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Engineering Science and Technology, an International Journal 24 (2021) 145–157

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Engineering Science and Technology,


an International Journal
journal homepage: www.elsevier.com/locate/jestch

Full Length Article

A novel simple method for elimination of DOL starting transient torque


pulsations of three-phase induction motors
Mehmet Akbaba
Department of Computer Engineering, College of Engineering, Karabuk University, Balıklar Katyası Mevkii Demir Celik Kampusu, 78050 Karabuk, Turkey

a r t i c l e i n f o a b s t r a c t

Article history: This paper presents a novel method for elimination of transient torque pulsations of three phase induc-
Received 8 April 2020 tion motors which arises on direct-on-line (DOL) starting. When started DOL, during run-up period,
Revised 10 June 2020 induction motors produce large transient torque pulsations well in excess of full-load torque. These tor-
Accepted 14 June 2020
que pulsations can be detrimental as it may cause shock-loading on the driven equipment and damage to
Available online 25 June 2020
the mechanical system components such as shaft, gear and couplings. Also, high inrush current is drawn
by the motor and this, due to extra temperature rise, may cause winding insulation failure and extra
Keywords:
stress on power utilities. With this method faster starting is achieved, which result in faster decaying
Eliminating torque pulsations
Induction motors
of inrush currents, and hence reduced stress on both the winding insulation and supply utilities. The
Fast starting method is composed of inserting an optimized and series connected capacitor-resistor pair between
Optimization the motor and the supply in order to eliminate the low frequency transient components available in
External capacitor and resistor the stator and rotor currents, which are the root cause of transient torque pulsations. The proposed
method is simulated with full details on two different motors and the results obtained are very satisfac-
tory and promising.
Ó 2020 Karabuk University. Publishing services by Elsevier B.V. This is an open access article under the CC
BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

1. Introduction demand precautions against all these detrimental effects.


Therefore, to prevent these detrimental effects there is need for:
Induction motors have wide range of applications in many
industrial as well as manufacturing processes. They are highly effi- - To reduce the torque pulsations during direct online starting
cient motors when operated near to its rated torque and speed. - To reduce the amplitude of the inrush currents
Starting methods of induction motors well documented in the lit- - To reduce the speeding up time so that the settling time of the
erature [1–3]. These can be summarized as DOL starting, reduced transient (inrush) current will be short enough and hence ther-
voltage starting, slid-state controlled reduced voltage starting [4] mal stress on the windings and insulation will be reduced.
and modern starting methods such as variable frequency starting,
soft and smooth starting methods [5–9]. DOL starting method is First attempts toward reducing in rush current started with
the cheapest and most widely used method. When three phase reduced voltage starting and gradually moved to smooth starting
induction motors started DOL with full voltage will produce large methods [5–9]. It is well known hat in induction motors torque
torque pulsation well in excess of full-load torque during acceler- is proportional with the square of the voltage and current is
ation [10–14]. This can be detrimental as it may cause shock- directly proportional with voltage. Therefore, with reduced voltage
loading on the driven equipment and damage to the mechanical starting, to obtain enough reduction in inrush current will require
system components such as shaft, gear, coupling etc. These motors excessive reduction in torque. In such a case motors will not be
will also draw high inrush current which may cause winding and able to start against types of loads that require high starting torque
insulation failure and extra stress on power utilities that are having such as static or partially static loads and high inertia loads. In such
limited generating and distribution capacity. Large inertia loads cases mostly problem is partially solved by using wound rotor
and large static loads may prevent motors from speeding up induction motors which are approximately 70% more expensive
rapidly enough causing the motors to draw high current long and less robust than cage induction motors [15], and also could
enough so that to trip on thermal overload. Certain process may not resolve the detrimental effects arising from starting torque
pulsations. On the other hand, soft and smooth starting methods
are highly expensive setups as they involve a many equipment
E-mail address: mehmetakbaba@karabuk.edu.tr

https://doi.org/10.1016/j.jestch.2020.06.007
2215-0986/Ó 2020 Karabuk University. Publishing services by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
146 M. Akbaba / Engineering Science and Technology, an International Journal 24 (2021) 145–157

