4/24/2014 Classification of Electric Motors - Part Two ~ Electrical Knowhow

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Classification of Electric Motors - Part Two
Bosch e-mobility
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In the previous topic” Classification of Electric Motors “ , I explained the different types of the Brushed
Bosch is helping to
expand e-mobility in DC motor (BDC) which as in the following diagram:
Singapore. Learn (3) Online
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Electrical Load Estimation Course

An Introduction to Heating,
Ventilation and Air Conditioning
(HVAC) Systems Electrical

An Introduction to Lighting Design

Today, I will explain the Brushless DC motor (BLDC) and the AC induction motors as follows.
An Introduction to Electrical Motor
Basics
You can review the following related topics for review and good following.
Electrical Motors Basic Components
Dwelling U
ELECTRICAL BOOKS

Electrical Books & Design Guides 2- Brushless DC motors

Code of Practice for Energy

Efficiency of Electrical Installations

GE Lighti
Guide for electrical design engineers

Maintenance Manager's Guide to

Power Quality

Power Quality & Utilization Guide

Selective
Engine Application and Installation
Guide

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4/24/2014 Classification of Electric Motors - Part Two ~ Electrical Knowhow
Liquid Cooled Genset Application
Manual

MV Design & Technical Guide

Brushless DC motors

MV Application catalogue

In brushes DC motors, the mechanical commutator and associated brushes are problematical for a
Electrical and Traffic Engineering
Manual number of reasons as follows:

1. Brush wear occurs, and it increases dramatically in low-pressure environment.

2. Sparks from the brushes may cause explosion if the environment contains explosive materials.
ELECTRICAL SOFTWARE 3. RF noise from the brushes may interfere with nearby TV sets, or electronic devices, etc.

Electrical Software Programs

Brushless Direct Current (BLDC) motors are one of the motor types rapidly gaining popularity. BLDC
motors are used in industries such as Appliances, Automotive, Aerospace, Consumer, Medical, Industrial
Riesgo Software For Performing The Automation Equipment and Instrumentation.
Risk Assessment Study
As the name implies, BLDC motors do not use brushes for commutation; instead, they are electronically
StrikeRisk V5.0 for performing the commutated.
Risk Assessment Study

BLDC motors have many advantages over brushed DC motors and induction motors, a few of these are:
RAPAL Software for performing the
Risk Assessment Study
1. Better speed versus torque characteristics.
2. High dynamic response.
Erico-GEM Software Program for
Earthing Calculations 3. High efficiency.
4. Long operating life.
Visual Professional Edition Software
(6) - Print the Results by Using the 5. Noiseless operation.
Print Editor 6. Higher speed ranges.

Visual Professional Edition Software

(5) - Inserting Calculation Planes
In addition, the ratio of torque delivered to the size of the motor is higher, making it useful in
applications where space and weight are critical factors.
Visual Professional Edition Software
(4) - Inserting Luminaires

Visual Professional Edition Software Construction

(3) - Starting Steps

Visual Professional Edition Software BLDC motors are a type of synchronous motor. This means the magnetic field generated by the stator
(2) - Checking the Default Settings and the magnetic field generated by the rotor rotates at the same frequency.

Visual Professional Edition Software

(1) – Understanding the Program BLDC motors come in single-phase, 2-phase and 3-phase configurations. Corresponding to its type, the
Interface stator has the same number of windings. Out of these, 3-phase motors are the most popular and widely
used.
CalcuLux Software(1) - Main Window
and Bar Menus

CalcuLux Software(2) - Checking (6) Differe

The Default Settings 1- Stator

CalcuLux Software(3) - Example for

Ligthing design of an Office

Conducto
CalcuLux Software - Part Four

Conducto
CalcuLux Software - Part Five

CalcuLux Software - Part Six

CalcuLux Software-Part Seven

ID-Spec Software Stator of a BLDC Motor

DIALux Lighting Software Program- The stator of a BLDC motor consists of stacked steel laminations with windings placed in the slots that
Blue Version
are axially cut along the inner periphery.

DIALux Lighting Software Program -

Red Version Most BLDC motors have three stator windings connected in star fashion. Each of these windings is
constructed with numerous coils interconnected to form a winding. One or more coils are placed in the
DIALux - Indoor Lighting Calculations slots and they are interconnected to make a winding. Each of these windings is distributed over the

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4/24/2014 Classification of Electric Motors - Part Two ~ Electrical Knowhow
Menu Options stator periphery to form an even numbers of poles.

