
can be classified into different duty cycles describing
the “Inrush” current and is usually about 6-8 times the FLA of
operating time and load variations.
the motor.
Starting and Stopping
35. Frequency of starting and stopping.
• For frequent starts, ensure winding and core temperature
do not exceed motor rating (Duty types as defined in IEC
60034-1)
36. Starting torque requirement.
• Pay special attention to high inertia loads to ensure motor
starting torque is adequate.
37. Acceleration restrictions.
• Ensure the motor driving the load reaches full speed quickly
enough to avoid tripping the overload protection. Conversely,
some loads require time to accelerate to full speed, e.g. a
conveyor belt – a variable speed drive may be justified to
achieve this and keep current lower when starting up.
38. AMBIENT TEMPERATURE-- is the temperature of the air
surrounding the motor.
39. MAXIMUM OPERATION TEMPERATURE -- is the
maximum permissible hot spot temperature of a winding
(rated temperature of the insulation system).
40. MOTOR SERVICE FACTOR -- is an indication of the ability
to exceed the mechanical power output rating on a sustained
basis. A service factor greater than 1.0 allows a margin for
peak power demand without selecting the next larger motor
size.
41. MOTOR EFFICIENCY -- is usually reduced during operation
at the service factor rating.
Energy Saving Strategies
 Choose a Replacement Before a Motor Fails
 Match Motor Operating Speeds
Motor sizing
 Properly Size the Motor for your Application
 Properly Size the Motor for your Application
DC MOTORS
42. DC MOTOR OR DIRECT CURRENT MOTOR
-- is an electrical machine that transforms electrical energy
into mechanical energy by creating a magnetic field that is
powered by direct current. When a DC motor is powered, a
magnetic field is created in its stator. The field attracts and
repels magnets on the rotor; this causes the rotor to rotate.
To keep the rotor continually rotating, the commutator that
is attached to brushes connected to the power source supply
current to the motors wire windings.
-- A DC motor is based on the idea that when a current
carrying conductor is placed in a magnetic field, it produces
mechanical force. The direction of the force is determined by
the left hand rule. Since DC motors and DC generators have
the same construction, they can be used interchangeably.
Basic Parts and its functions
A.) Stator -- is the unmoving main body of the motor,
and it provides support and protection for the
motor. The stator provides a rotating magnetic field
that drives the armature or rotor.
B.) Shaft -- The windings and the commutator rotate the
shaft, which is at the center of the motor and made
of a hardened metal, usually steel, to withstand the
loads of the application.
C.) Terminals -- A DC motor has two terminals: positive
and negative. When the positive wire is connected
to the positive terminal and the negative wire
connected to the negative terminal, the motor
rotates clockwise.
D.) Magnets -- The magnets used in DC motors are
referred to as permanent magnets; this means their
magnetic field is always active.
E.) Rotor -- The rotor or armature is made of multiple
disks that are insulated from each other by
laminated sheets.
F.) Coil Windings -- The coil windings are wrapped
around the rotor. The coiling of the wire creates a
strong and powerful magnetic field.
G.) Brushes -- The brushes of a DC motor provide the
coils with power and are metal pieces that act like
springs.
H.) Commutator -- The commutator is made of small
copper plates that are mounted on the shaft and
rotate as the shaft rotates.
TYPES OF DC MOTOR
43. Separately Excited DC Motor
-- In a separately excited DC motor, the motor has separate
electrical supplies to the armature winding and field winding,
which are electrically separate from each other.
44. Permanent Magnet DC Motor
The permanent magnet motor uses . Permanent magnet DC
motors have excellent starting torque capability with good
speed regulation.
45. Self-Excited DC Motor
-- In case of self-excited DC motor, the field winding is
connected either in series or in parallel or partly in series,
partly in parallel to the armature winding. Based on this, self-
excited DC Motors can be classified as:
1. Shunt Wound DC Motor
--In case of a shunt wound DC motor or more
specifically shunt wound self-excited DC motor, the
field windings are exposed to the entire terminal
 voltage as they are connected in parallel to the
armature winding as shown in the figure. A shunt