and components around motors. In an earlier attempt towards is beyond the scope of this paper. But in Section 3, observing the
attenuating torque pulsations, a kind of optimization process was transient torque and envelope of the transient currents, strong
exercised on the design parameters of motors and a reduction of arguments will be forwarded in support of the above proposals.
about 30% was achieved [15]. In another attempt about 60% reduc- In an earlier work existence of low frequency current components
tion in the first peak of pulsating torque was achieved by placing a mentioned above are investigated experimentally [15], but their
series resonant L-C circuit, resonating at fundamental frequency, relation to pulsating toques was not investigated. Therefore, if
closed with a suitable resistor was inserted in each phase between the transient low frequency components of the stator currents
the supply and motor [16]. In two other studies some improve- can be eliminated then the low frequency components of the rotor
ments were achieved on reducing transient current and attenuat- current will be eliminated too, and hence transient torque pulsa-
ing transient toque pulsations, but torque pulsations still tions also will be eliminated. Since capacitors impose large reac-
remained sound having both positive and negative peaks [5,17]. tance against low frequency currents it is possible to benefit
In another work authors managed to eliminate pulsating torques from capacitors to attenuate low frequency current components.
by connecting two phases of the motor to the supply simultane- On the other hand, inductances impose very low reactance against
ously at t = 0 and delaying the connection of third phase by low frequency currents. Hence motor winding inductances alone
t1 = 0.013333 s [18]. But there is no explanation in the paper are not effective in attenuating the low frequency current compo-
how this particular time delay was obtained. 0.013333 s corre- nents. Only the winding resistances of the motor works against
sponds to 240° on the point wave of 50 Hz supply. Author of this these low frequency current components. But the values of the
paper tried the same delay on four different motors and noticed winding resistances are very low and insufficient to attenuate
that torque pulsations are not eliminated. Therefore, it seems that the low frequency current components sufficiently. Therefore, only
the mentioned time delay is obtained by trial and error for a par- during run-up for a few hundred milli seconds, an optimized and
ticular motor and valid for that particular combination of the series connected capacitor (Cext) and resistor (Rext) pair, as shown
motor parameters. In a relatively recent paper using soft starting in Fig. 1, connected in series with the stator windings in each
technique, torque pulsations have been eliminated successfully phase, could be a good solution for eliminating the transient torque
[19], but as compared to the technique proposed in this paper, it pulsations. In order not to cause any deterioration in the steady
involves much complex and expensive equipment, which may state performance of the motor, when speed rises close to the syn-
not be preferred in every cases. chronous speed, the externally connected capacitor-resistor pair
In this paper a novel simple method is proposed for full elimi- must be taken out by placing a short circuit across them.
nation of DOL starting torque pulsation and fast starting. The val- The values of the capacitor and resistor are critical. Selection of
ues of the required external circuit elements are obtained by an the optimum values of the external capacitor and resistor will be
optimization process. The method has been tested on two different explained in the Section 2.2.
size motors and very encouraging results are obtained. Toque, cur-
rent and speed transients are examined by simulation on a small
2.2. Optimum values of the external capacitor Cext and external resistor
size low voltage motor and a medium size high voltage motor. It
Rext
is clearly observed that the transient pulsating torques are elimi-
nated completely in both motor cases. Also, starting capability of
It has been observed from computational experiments that
the optimized motors starting against hard loads such as static
when capacitive reactance of Cext, xc, exceeds the 70% of stator leak-
loads have been studied and highly encouraging results are
age reactance of the stator winding, xs, motor becomes unstable.
obtained.
Therefore, in the optimization process, described below, the upper
limit of xc is set to 0.7xs, and it was observed that at each case xc
converges to its upper limit. Therefore, optimum value of xc is fixed
2. Material and methods
at xc = 0.7xs. Hence the optimum value of the external capacitor Cext
is expressed as.
2.1. Cause of large transient torque pulsations
C ext;opt ffi @1000000=ð0:7xxs ÞlFðxc ¼ 0:7xs Þ ð1Þ
On DOL starting of induction motors, transient pulsating torque,
with large positive and negative peaks, is developed. In literature where
few claims are made for the root cause of these transient torque x = 2pf, f: Frequency of the supply voltage (Hz)
pulsations [18,20]. In [18], without further elaboration, transient Optimum value of the Rext is obtained through constrained opti-
torque pulsations attributed to the interaction between transient mization process described below. In this regard two different
stator currents and transient rotor flux, while in [20] it is attributed approaches adopted:
to the interaction between the transient stator currents and rotor
flux vectors. These proposals may partially be correct, but a clear a) Newly designed but not yet manufactured motors
relation with transient torque pulsations could not been estab- b) Existing motor
lished. It is proposed in this paper that the root cause of transient
torque pulsations is the interactions between transient low fre- Reason for adopting two different approaches is that the equiv-
quency components of the stator currents with approximately fun- alent circuit parameters of existing motor cannot be changed, but
damental frequency (supply frequency) component of the rotor equivalent parameters of a newly designed motor can be modified
currents (at low speeds frequency of the fundamental rotor current
is close to the supply frequency) and also interaction between the
low frequency components of the rotor currents and the funda-
mental frequency component of the stator currents. Author of this
paper believes that these low frequency current components are
resulting from the asymmetrical transient flux components gener-
ated during run-up period and they decay to zero as the shaft
acceleration comes close to zero. Mathematical modeling of low
frequency current components or the asymmetrical transient flux Fig. 1. Connection of external capacitor and resistor.
M. Akbaba / Engineering Science and Technology, an International Journal 24 (2021) 145–157 147

to some extend by some manipulation on design parameters Ts is taken as nonlinear equality constraint, i.e., D(x), and steady
before the manufacturing process. state starting current, Is, and pull out torque, Tpo, are taken as non-
linear inequality constraint, i.e., C(x), and they are expressed as
2.2.1. Newly designed but not yet manufactured motors case follows:
To find the optimum value of Rext for this option the approxi-
mate value of the first positive peak of the pulsating transient tor- 30Rr V 2L
Ts ¼ ¼ T sn ð5Þ
que, expressed in terms of steady-state starting torque and pns ½ðR1 þ Rr Þ2 þ ðx1 þ xr Þ2 
equivalent circuit parameters [15], including xc and Rex, and this
expression is taken as the objective function to be minimized. Then
 pffiffiffi qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
Is ¼ V L = 3 = ðR1 þ Rr Þ2 þ ðx1 þ xr Þ2 6 Isn ð6Þ
the steady-state torque, pull-out torque and the steady-state start-
ing current, are expressed in terms of equivalent circuit parameters
of designed motor (this design is an optimized design for best effi- 15V 2L
T po ¼ 6 T pon ð7Þ
ciency condition), xc and Rex, are used as nonlinear constraints of pns ðx1 þ xr Þ
the optimization process. In this process also minor modification
are allowed in equivalent circuit parameters by selecting upper where VL is the line (line-to-line) voltage
and lower boundary value for each parameter of the motor and Reason for taking Ts as nonlinear equality constraint is that
these also included in the optimization process as further keeping the value of Ts high the average value of the transient tor-
constraints. que will be higher.
An optimization routine available in MATLAB [21], ‘fmincon’, Where:
which uses mid-point algorithm [22,23] is used as optimization Tsn, Isn and Tpon are taken as equal to d.Ts, d. Is and Tpo respec-
tool. The matrices and functions used in this routine are described tively, where Ts, Is and Tpo, are calculated using equivalent circuit
as follows: parameters of the original motor. d is a constant which can vary
minx f(x), where f(x) is the main (objective) function to be between 1.1 and 1.5 as convenient. Reason using factor d is that
minimized the starting torque and starting current of the motor with opti-
mized configuration are always higher than that of the original
ðx : x 1 ; x 2 ; x 3 ; . . . . . . x n Þ motor. Initial condition for starting optimization process can be
where x are the parameters that will minimize the objective func- taken as lower bonds of original motor parameters, and 2.Rs for Rext.
tion f(x). Larger value of d gives smaller value for Rext, which is preferable,
C(x)  0, Nonlinear inequality constraints equations and it should be taken on higher side as much as convergence of
D(x) = 0, Nonlinear equality constraints equations optimization problem and stability of motor allows.
A.x  a, A is the coefficients matrix of the left-hand side and ‘a’ Additional constraints are the upper and lower boundaries of
is the right hand side upper limits vector of the linear inequality the parameter R1, x1, Rr, xr. Since the motor is already designed,
constraints equations in order not to violate the required steady-state performance,
B.x = b, B is the coefficients matrix of the left-hand side and ‘b’ is upper and lower of boundaries of xs, Rr and xr are selected as 5%
the right hand side vector of the linear equality above and 5% below the original values obtained from original
constraints equations design. Lower boundary of R1 is selected as 2.Rs and its upper
Dlower  x  Dupper, Dlower: lower bounds of the ‘x’ variables boundary is selected as 10Rs. Therefore, the lower and upper
Dupper: upper bounds of the ‘x’ variables boundary constrains have been set as:
The left-hand side of the routine ‘fmincon’ can be written in Dlower ¼ ½2:Rs 0:95Rr 0:95xs  xc 0:95xr  ð8Þ
many ways, to include several information. In the problem in hand
we are interested only in parameters values that optimize the Dupper ¼ ½10Rs 1:05Rr 1:05xs  xc 1:05xr  ð9Þ
objective function. Therefore, for the problem in hand syntax of
the ‘fmincon’ routine can be written as: Since there are no linear inequality and equality constrains
X = fmincon(‘mainfunction’,X0,A,a,B,b,Dlower,Dupper, associated matrices will be empty matrices, i.e.:
’constraintsfunction’)
A ¼ ½ ; a ¼ ½ ; B ¼ ½  and b ¼ ½ :
Where:
X: Values of the ‘x’ variables that minimize the objective (main) Earlier it was mentioned that in order not to disturb the steady-
function state performance, the external elements Cext and Rext will be
’mainfunction’: a function file containing the expression of the shorted out at instant, tcut, when the rotor speed rises close to
objective (main) function the synchronous speed. Using approximate torque equation for
X0: Initial values of ‘x’ variables the steady-state case the starting time, tst, from rest to the syn-
’constraintsfunction’: a separate function file containing the chronous speed for a free running motor can be obtained as [15]:
nonlinear inequality and nonlinear equality constraint equations,
C(x)  0 and D(x) = 0 J x2s  2 
tst ¼ 2
Rs þ R2r þ ðxs þ xr Þ2 þ 2Rs Rr ð10Þ
Main (objective) function to be optimized is the equation of the Rr V L
first peak of the pulsating transient torque, T+, that is expressed as
where
[15]:
J: total inertia of the shaft (kg-m2)
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
xs: mechanical angular synchronous frequency (rad/s)
T þ ¼ T s ð1 þ 1 þ ððx1 þ xr Þ=ðR1 þ Rr ÞÞ2 Þ ð2Þ
Numerical experiments showed that a tcut can be expressed in
where terms of tst as:

x1 ¼ xs - xc ðxc ¼ 1=ð2pfC ext ÞÞ ð3Þ tcut ¼ k:tst ð11Þ

where k is a constant which can vary from case to case. However,


R1 ¼ Rs þ Rext ð4Þ
through numerical examples it was found that it can be chosen
Ts: Steady state starting torque between 0.5 and 2.5 as convenient.
148 M. Akbaba / Engineering Science and Technology, an International Journal 24 (2021) 145–157

Set-time of an adjustable time relay triggering circuit given in In this case there will be no need for any externally added resistor.
Fig. A1 in Appendix can be set to tcut for shoring- out Cext and Rext. This procedure will be done only once in the whole life of the motor.
Differential equations governing the transient behavior of the
motor in stationary reference frame are given below. 2.2.2. Existing motors case
Voltage equations when Cext and Rext are present are given as: In case of existing motors, equivalent circuit parameters are
diqs diqr Q q already fixed and cannot be changed. The only variable parameter
R1 iqs þ Ls þ M1 þ ¼ V qs ð12Þ will be R1 which includes Rext. In order to preserve the structure of
dt dt C ext
the optimization process described above for newly designed
dids didr Q d motor, parameters of the existing motor will appear in upper lower
R1 ids þ Ls þ M1 þ ¼ V ds ð13Þ boundary matrices, Dlower and Dupper, but their upper and lower val-
dt dt C ext
ues will be same. Hence:
diqs diqr
M1  xe ids þ Rr iqr þ Lr  xe idr ¼ 0 ð14Þ Dlower ¼ ½2:Rs Rr xs  xc xr  ð22Þ
dt dt

dids didr Dupper ¼ ½10Rs Rr xs  xc xr  ð23Þ


M1 þ xe iqs þ Rr idr þ Lr þ xe iqr ¼ 0 ð15Þ
dt dt The other constraints are same as the ones given in Eqs. (5), (6)
and (7). Also, the governing differential equations are same as
dQ q
¼ iqs ð16Þ those are given for the newly designed motors case.
dt
Application examples are given in Section 3.
dQ d
¼ ids ð17Þ
dt 3. Results and discussions
where
M1 = 1.5xm/x, Ls = M1 + xs/x, Lr = M1 + xr/x, and Qq and Qd are the 3.1. Newly designed motor example
electrical charges on Cext placed on the stator q and d axis. xe is the
rotor angular frequency in electrical terms, i.e., xe = Poxr, where xr As a newly designed motor a 10 kW, 440 V, 50 Hz, 4 poles,
is the rotor angular frequency in rad/s, and Po is the number of pole 1440 rpm, 66 Nm, 14.7 A cage induction motor has been selected.
pairs of the motor. (With the optimized parameters, the torque and current calculated
Equations (11), (12), (15) and (16) are valid as long as Cext and from the equivalent circuit at rated speed are 63 Nm and 14.7 A
Rext are present. When t  tcut, i.e., after shorting out Cext and Rext, respectively.) From design details equivalent circuit parameters
voltage equation will become as usual voltage equation in which of this motor has been obtained as:
4th terms of Eqs. (11) and (12) and also Eqs. (15) and (16) will Rs = 0.249 O, xs = 1.911 O, Rr = 0.696 O (referred to stator side),
be dropped out. xr = 2.111 O (referred to stator side), Xm = 62.24 O (referred to stator
The induced electromechanical torque can be expressed as: side) and iron losses ignored. Where Xm is the magnetizing reactance.
Total inertia on the shaft is J = 0.164 kg-m2 and the motor is
3  
Te ¼ Po Lm iqs idr  ids iqr ð18Þ assumed to drive a pump type load of (that gives almost rated tor-
2 que at rated speed):
where Lm = xm /x
Finally, the mechanical shaft equation can be written as: T L ¼ 0:0022x2r þ 0:0956xr ð24Þ