Depending upon the control power supply capability, the motor with the correct voltage rating of the
stator can be chosen. Forty-eight volts, or less voltage rated motors are used in automotive, robotics,
HOW TO
small arm movements and so on. Motors with 100 volts, or higher ratings, are used in appliances,
Perform Need for Lightning automation and in industrial applications.
Protection Calculations by (4)
Different Methods
2- Rotor
Perform Grounding Calculations by
(6) Different Methods

Size Earthing Conductors Using NEC

Tables

Size Earthing Conductors Using BS

7671

Select the Best Earthing System

Calculate Voltage Drop as per U.S.

and European Methods

Use NEC Annex B Tables in

Conductor Ampacity Calculations
Rotor of a BLDC Motor
Perform Conductor Ampacity
Calculations Using NEC under
Engineering Supervision Method

Perform Conductor Ampacity

The rotor is made of permanent magnet and can vary from two to eight pole pairs with alternate North
Calculations Using NEC Section
310.15 Tables (N) and South (S) poles.

Size Overcurrent Protection Devices

Calculate the Total Demand

Electrical Load for Non-Dwelling
Buildings

Calculate Electrical Demand Load for

Dwelling Buildings as per NEC
Optional Method

Calculate Electrical Demand Load for

Dwelling Buildings as per NEC
Standard Method

Calculate general-use receptacles

load in a dwelling unit

BLDC Rotor Magnet Positions

Calculate Maximum Permissible
Number Of Lighting Fixtures On A
General Lighting Branch Circuit
Based on the required magnetic field density in the rotor, the proper magnetic material is chosen to
make the rotor. Ferrite magnets are traditionally used to make permanent magnets.
Calculate Track Lighting Load

Calculate The Minimum Number Of

General Lighting Branch Circuits For
Any Building 3- Hall Sensors

Calculate General Lighting Branch

Circuit Load For Any Building

Calculate Sign And Outline Branch

Circuits Load
Checklists
Calculate Show Window Lighting
Load
Checklist
Calculate The Minimum number of
receptacle branch circuits for bank or
office buildings

Calculate the Maximum allowable

number of receptacles on a branch
circuit in a dwelling unit

Estimate Preliminary Load By Using

Area Method
BLDC Hall Sensors
Estimate Preliminary Load By Using
The Building Area Method

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4/24/2014 Classification of Electric Motors - Part Two ~ Electrical Knowhow
Estimate Preliminary Load By Using Unlike a brushed DC motor, the commutation of a BLDC motor is controlled electronically. To
Space-By-Space Method (Functional rotate the BLDC motor, the stator windings should be energized in a sequence. It is
Area Method)
important to know the rotor position in order to understand which winding will be energized
Design Outdoor Lighting By Using following the energizing sequence. Rotor position is sensed using Hall Effect sensors
Isolux Diagram Method embedded into the stator. Course EE

Most BLDC motors have three Hall sensors embedded into the stator on the non-driving end
Design Outdoor Lighting By Using
of the motor. Course EE
The Beam-Lumen Method As Per IES
Whenever the rotor magnetic poles pass near the Hall sensors, they give a high or low signal,
Design Outdoor Lighting By Using indicating the N or S pole is passing near the sensors. Based on the combination of these
The Beam-Lumen Method As Per Course EE
CIE three Hall sensor signals, the exact sequence of commutation can be determined.
Based on the physical position of the Hall sensors, there are two versions of output. The Hall
Design Outdoor Lighting By Using sensors may be at 60° or 120° phase shift to each other. Based on this, the motor
Point-By-Point Method
manufacturer defines the commutation sequence, which should be followed when controlling
the motor.
Design Interior Lighting By Using By
Using Quick Estimate Charts Note: The Hall sensors require a power supply. The voltage may range from 4 volts to 24 volts. Required
current can range from 5 to 15 mAmps.
Design Interior Lighting By Using
Course Lig
Watt Per Square Feet Method

Theory of Operation
Design Interior Lighting By Using
Point By Point Method

Design Interior Lighting By Using The Each commutation sequence has one of the windings energized to positive power (current
Zonal Cavity (Lumen) Method enters into the winding), the second winding is negative (current exits the winding) and the
third is in a non-energized condition.
Build Preliminary Single Line
Diagram Like Professionals Torque is produced because of the interaction between the magnetic field generated by the
stator coils and the permanent magnets of the rotor.
Make A Preliminary Design Like In order to keep the motor running, the magnetic field produced by the windings should shift
Professionals Course EP
position, as the rotor moves to catch up with the stator field. What is known as “Six-Step
Commutation” defines the sequence of energizing the windings.
Write Electrical Design Criteria Like
Professionals In six-step commutation, only two out of the three Brushless DC Motor windings are used at a
time. Steps are equivalent to 60 electrical degrees, so six steps make a full, 360 degree
Specify The Required Type Of rotation. One full 360 degree loop is able to control the current, due to the fact that there is
General-Use Receptacles For Each
Area In A Dwelling Unit
only one current path. Six-step commutation is typically useful in applications requiring high
speed and commutation frequencies. A six-step Brushless DC Motor usually has lower torque
Distribute General-Use Receptacle efficiency than a sine-wave commutated motor.
Loads In A Dwelling Unit

Select Receptacle Rating For A

Branch Circuit In A Dwelling Unit Typical BLDC Motor Applications

We can categorize the type of BLDC motor control into three major types:
CONTACT FORM

Name 1. Constant load.