motor is used for applications that require a
constant torque, where the load is not significantly
altered by speed, such as conveyor belts, mixers and
hoists.
2. Series Wound DC Motor
--In a series DC motor, the field is connected in series
with the armature. The field is wound with a few
turns of large wire because it must carry the full
armature current.
3. Compound Wound DC Motor
--Compound DC motors or compound wound motors
have both series and shunt field windings. These
types of motors offer good starting torque, but they
may have control problems in variable speed drive
applications.
 Short Shunt DC Motor
--If the shunt field winding is only parallel to the
armature winding and not the series field winding
then its known as short shunt DC motor or more
specifically short shunt type compound wound DC
motor.
 Long Shunt DC Motor
--If the shunt field winding is parallel to both the
armature winding and the series field winding then
it’s known as long shunt type compounded wound
DC motor or simply long shunt DC motor.
46. Cumulative Compound DC Motor
--When the shunt field flux assists the main field flux,
produced by the main field connected in series to the
armature winding then it’s called cumulative compound DC
motor.
47. Differential Compound DC Motor
--In case of a differentially compounded self-excited DC
motor i.e. differential compound DC motor, the arrangement
of shunt and series winding is such that the field flux
produced by the shunt field winding diminishes the effect of
flux by the main series field winding.
48. BRUSHED DC MOTOR -- is the original DC motor. The
classic brushed motor features a commutator, to reverse the
current every half cycle and create single direction torque.
While brushed DC motors remain popular for electrical
propulsion, cranes, paper machines, and steel rolling mills,
many have been phased out for the more efficient brushless
model in recent years.
49. BRUSHLESS DC MOTORS -- are also known as
electronically commutated motors, or synchronous DC
motors, and differ to the brushed motor, thanks to the
development of solid state electronics.
Advantages of using DC Motors
A. Startup Torque
torque it can generate. DC motors generate an
exceptional speed to torque curve that is more linear
than other motors.
C. No Harmonic Effects
Harmonic effects degrade a power system‘s performance and
reliability and may become a safety problem. When harmonic
effects exist, they must be immediately identified and
corrected. Damage to equipment can cause metal
components to heat up and become dangerous. This
particular issue is not a problem in the operation of DC
motors.
D. Speed Control
Another factor that is regularly discussed regarding DC
motors is the ability to monitor and control their speed.
E. Installation
When a DC motor is installed, it requires fewer electronic
rectifications in the power system and fewer adjustments in
general. Once a DC motor is installed, it can be used
immediately by feeding power to it directly from the power
source.
F. Maintenance
The design of DC motors is simple, which makes them easy to
repair or replace. DC motors have been around for over 130
years and are familiar to technicians and electricians. The
many years they have been used makes them easy to
diagnose and repair at very low cost.
G. Low Cost
The obvious final reason for using DC motors is their low cost;
they are cheaper than AC motors, though brushless and
permanent magnet DC motors are more expensive. The cost
advantage of brushless motors is their exceptionally long life
span. Though brush motors are less expensive, they tend to
have a shorter life span and require regular repair, a negative
aspect that is balanced by their low cost of repair.
AC Motors
50. AC motor -- is an electric motor driven by an alternating
current (AC). An AC motor or alternating current motor
commonly consists of a stator with a coil that is supplied with
alternating current to convert electric current into
mechanical power. The stator is the stationary part of the
motor while the rotor is the rotating part. AC motors can be
single or three phase with three phase motors mainly used
for bulk power conversion. Single phase AC motors are used
for small power conversions.
--AC motors are a power source for a wide variety of
applications due to their flexibility, efficiency, and noiseless
operation. They are used on pumps, water heaters, garden
equipment, ovens, off road equipment and are commonly
found in many appliances, equipment, and tools.