dxe P o From Eq. (1) the capacitive reactance of the optimum capacitor
¼ ðT e  T L Þ ð19Þ Cext is obtained as:
dt J
xc = 0.7*1.911 = 1.377 O and
The mathematical model given above do not include the skin Cext = 1/ (2*p*50*1.377) = 0.002312F or 2312 mF
and saturation effects. Which they have significant effect on the For this motor, using d = 1.2, constants for the right-hand side of
accuracy of the simulation results [24–26] especially for large the nonlinear inequality and equality constrains, Eqs. (5)–(7), are
motors. obtained as:
Transformation between the stationary reference frame quanti- Tsn = 56.3 Nm, Isn = 73.06 A and Tpon = 142.56 Nm.
ties (q, d) and actual coordinate system quantities (a, b, c) are given The other properties of optimization for this motor are (Eqs. (8)
in [27]. and (9)):
Differential equations given above are solved using 4th order
Runge-Kutta method [28] with a step size of h = 0.0005 s. All initial Dlower ¼ ½0:5 0:668 0:2 2:002
conditions are zero.
In practical application internal resistance of Cext should be Dupper ¼ ½2:5 0:692 0:63 2:211
taken into consideration. The external resistance, Rext, to be added
should be Applying the optimization procedure described above, after 6
iterations, the following new set of equivalent circuit parameter
Rext;actual ¼ Rext;optimum  Rc ð20Þ are obtained:
where Rc is the internal resistance of Cext. In cases when Rc > Rext,op-
R1 ¼ 2:238X; Rr ¼ 0:692 X; x1 ¼ 0:55 X and xr ¼ 2:011X;
timum smaller capacitors must be connected in parallel in in such a
way that equivalent capacitor = Cext. About ± 7% tolerance in Rext,op- from which we obtain:
timum will not significantly affect the transient performance of the
motor. Hence the equivalent resistance of the parallel connected Rext ¼ 2:238  0:249 ¼ 1:989 ffi 2:0X and xs ¼ 0:55 þ 1:377
capacitor, Rceq can be: ¼ 1:927X:
0:93Rext;optimum 6 Rceq 6 1:07Rext;optimum ð21Þ It is clear that required from the above values that required
modification in motor equivalent circuit parameters are not more
M. Akbaba / Engineering Science and Technology, an International Journal 24 (2021) 145–157 149

than 5% and can be easily achieved by some manipulation on the


design parameters, without significantly disturbing the steady-
state performance of the motor.
The starting time, tst, calculated from Eq. (10) is obtained as
0.398 sec. Choosing k = 1.5 (Eq. (11) for convenience, the time to
short-out the Cext and Rext is obtained as tcut = 0.6 s.
Using Eqs. (12) through (23) and solving the associated differ-
ential equations for both the initially designed (original) motor
and the motor with optimized parameters including Cext and Rext,
the transient torque, transient current and the transient speed
are calculated and plotted versus time in Figs. 2–4 respectively.
Examination of Fig. 2 clearly shows that for the motor with opti-
mized configuration the transient torque pulsations are fully elim-
inated. Data obtained from data cursor of MATLAB showed that for
the original motor positive torque peak is 269 Nm, negative torque
peak is 276 Nm and peak-to-peak torque is 545 Nm, whereas for
the motor with optimized configuration, i.e., with the optimum
values of Cext and Rext inserted, transient torque pulsations disap-
peared completely and a unidirectional torque is obtained, which
almost fallows the average steady-state torque and the positive
torque peak is only 88 Nm. This corresponds to 84% reduction in
the peak-to-peak torque. Therefore, the claimed aim of this paper
is perfectly achieved. The transient torque occurred after shorting
out Cext and Rext at 600 ms retained within reasonable low limits
which will not pose any harm to the driven load and to the motor
itself.
It is interesting to observe From Fig. 3 that, for the original Fig. 3. Transient stator currents versus time (a) Original (b) Optimized (10-kW
motor case envelope of the transient current is not symmetrical motor).
with respect to time axis due to existence of asymmetrical low fre-
quency decaying current components, whereas in case of the
motor with optimized configuration envelope of the transient cur-
rent is symmetrical with respect to time axis. This fact is a clear
proof of the claim forwarded in this paper that the root cause of
the large transient torque pulsations is the existence of decaying
low frequency current components of transient currents. It can
be seen from this figure that in case of optimized motor the tran-
sient current settles to its steady-state value much faster as com-
pared to the original motor case. Current settling time is about
893 ms for the original motor, whereas it is 472 ms for the opti-
mized motor, which means a reduction of about 48% in the settling
time. This is another important achieved advantage, when consid-
ering winding heating and insulation life. This advantage may be
considered as a kind of soft starting [5–9].
It can be observed from Fig. 4 that the motor with the optimized Fig. 4. Transient speed versus time a) Original b) Optimized (10-kW motor).
configuration runs-up much faster than the original motor, causing
the transient current to settle to its steady state value much faster
during run-up period, as shown in Fig. 3. Speed settling time is
about 890 ms in case of original motor, whereas it is about
469 ms for optimized case, corresponding to a reduction of about
48% in settling time.
Earlier in this paper it is proposed that if low frequency compo-
nents of the stator current are eliminated, as a result of interaction
between stator and rotor, also low frequency components of the
rotor current will be eliminated. To prove this proposal rotor cur-
rents, referred to stator side, are plotted in Figs. 5a and 5b respec-
tively for both the original and optimized motors. Examination of
Fig. 5 clearly shows that envelope of the transient rotor current
for original motor is not symmetrical with respect to time axis,
due to the existence of low frequency current components, but
for the optimized motor envelope of the transient current is com-
pletely symmetrical with respect to time axis. This a clear proof of
the proposal forwarded in this paper that if low frequency compo-
nents of the stator currents are eliminated then the low frequency
components of the rotor currents also will be eliminated, and as a
natural result of this the transient torque pulsations will be
Fig. 2. Transient torque versus time (10-kW motor). eliminated.
150 M. Akbaba / Engineering Science and Technology, an International Journal 24 (2021) 145–157