2. Varying loads.
3. Positioning applications.
Email *

Message * 1- Applications with Constant Loads:

These are the types of applications where a variable speed is more important than keeping the accuracy
of the speed at a set speed. In addition, the acceleration and deceleration rates are not dynamically
changing. In these types of applications, the load is directly coupled to the motor shaft.
For example, fans, pumps and blowers come under these types of applications. These applications
demand low-cost controllers, mostly operating in open-loop.
Send

2- Applications with Varying Loads:

These are the types of applications where the load on the motor varies over a speed range. These
applications may demand high-speed control accuracy and good dynamic responses.
For example,

In home appliances: washers, dryers and compressors.

In automotive, fuel pump control, electronic steering control, engine control and electric
vehicle control.
In aerospace, there are a number of applications, like centrifuges, pumps, robotic arm
controls, gyroscope controls and so on.
These applications may use speed feedback devices and may run in semi-closed loop or in total closed
loop.

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4/24/2014 Classification of Electric Motors - Part Two ~ Electrical Knowhow

3- Positioning Applications:
Most of the industrial and automation types of application come under this category. The applications in
this category have some kind of power transmission, which could be mechanical gears or timer belts, or
a simple belt driven system. In these applications, the dynamic response of speed and torque are
important. Also, these applications may have frequent reversal of rotation direction.
These systems mostly operate in closed loop.

Finally, a comparison between Brushed DC motor (BDC) and Brushless DC motor (BLDC) is as shown
in the below image.

Second: AC Motors

Alternating current (AC) motors use an electrical current, which reverses its direction at regular
intervals.

The main advantage of DC motors over AC motors is that speed is more difficult to control for AC
motors. To compensate for this, AC motors can be equipped with variable frequency drives but the
improved speed control comes together with a reduced power quality.

Types of AC Motors:

AC motors in common use today may be divided into two broad categories:

1. Induction (asynchronous) motors.

2. Synchronous motors.
3. Linear Motors.

These two types of motors differ in how the rotor field excitation is supplied as follows:

For induction motors, there is no externally-applied rotor excitation, and current is instead induced into
the rotor windings due to the rotating stator magnetic field.

For synchronous motors, a field excitation is applied to the rotor windings. This difference in field
excitation leads to differences in motor characteristics, which leads in turn to different protection and
control requirements for each motor type.

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4/24/2014 Classification of Electric Motors - Part Two ~ Electrical Knowhow
1- Induction motor

Induction motors are the most common motors used for various equipments in industry.

Induction Motor: So called because voltage is induced in the rotor (thus no need for brushes), but for
this to happen, the rotate than rotor must at a lower speed the magnetic field to allow for the
existence of an induced voltage.

Therefore a new term is needed to describe the induction motor which is the slip.

The slip:

A driving torque can only exist if there is an induced current in the shading ring. It is determined by the
current in the ring and can only exist if there is a flux variation in the ring. Therefore, there must be a
difference in speed in the shading ring and the rotating field. This is why an electric motor operating to
the principle described above is called an “asynchronous motor”.

The difference between the synchronous speed (Ns) and the shading ring speed (N) is called “slip” (s)
and is expressed as a percentage of the synchronous speed.

S= (Nsyn – Nm)/ Nsyn

Where s is the slip. Slip is one of the most important variables in the control and operation of induction
machines.

s = 0 : if the rotor runs at synchronous speed.

s = 1 : if the rotor is stationary.

s is –ve : if the rotor runs at a speed above the synchronous speed.

s is +ve : if the rotor runs at a speed below the synchronous speed.

Advantages:

1. Simple design, rugged, low-price, easy maintenance.

2. Wide range of power ratings: fractional horsepower to 10 MW.
3. Run essentially as constant speed from no-load to full load.
4. Its speed depends on the frequency of the power source.
5. Most popular motor today in the low and medium horsepower range.
6. Very robust in construction.
7. Have replaced DC Motors in areas where traditional DC Motors cannot be used such as mining or
explosive environments Of two types depending on motor construction; Squirrel Cage or Slip Ring.

Disadvantages:

1. Not easy to have variable speed control.

2. Requires a variable-frequency power-electronic drive for optimal speed control.
3. Most of them run with a lagging power factor.

Principle of operation:

The stator is usually connected to the grid and, thus, the stator is magnetized.
Stator magnetic field cuts the rotor windings and produces an induced voltage in the rotor
windings.
Due to the fact that the rotor windings are short circuited, for both squirrel cage and wound-
rotor, and induced current flows in the rotor windings.
The rotor current produces another magnetic field.
A torque is produced as a result of the interaction of those two magnetic fields.