Constantly discussed in regard to DC motors is their high

startup torque. For applications that need constant and
consistent speed with variable torque, DC motors are the
ideal choice.

B. Linear Speed Torque

The curve between the torque and speed of a motor
explains how fast the motor spins and how much

51. ENCLOSURE
--The enclosure consists of a frame (or yoke) and two end
brackets (or bearing housings).
There are two categories of enclosures as follows:
 Open Enclosure
-Open enclosures permit cooling air to flow through
the motor.
 Totally enclosed Enclosure.
-This category will include the following three types:
1. Totally Enclosed Non-Ventilated Enclosure,
2. Totally Enclosed Fan-Cooled Enclosure and
3. Explosion-Proof Enclosure.
52. STATOR
--The motor stator consists of two main parts:
 Stator Core -- The stator is the stationary part of the
motor’s electromagnetic circuit.
 Stator (Windings) -- Stator laminations are stacked
together forming a hollow cylinder. Coils of insulated
wire are inserted into slots of the stator core.
53. ROTOR -- is the rotating part of the motor’s
electromagnetic circuit. Magnetic field from the stator
induces an opposing magnetic field onto the rotor causing the
rotor to “push” away from the stator field.
54. BEARINGS -- mounted on the shaft, support the rotor and
allow it to turn. Not all bearings are suitable for every
application; a universal, all-purpose bearing does not exist.
55. Fan -- In AC motors, heat builds up in the windings. For
this reason, AC motors have a built in cooling system. Inside
the enclosure, a fan is attached to the shaft of the rotor at
the opposite end of the axle that drives the machine that the
AC motor is attached to.
56. AIR GAP -- is the gap between the rotor and stator, which
is a necessary part of the motor and a key to its design.
57. CONDUIT BOX -- Point of connection of electrical power
to the motor’s stator windings.
58. EYE BOLT -- Used to lift heavy motors with a hoist or
crane to prevent motor damage.
59. The AC motor, invented by NIKOLA TESLA
Types of AC Motors
60. SINGLE PHASE AC MOTORS -- are used where there is a
single phase supply. This type of AC motor is smaller and less
expensive.
61. POLYPHASE AC MOTOR – Polyphase Motors, or many
phase motors, are a type of AC motor that can be two or
three phase and are similar to single phase motors in how
they operate. The stator poles in a polyphase motor are not
aligned with each other, which means that the rotor passes
by the stator poles at different times.
 A polyphase system has a group of equal voltages at
the same frequency that are placed to have an equal
phase difference between the adjacent
electromagnetic fields (EMF).
A polyphase system can be two, three, or six phase
with the majority
being three phase.
A polyphase system is commonly referred to as a
three phase system and produces 1.5 times more
output than a single phase system. The current from
a polyphase system is constant, which is unlike the
single phase system that is pulsating.
62. SYNCHRONOUS AC MOTOR -- is where the rotation of the
shaft is at the same frequency as the current supply with the
rotation period being equal to the integral number of AC
cycles.
63. RELUCTANCE MOTORS -- are a single phase motor, which
operate with an accurate value of rotating magnetic field
without any synchronous speed.
64. HYSTERESIS AC MOTOR -- has a core of non-magnetic
material with a layer of special magnetic material.
65. REPULSION MOTOR -- is a type of single phase motor that
works by the repulsion of similar poles.
66. ASYNCHRONOUS MOTOR -- uses an induced current in its
rotor to produce rotatory motion.
Why use an AC motor?
 Efficiency – AC motors have a high speed to torque
characteristic, which offers excellent performance
without overheating, braking, or degeneration.
 Lifespan – AC motors last in the most demanding of
conditions.
 Quiet – Since AC motors have a very low sound
output, they are chosen for commercial
environments where food is being served or
customer service is essential.
 Adaptability – There are several factors that make
AC motors adaptable and flexible.
 Accessibility – Every industrial operation has a
variety of conditions that require multiple sources of
power and energy.
 Simplicity – The fact that an AC motor has only one
moving part is a major benefit to their use.
 Brushless – A brush motor uses brushes and a
commutator to supply electricity to magnetic coils
on the armature.
 Self-Starting – Only AC excitation is necessary to
operate an AC motor.
 Speed Regulation – The speed of an AC motor can
be controlled by changing the frequency that is sent
 to the motor, which causes it to speed up or slow servomechanism that is able to detect and adjust the
down. angle of the rotor.
 Single Phase Input – Part of the adaptability of an AC 25. DC motor - An electric motor that uses direct current
motor is how it can run using a single phase input for as a power supply
a three phase motor even though the location may 26. Enclosure - Protects the internal components of an
not have a three phase input. AC motor from moisture and contaminants
27. Rotor - Rotating part of the motor’s electromagnetic
QUIZ 28.
circuit
Single phase AC motor - An AC motor that uses a
1. Motion Control - focused on moving a load from one single-phase power supply
place to another. It does this by precisely controlling 29. Asynchronous motor - Uses an induced current in its
the position, velocity, and acceleration of the load rotor to produce rotary motion
under defined operating conditions. 30. Synchronous AC motor - A type of AC motor where
2. Electric Drives - drives employing electric motors the rotation of the shaft is at the same frequency as
3. Power Modulator - Regulate the power flow from the current supply with the rotation period being
source to the motor equal to the integral number of AC cycle
4. Electric motor - An electrical machine that converts
electrical energy to mechanical energy
5. Control - Adjusts motor and load characteristics for
optimal mode
6. Torque - amount of rotational force that the motor
develops
7. Speed - rate at which the motor rotates
8. Moment of inertia - Quantitative measure of the
rotational inertia of a motor
9. Forward motoring - Mode of the motor wherein the
torque and speed developed are both positive
10. Braking - Mode of the motor where it works as a
generator converting mechanical energy to electrical
energy
11. Magnetic contactor - It is powered by magnetism
and used to open and close the contacts in the
motor control circuit
12. Overload relay - Opens the circuit in the event of an
electrical, thermal or power overload
13. Auxiliary contact - Physically linked to the main
contacts of magnetic contractor and activated at the
same time
14. Phase to phase short - This is when one phase goes
into another (two phases with no insulation
accidentally touch each other). They create an
unrestricted path of a control circuit
15. Normally closed contactor - Opens the contact point
of a control circuit
16. Maximum operation temperature - Maximum
permissible hot spot temperature of a winding
17. Ambient temperature - Temperature of the air
surrounding the motor
18. Motor service factor - Indication of the ability to
exceed the mechanical power output rating on a
sustained basis
19. IEC 60085 - Standard that gives the maximum
operating temperature for each thermal class
20. Synchronous motor selection - Selecting a motor
with higher horsepower than the required load
application
21. Brushes - Provide the coils with power and are metal
pieces that act like springs
22. Separately Excited DC Motor - Type of DC motor
that has separate electrical supplies to the armature
winding and field winding
23. Permanent magnet DC motor - Uses permanent
magnet and have excellent starting torque capability
with good speed regulation
24. Brushless DC motor - Type of DC motor that doesn’t
have a commutator and is replaced by an electronic
Draw the power and control circuit for a forward-reverse-star-delta
starter of a 3-phase AC motor. Add 4 pilot lights (red, orange, green
and yellow) in the control circuit; the red PL should turn on when
the motor is running forward, the orange PL should turn on when
the motor is running in reverse, the green PL should turn on when
the motor is not running, the yellow PL should turn on when there is
overload.