The starting time, tst, calculated from Eq. (10) is obtained as


0.92 s. Choosing k = 0.75 (Eq. (11) for convenience, the time to
short-out the Cext and Rext is selected as tcut = 0.7 s.
Similar to the first motor case, solving the system differential
equations with inclusion of the new load torque given in Eq.
(23), the transient torque, transient current and transient speed
are calculated and plotted versus time in Figs. 6, 7a, 7b and 8
respectively.
Examination of Fig. 6 clearly shows that with optimized case
the transient torque pulsations are fully eliminated and totally uni-
directional transient torque is obtained. Data obtained from data
cursor of MATLAB showed that for the original motor positive tor-
que peak is 2790 Nm, negative torque peak is 2084 Nm and peak-
to-peak torque is 4874 Nm where as for the optimized motor with
optimum values of Cext and Rext inserted, torque pulsations disap-
peared completely, a unidirectional torque is obtained, which
almost follows the average steady-state torque and the positive
torque peak is only 1295 Nm. There is about 74% reduction in
the peak-to-peak torque. Therefore, the objective of this paper is
perfectly achieved. The transient torque occurring after shorting
out Cext and Rext at 450 ms retained within very low limits which
will not pose any harm to the driven load and to the motor itself.
As for the first motor case, Figs. 7a and 7b shows that for the
original motor the envelope of the transient stator current is not
symmetrical with respect to axis due to the existence of asymmet-
rical low frequency decaying current components, whereas, in case
of the motor with optimized configuration the envelope of the
transient current is symmetrical with respect to time axis. This
Fig. 5. Transient rotor currents versus time (Referred to stator side) a) Original b) fact, ones more, is a clear proof of the proposal forwarded in this
Optimized (10-kW motor).
paper that the root cause of the large transient torque pulsations
is the existence of asymmetrical decaying low frequency current
3.2. Existing motor example components. It can be seen from Fig. 8 that the motor with opti-
mized configuration runs-up faster and the transient current set-
As an existing motor, a 75 kW, 3300 V, 50 Hz, 4 poles, 1445 rpm, tles to its steady-state value earlier than that of the original
cage induction motor has been selected. Equivalent circuit param- motor. The current settling time is about 974 ms for the original
eters of this motor are given as: motor, whereas it is 568 ms for the optimized motor, which means
Rs = 4.261 O, xs = 12.57 O, Rr = 3.867 O (referred to stator side), a reduction of about 42% in settling time. This is another important
xr = 12.57 O (referred to stator side), Xm = 593.5 O (referred to stator achieved advantage, when considering the winding heating during
side) and iron losses ignored. Where Xm is the magnetizing run-up and winding insulation life. The above-mentioned reduc-
reactance. tion in the current settling time is an important contribution
Total inertia on the shaft is J = 2.22 kg-m2 and the motor is towards smooth starting of induction motors.
assumed to drive a pump type load of: It can be observed from Figs. 7a and 7b that the optimized
motor speeds-up much faster than the original motor, causing
T L ¼ 0:0204x2r þ 0:107xr ð25Þ the transient current to settle fast during run-up period, as shown
in Fig. 6. Speed settling time is about 986 ms in case of original
From Eq. (1) the capacitive reactance of the optimum capacitor
motor, whereas it is 579 ms for the optimized motor, correspond-
Cext is obtained as:
ing to a reduction of about 42% in the settling time.
xc = 0.7*12.57 = 8.799 O and
Cext = 1/ (314*8.799) = 0.000362F or 362 mF
Using d = 1.435, the right-hand side of the nonlinear inequality
and equality constrains, Eqs. 5–7, are obtained as:
T sn ¼ 552 Nm; Isn ¼ 103 AandT pon ¼ 1164 Nm:
The other properties of optimization for this motor are, Eqs. (8)
and (9):
Dlower ¼ ½8:52 3:867 3:771 12:57

Dupper ¼ ½40 3:867 3:771 12:57


Applying the optimization procedure described above, after 6
iterations, R1 is obtained as:
R1 = 10.911 O, (naturally there is no change in the equivalent cir-
cuit parameters of the motor), from which the optimum value of Rext
is obtained as:
Fig. 6. Transient torque versus time (75-kW motor).
Rext ¼ 10:911  4:261 ¼ 6:6X:
M. Akbaba / Engineering Science and Technology, an International Journal 24 (2021) 145–157 151

Fig. 7a. Transient stator currents versus time Original motor case (75-kW motor). Fig. 9b. Transient rotor currents versus time (Referred to stator side) Optimized
motor case (75-kW motor).

Figs. 9a and 9b depicts the transient rotor currents versus time


for both the original and optimized motors. This figure clearly
shows that, as have been observed in case of first motor, envelope
of the transient rotor current for original motor is not symmetrical
with respect to time axis, due to existence of asymmetrical low fre-
quency current components, but for the optimized motor envelope
of the transient current is completely symmetrical with respect to
time axis. Again this a clear proof of the proposal forwarded in this
paper that if low frequency of components the stator currents are
eliminated then the low frequency components of the rotor cur-
rents also will be eliminated, and as a natural result of this the
transient torque pulsations will be eliminated.
In certain applications there is need for many start-stops in rel-
Fig. 7b. Transient stator currents versus time Optimized motor case (75-kW atively short time. In such special cases it may not be practical to
motor).
cut-out Cext and Rext for each starting case. In order to see the
impact of not cutting out these external elements on the steady
state performance of the motors, the steady state torque, steady
state efficiency and steady state power factor of the second motor
are calculate, for the case when Cext and Rext are connected, and
plotted versus speed in Figs. 10, 11, 12a and 12b.
Fig. 10 shows the torque-speed characteristic of 75-kW motor
in the stable operating region, for both the original and optimized
motor configuration with Cext and Rext are connected. Operating
points are obtained at the intersection pint of load torque and
motor torque. Using MATLAB data cursor, the operating speeds
are obtained as 1452 rpm and 1450 rpm and operating torques
are obtained as 499.8 Nm and 498 Nm respectively for original
and optimized motor cases. There is only 1.8 Nm reduction in
the torque at the operating point which is very close to rated oper-
Fig. 8. Transient speed versus time (a) Original b) Optimized (75-kW motor).
ating point. Considering the important advantages accrued from
the optimized configuration during the transient period, together
with many start-stops in relatively short time in certain applica-
tions, it may worth to sacrifice a few Nm in the toque in the normal

Fig. 9a. Transient rotor currents versus time (Referred to stator side) Original motor Fig. 10. Steady state torque-speed characteristic of 75-kW motor for original and
case (75-kW motor). optimized cases (Rext and Cext not shorted out).
152 M. Akbaba / Engineering Science and Technology, an International Journal 24 (2021) 145–157

rated point to synchronous operating point (no load operation) the


drop in the current due to the effect of Rext and Cext is very small.