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4/24/2014 Classification of Electric Motors - Part Two ~ Electrical Knowhow
Construction:

An induction motor has two main parts

1- Stator

Induction Motor Stator

This is the immobile part of the motor. A body in cast iron or a light alloy houses a ring of thin silicon
steel plates (around 0.5mm thick). The plates are insulated from each other by oxidation or an
insulating varnish. The “lamination” of the magnetic circuit reduces losses by hysteresis and eddy
currents.

The plates have notches for the stator windings that will produce the rotating field to fit into (three
windings for a 3-phase motor). Each winding is made up of several coils. The way the coils are joined
together determines the number of pairs of poles on the motor and hence the speed of rotation.

2- Rotor

This is the mobile part of the motor. Like the magnetic circuit of the stator, it consists of stacked
plates insulated from each other and forming a cylinder keyed to the motor shaft.

Types of Induction Motors

Types of Induction Motors

Induction motors are classified according to the Rotor Type as follows:

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4/24/2014 Classification of Electric Motors - Part Two ~ Electrical Knowhow
A- Squirrel-Cage Rotor:

Squirrel-Cage Rotor

It consists of thick conducting bars embedded in parallel slots. These bars are short-circuited at both
ends by means of short-circuiting rings.

B- Wound Rotor:

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4/24/2014 Classification of Electric Motors - Part Two ~ Electrical Knowhow

Wound Rotor

It has a three-phase, double-layer, distributed winding. It is wound for as many poles as the stator. The
three phases are wired internally and the other ends are connected to slip-rings mounted on a shaft with
brushes resting on them.

Each of the two types of Induction motors above can be classified into two main groups as follows:

I- Single-phase induction motors:

These only have one stator winding, operate with a single-phase power supply, have a squirrel cage
rotor, and require a device to get the motor started. This is by far the most common type of motor
used in household appliances, such as fans, washing machines and clothes dryers, and for applications for
up to 3 to 4 horsepower.

Single phase induction motors come also with wound rotor which has excellent starting and accelerating
characteristics, and they are ideal for Value Operators, Farm Motor Applications, Hoists, Floor
Maintenance Machines, Air Compressors, Laundry Equipment and Mining Equipment.

II- Three-phase induction motors:

The rotating magnetic field is produced by the balanced three-phase supply. These motors have high
power capabilities, can have squirrel cage or wound rotors (although 90% have a squirrel cage rotor),
and are self-starting. It is estimated that about 70% of motors in industry are of this type, are used in,
for example, pumps, compressors, conveyor belts, heavy-duty electrical networks, and grinders. They
are available in 1/3 to hundreds of horsepower ratings.

Now, let us see the first classification of induction motors based on the above types:

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4/24/2014 Classification of Electric Motors - Part Two ~ Electrical Knowhow
1- Single Phase, Squirrel Cage, Induction Motor:

This category have many types as shown in the below image.

A- Shaded-Pole Induction Motors

Construction and operation principle:

Shaded-Pole Induction Motors

Shaded-pole motors have only one main winding and no start winding. Starting is by means of a design
that rings a continuous copper loop around a small portion of each of the motor poles. This “shades”
that portion of the pole, causing the magnetic field in the shaded area to lag behind the field in the
unshaded area. The reaction of the two fields gets the shaft rotating.

Advantages:

1. Because the shaded-pole motor lacks a start winding, starting switch or capacitor, it is electrically
simple and inexpensive.
2. The speed can be controlled merely by varying voltage, or through a multi-tap winding.
3. Mechanically, the shaded-pole motor construction allows high-volume production.
4. These are usually considered as “disposable” motors, meaning they are much cheaper to replace
than to repair.

Disadvantages:

1. It’s low starting torque is typically 25% to 75% of the rated torque.
2. It is a high slip motor with a running speed 7% to 10% below the synchronous speed.
3. Generally, efficiency of this motor type is very low (below 20%).

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4/24/2014 Classification of Electric Motors - Part Two ~ Electrical Knowhow

Applications:
The low initial cost suits the shaded-pole motors to low horsepower or light duty applications. Perhaps
their largest use is in multi-speed fans for household use. But the low torque, low efficiency and less
sturdy mechanical features make shaded-pole motors impractical for most industrial or commercial use,
where higher cycle rates or continuous duty are the norm.

In the next Topic, I will continue explaining other types of Single Phase, Squirrel Cage Induction
Motor. So, please keep following.

Note: these topics about Motors in this course EE-1: Beginner's electrical design course is an introduction
only for beginners to know general basic information about Motors and Pumps as a type of Power loads.
But in other levels of our electrical design courses, we will show and explain in detail the Motor and
Pumps Loads calculations.

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