3.3. Advantages of the motors with optimized configuration over the


original motors when starting against static loads

Static loads are the types of loads that do not change over time,
such as hoists and lifts, and goods or materials to be transferred to
certain higher locations. In this section superiority of the motors
with optimized configuration over the original motors when start-
ing against static loads will be investigated. Investigation has been
conducted on the 75-kW motor which has a full load torque of
Fig. 11. Steady state efficiency- speed characteristic of 75-kW motor for the
489.6 Nm and average starting torque of 384 Nm with original con-
original and optimized cases (Rext and Cext not shorted out).
figuration. Starting torque is approximately 78% of the full load tor-
que. It was found that the motor with optimized configuration can
comfortably start against a static load up to 96% of the full load tor-
que, which is 18% more than the starting torque of the original
motor. This is another important advantage of the motors with
optimized configuration. On the other hand, the original motor
fails to start against static loads greater than 77% (1% less than
its starting torque due to effect of inertia) of the full load torque.
Therefore, to prove the above arguments, starting performance is
examined for these two limit cases, i.e., for starting against a static
load equal to 77% full load torque, and starting against a static load
equal to 96% of the full load torque.

3.3.1. Starting against a static load equal to 77% of the full load torque
Fig. 12a. Steady state power factor- speed characteristic of 75-kW motor for Transient torque, transient current and transient speed are cal-
original and optimized cases (Rext and Cext not shorted out). culated when starting against a static load equal to 77% full load
and are plotted versus time in Figs. 13–15 respectively.
From Fig. 13 clearly seen that when starting against a static load
equal to 77% of the full load torque the motor with optimized con-
figuration starts fast enough without endangering the windings
from heating point of view, whereas the original motor takes very
long time to complete starting. If protection system does not act in
due time it is most likely that winding of the original motor may
get burned due to excessive heat due to carrying high current in
prolonged time. This fact clearly shows superiority of the opti-
mized motors when starting against large static loads.
It can be observed from Fig. 14 that in case of optimized motor,
current settles to its steady state value much faster as compared to
the original motor. Current settling time is about 910 ms for the
optimized motor whereas it is 5991 ms for the original motor,
Fig. 12b. Steady state Current- speed characteristic of 75- kW motor for original
which means the optimized motor starts about 6.5 times faster
and optimized cases (Rext and Cext not shorted out).
than the original motor. This fact is an additional superiority of
optimized motor over the original motor.

steady state operating region. Therefore, for such operating condi-


tions keeping Cext and Rext intact for all times may be acceptable.
Figs. 11 and 12a shows the efficiency-speed and power factor-
speed characteristics of the 75-kW motor respectively, in the stable
operating region. Operating points at 1452 rpm and at 1450 rpm,
as obtained above, are marked on both figures.
Using MATLAB data cursor, from Fig. 11 we obtain 2.9% drop in
the efficiency at operating point, which is again very close to the
rated operating point. In the region from rated operating point to
synchronous operating point drop in efficiency is even less. On
the other hand, using MATLAB data cursor, from Fig. 12a we obtain
3.6% improvement in the power factor. Naturally drop in the effi-
ciency results from power losses on Rext and improvement in the
power factor is the result of the power factor correction effect of
Cext. Therefore, due to these adverse effects of Rext and Cext, the
drop in the steady state torque is minor.
Fig 12b shows the steady-state current-speed characteristics of Fig. 13. Transient torque versus time for original and optimized motor cases when
both motors. From this figure it is evident that the region between starting against a static load equal to 77% of the full load torque (75-kW motor).
M. Akbaba / Engineering Science and Technology, an International Journal 24 (2021) 145–157 153

Fig. 17a. Transient stator current versus time for original motor when starting
against a static load equal to 96% of the full load torque (75-kW motor).

Fig. 14. Transient stator currents versus time for original and optimized motor
cases when starting against a static load equal to 77% of the full load torque (75-kW
motor).

Fig. 17b. Transient stator current versus time for optimized motor when starting
against a static load equal to 96% of the full load torque (75-kW motor).

3.3.2. Starting against a static load equal to 96% of the full load torque
Fig. 16. Shows the seed-time characteristics for starting against
a static load equal to 97% of the full load torque. From this figure it
is evident that the original motor fails to start whereas the motor
with optimized configuration stars comfortably in a reasonable
time without endangering windings from heating point of view.
It can be observed from Fig. 16 that since original motor fails to
run- up and as seen from Figs. 17a and 17b it draws very high start-
Fig. 15. Transient speed versus time for original and optimized motor cases when ing current for all times. It is known that in such a situation fuse or
starting against a static load equal to 77% of the full load torque (75-kW motor).
protection equipment should interrupt the motor as otherwise
windings will get burned. On the other hand, the current for opti-
Fig. 15 confirms what is mentioned for current from the obser- mized motor settles to its steady value in about 960 ms, which is
vation of Figs. 12a and 12b. Speed settling time is 920 ms for opti- about only 1.6 times the starting time of free running (unloaded)
mized motor whereas it is 5978 ms for the original motor, which original motor, and this amount of time is quite acceptable
again means that optimized motor start about 6.5 times faster. If Fig. 18 depicts the transient torque-time characteristic for start-
thermal relay is equipped, then it may trip the original motor ing against a static torque equal to 96% of full load torque. From
before winding temperature reaches the limit temperature. this figure one can observe that in case of original motor the
induced final electromagnetic torque falls below the load torque,
which causes the motor to stall. This is due to fact that winding
copper losses increase excessively under high winding currents.
But the motor with optimized configuration runs-up without any
problem.

4. Method of remedying for high capacitor requirement in


motors with low leakage reactance

Very high capacitor value is required for motors with low leak-
age reactance, has been seen in case of first example motor of this
paper (10-kW motor). For this motor Cext is obtained as 2312 mF.
Such a high value capacitor, in high current and relatively high
Fig. 16. Transient speed versus time for original and optimized motor cases when voltage range, may not be available off the shelve. Therefore, there
starting against a static load equal to 97% of the full load torque (75-kW motor). is need for lower value capacitors, without violating the benefits of
154 M. Akbaba / Engineering Science and Technology, an International Journal 24 (2021) 145–157

Fig. 20. Transient speed versus time (10-kW motor) for both the original and
optimized motor, when Lext is present and capacitor size is limited to 600 mF.

Fig. 18. Transient torque versus time for original and optimized motor cases when Dlower ¼ ½0:5 0:63 2 2;
starting against a static load equal to 96% of the full load torque (75-kW motor).

Dupper ¼ ½4 0:69 2:2 2:128


After 7 iteration optimization process converged to following
values:
R1 ¼ 0:774X; Rr ¼ 0:668X; x1 ¼ 2:165X; and xr ¼ 2:0X
From these values we obtain:
Rext ¼ 0:525X and xs ¼ 1:815 X
With these vales transient torque-time and transient speed-
time characteristics of 10-kW motor are recalculated with the
same load torque given in Eq. (24) and results are plotted in Figs. 19
and 20 respectively.
From Fig. 19 it is clearly seen that in this case too, the transient
torque pulsations are fully eliminated. Transient torque character-
istic is much smoother than its earlier counterpart given in Fig. 2.
This is due to having more inductance in the stator circuit. Com-
Fig. 19. Transient torque versus time (10-kW motor) for original and optimized
motor cases, when Lext is present and capacitor size limited to 600 mF. parison of Fig. 2 with Fig. 19 show similar characteristics, except
that in Fig. 19 at around t = 70 ms there is a significant torque deep,
which may be attributed to a very low order torque harmonic. This
method mentioned above. For this purpose, the leakage reactance torque deep may cause motor to crawl at very low speeds, if load
of the stator winding can be increased artificially by adding a small torque exceeds the lower value of torque deep. This reduces the
inductance in series with Cext in each phase. In this case capacitor capability of the motor starting against high static loads. This is a
size can be limited to a certain value, for example to 600 mF, for disadvantage of this scheme when capacitor limited to a certain
any motor requiring capacitor size of more than 600 mF. With fixed value and Lext is inserted.
size capacitor, required value of external inductance, Lext, can be Comparison of the transient speed characteristic given in Fig. 20
obtained as follows: with its counterpart given in Fig. 4 show that the two figures are
The total leakage reactance of the stator will appear as xs + Xext, almost identical, except that motor with limited capacitor and
where Xext = x*Lext. Limiting capacitor size to 600 mF and using Eq. added Lext is slightly slower.
(1):
600 ¼ 1000000=ð0:7  w  ðxs þ X ext ÞÞ ð26Þ 5. Impact of deviations of Cext and Rext from their optimum
values on the motor transient performance
From which one obtains,
X ext ¼ 1000000=ð0:7  600  wÞ  xs ð27Þ This topic involves involve stability analysis that would also
involve the eigenvalue analysis, which is out of scope of this paper.
Applying this to the first example motor (10-kW motor) one But results of few observed cases will be summarized here without
obtains: going into details.
Xext ¼ 1000000=ð0:7  600  2  p  50Þ  1:911 ¼ 5:668 X and Case1: Keeping Rext at its optimum value but reducing the value
of Cext below approximately 95% of its optimum value:
Lext ¼ 18 mHxc ¼ 0:7  ð1:911 þ 5:668Þ ¼ 5:318X: In this case real part of a pair of eigen values becomes positive
and the transient response of currents and hence of the torque
From this point we can moved to optimization process. In this oscillates with growing amplitude, leading to an unstable system.
option starting torque and starting current are less. Therefore, Case 2: Keeping Rext at its optimum value but increasing the
low values need to be used for constraint functions. Selecting fol- value of Cext above approximately 110% of its optimum value and
lowing values: more:
T sn ¼ 35:5 Nm; Isn ¼ 58 A; T on ¼ 123 Nm In this case system remains stable, amplitude of the transient
current reduces as the capacitor value increases. But contrarily cur-
M. Akbaba / Engineering Science and Technology, an International Journal 24 (2021) 145–157 155

Fig. 22. Transient speed-time characteristic of 10 kW motor when Cext is 8% more


than its optimum value and Rext is 20% less than its optimum value.

Fig. 21. Transient toque-time characteristic of 10 kW motor when Cext is 8% more


than its optimum value and Rext is 20% less than its optimum value.

rent settling time increases. Also, high capacitor value must be


avoided due to the cost and availability.
Case3: Keeping Cext at its optimum value but reducing the value
of Rext below approximately 70% of its optimum value:
In this case system becomes unstable due to again some eigen-
values with positive real part. System recovers itself after shorting
out Cext and Rext, but recovery takes long time and motor draws
very high current until it recovers.
Case4: Keeping Cext at its optimum value but increasing the
Fig. 23. Voltage across Cext versus time. (a) 10 kW, 440 V motor (b) 75 kW, 3300 V
value of Rext more than 12% above its optimum value: moor.
In this case system remains stable. Increasing the value of Rext
decreases the amplitude of transient current, but on the contrary
acceleration time is increased causing windings to remain under
high currents for longer period. In this case also, as the value of Rext
increased more and more the transient torque pulsations occurring
after shorting out Cext and Rext increases excessively with negative
torque peaks.
Therefore, to avoid instability and preserve good performance,
Cext can be selected approximately between 105% and 110% of its
optimum and Rext can be selected approximately between 80%
and 100% of its optimum value.
Figs. 21 and 22 shows the torque-time and speed-time charac-
teristic of 10 kW motor for Cext = 1.08 times its optimum value,
which means 13% away from the instability limit, Rext = 0.8 times
its optimum value, which means 10% away from the instability
limit. Comparison of Fig. 21 with Fig. 2 shows that transient
torque-time remains almost same. Comparison of Fig. 22 with Fig. 24. Voltage across the stator winding of 10 kW motor.

Fig. 4 shows that the optimized motor again runs up much faster
than the original motor and the two Figs. Are almost identical.
time, their power ratings can be rounded to 0.4 kW and 1.5 kW
Therefore, there are ample tolerance in optimum values of Cext
respectively.
and Rext to avoid instability and preserve good performance.
Fig. 24 shows the phase voltage (voltage across the stator wind-
ing) of 10 kW motor. The red dashed line shows the instant of short
circuiting Rext and Cext. The peak value of the rated phase voltage of
6. Ratings of Cext and Rext
the motor is
p p p p
2*VL / 3= 2*440/ 3 = 359 V. Using MATLAB data cursor, the
Fig. 23a and b shows the transient voltage across the Cext for
_ can be seen from Fig. 23a that the maximum volt- peak value of the voltage shown in Fig. 24, after shorting circuiting
both motors. It
Rext and Cext, is obtained as 359 V, which matches exactly with the
age, Vmax, across Cext of 10 kW, 440 V motor is about 150 V. Simi-
rated voltage of the motor. During the initial phase of transient
larly, it can be seen from Fig. 23b that the maximum voltage,
period Cext causes some rise in the voltage across the stator wind-
Vmax, across Cext of 75 kW, 3300 V motor is about 1200 V.
ing and by the time as the motor speeds up it drops to a value very
Since the external resistances are in series with the stator wind-
close to the rated voltage, even before shorting out Rext and Cext.
ings, their current ratings will the rated currents of the moors. Rext
for 10 kW motor is obtained as 2 O. Rated current of this motor is
14.7 A. Therefore, the power rating of this external resistor will be 7. FFT of the stator and rotor starting currents
2*(14.7)^2 = 432 W. In case of 75 kW motor Rext is obtained as
6.6 O. Rated current of this motor is 15.5 A. Therefore, the power It can be seen from Fig. 25a that the stator current of original
rating of this external resistor will be 6.6*(15.5)^2 = 1585 W. Since motor besides fundamental frequency component, it has also a
the external resistors will be staying in the circuit for very short zero-order harmonic (average value) and some negligible ampli-
156 M. Akbaba / Engineering Science and Technology, an International Journal 24 (2021) 145–157

- The pulsating torque components fully eliminated, and a unidi-


rectional transient torque is obtained, which almost follows the
average steady state torque.
- The envelope of the transient (inrush) current became perfectly
symmetrical with respect to time axis, indicating that the low
frequency components of the transient currents are eliminated
and hence proving that these low frequency decaying current
components are responsible for the large torque pulsations.
- It has been shown that motors with optimized configuration
have far superior capability in starting against hard type loads
such as static loads.
- A method of remedying is proposed for large capacitor require-
ments in motors with low leakage reactance.
- It is pointed out that with optimum value of Rext, if Cext is
reduced below approximately 95% of its optimum value, the
motor becomes unstable and amplitudes of torque and currents
are increases continuously.
- With optimum value of Rext, if Cext increased above 110% of its
optimum value, amplitude of the inrush current reduces but
Fig. 25. FFT of the stator and rotor current for both original and motor cases (10 kW
motor) (a) FFT of the of the stator current of original motor (b) FFT of the of the acceleration time increases. This may cause more temperature
stator current of optimized motor (c) FFT of the of the rotor current of original rise in the windings and eventually windings may get damaged.
motor (d) FFT of the of the rotor current of optimized motor. Also, high values of capacitor are undesirable due to cost and
availability.
- With optimum value of Cext, if Rext reduced below approximately
tude sub-harmonics. This average value is resulting from the fact
70% of its optimum value, motor becomes unstable and recovers
that this current is not symmetrical with respect to time axis as
after shorting out Rext and Cext. But recovery time takes log, and
mentioned earlier. Fig. 25b reveals that the stator current of the
motor draws high inrush current during this time. Depending
optimized motor has no average value as it is almost symmetrical
on the type of load torque or the level of inertia on the shaft,
with respect to time axis as mentioned earlier. Besides fundamen-
due to extra temperature rise, windings or winding insulation
tal frequency component it has some negligible amplitude sub-
may be damaged.
harmonics. In case of rotor currents, it is known that when starting
from rest frequency of the rotor currents of an induction motor
It is shown that it is not compulsory to use exact optimum val-
drops from fundamental frequency to a few Hz as the motor speeds
ues of Cext and Rext. To avoid instability and preserve good perfor-
up (f2 = s*fn, f2 is frequency of the rotor currents, fn is the funda-
mance, Cext can be selected approximately between 105% and
mental frequency, s is the p.u. slip). Therefore, a complex FFT is
110% of its optimum and Rext can be selected approximately
expected for the rotor currents with full of sub-harmonics, as
between 80% and 100% of its optimum value.
shown in Fig. 25c and d. Again, as shown in Fig. 25c the rotor cur-
A further advantage of the proposed method is its simplicity as
rent of original motor contains a zero-order component (average
compared to other methods available in the associated literature.
value) as it is not symmetrical with respect to the time axis.
Declaration of Competing Interest
8. Conclusions
The authors declare that they have no known competing finan-
In this paper a novel simple method is proposed for elimination cial interests or personal relationships that could have appeared
of transient torque pulsations generated when DOL starting. It is to influence the work reported in this paper.
proposed that the root cause of these torque pulsations is the inter-
action between the transient low frequency components of the sta-
Appendix
tor currents with the fundamental rotor frequency rotor currents
and the interaction between the transient low frequency compo-
A proposed time relay triggering circuit for shorting out Rext and
nents of the rotor currents with the fundamental frequency stator
Cext (Fig. A1) 30 V DC should be obtained from a regulator that is
currents. It is also proposed that if the low frequency components
of the stator currents can be eliminated, then due to the interaction
between stator and rotor, the low frequency components of the
rotor currents and hence the transient pulsating torques will be
eliminated. By using the proposed optimized capacitor-resistor
pair, it has been observed that envelops of both the stator and rotor
currents have become completely symmetrical with respect to
time axis indicating that the low frequency components that dis-
tort the symmetry of currents have been eliminated. As a result
of this the pulsating torques are fully eliminated, which confirms
the correctness of the proposals made in this paper. Besides elim-
ination of the pulsating torques, also significantly shorter run-up
time is achieved, which in turn shortens the time duration of high
inrush currents, and this will result in reduced thermal stress on
the windings, extended insulation life and less stress on the supply
utilities. The proposed method has been applied to two different
motors and as a result following are observed: Fig. A1. Schematic of relay triggering circuit.
M. Akbaba / Engineering Science and Technology, an International Journal 24 (2021) 145–157 157

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