Prof. S.K.

Saha

Lecture 4 June 01, 2009

Announcement

DC & AC Motors • Outlines of the slides in the 1-

1-3 lectures on
May 15, 18, 21, 2009, respectively, are now
available from

Prof. S.K. Saha http://web.iitd.ac.in/~saha/ethiopia

http://web.iitd.ac.in/~saha/ethiopia/01lec.pdf
/01lec.pdf
Dept. of Mech. Eng.
IIT Delhi /02lec.pdf
/03lec.pdf
• Next class: June 11, 2009

Review of Lecture 3
Questions from Lecture 3?
• Pneumatic actuator
– Components Æ Advantages/disadvantages
• Rotary hydraulic actuator?
Æ Spool valve & Actuator figures
– Rack and Pinion type
• Hydraulic actuator – Helical g
gear types
yp
– Advantages/disadvantages Æ Applications
• Amplifier, e.g., hydraulic actuator
• Electric motors – Say, gear ratios for above actuators
– Advantages/disadvantages
• Operating pressures for Pneumatic/Hydraulic
– Stepper motors: Variable reluctance Æ
actuators?
Permanent magnet Æ Hybrid

Outline DC Motors
• DC motors
– Principle
• Direct Current: Used in toys etc.
– Permanent Magnet (PM) • Electrically driven robots us DC
– Brushless n PM – Introduced in 1974 by ABB

• AC motors
t – Powerful versions available
– Control is simple
– Induction
– Batteries are rarely used
– Synchronous
– AC supply is rectified to DC
• Selection of motors
– Sample calculation

DC & AC Motors 1
Prof. S.K. Saha

Principle of a DC Motor Features of a DC Motor

• High voltage in stator coils Æ Fast speed
• Magnetic Field Æ Stator
(simple speed control)
– Field coils wound on the stators
– Permanent magnet
• Varying current in armature Æ Controls
torque
q
• Conductor (Armature) Æ Rotor
• Reversing polarity Æ Turns opposite
– Current via brushes + commutators
• Larger robots: Field control DC motor
• Maximum torque for σ = 90o
– Current in field coils Æ Controls torque
– High power@high speed + High power/wt.

Specification & Characteristic More Characteristics

Technical Specifications of DC Motors

Brand Parvalux
Manufacturer Part No. PM2 160W511109
Type Industrial DC Electric Motors
Shaft Size (S,M,L) M
Speed (rpm) 4000 rpm
Power Rating (W) 160 W
Voltage Rating (Vdc) 50 V(dc)
Input Current 3.8 A
Height × Width × Length 78 mm ×140 mm × 165 mm

More Characteristics (contd.) Permanent Magnet (PM) Motor

• Two configurations
– Cylindrical [Common in industrial robots]
– Disk

• No field coils
• Field is by permanent magnets (PM)
• Some PM has coils for recharge
• Torque ∝ Armature current [Const. flux]

DC & AC Motors 2
Prof. S.K. Saha

Advantages of PM DC Motors Brushless PM DC Motor

• No power supplies for field coils • Problem with DC motors

– Commuter and brushes Æ Periodical reversal
• Reliability is high
of current through each armature coil
• No power
po e loss d
due
e to field ssupply
ppl – Brushes + Commutators Æ Sliding contact
Æ Sparks Æ Wear Æ Change brushes +
• Improved Efficiency + Cooling Resurface commuators

• Solution: Brushless motors

– Sequence of stator coils
– PM rotor

Principles of Brushless PM Advantages of Brushless PM

• Reverse principle than convention DC
• Current carrying conductor (stator)
experience a force
• Magnet (rotor) will experience a reaction
(Newton’s 3rd law)
• Better heat dissipation
• Reduced rotor inertia
• Weigh less Æ Less expensive + Durable
• Smaller for comparable power

• Current to stator coils is electronically • Absence of brushes Æ Reduced

switched by transistors (Expensive) maintenance cost

• Switching is controlled by rotor position Æ • Electric robots Æ Hazardous areas with

Magnet (rotor) rotates same direction flammable atmospheres (Spray painting)

Let’s take a break! AC Motors

• Alternating Current: Domestic supply

• Questions??
• 50 Hz; 220 V (India)
• Doubts?? • 60 Hz; 110 V (USA)
• ?? (Ethiopia)
• Difficult to control speed Æ Not suitable for
robots

DC & AC Motors 3
Prof. S.K. Saha

Specification & Characteristic

Principle of an AC Motor
Technical Specifications of AC Motor
Brand ABB
• External electromagnets (EM) around a Manufacturer Part No. 1676687
central rotor Type Industrial 1-, 3-Phase Electric Motors
Supply Voltage 220 – 240 Vac 50 Hz
• AC supply to EM Æ Polarity change Output Power 180 W
performs the task of mech. Switching Input Current 0.783 A
Shaft Diameter 14 mm
• Magnetic field of coils will appear to rotate
Shaft Length 30 mm
Æ Induces current in rotor (induction) or
Speed 1370 rpm
makes rotor to rotate (synchronous) Rated Torque 1.3 Nm
Torque Starting 1.3 Nm
Height × Length × Width 150 mm × 213 mm × 120 mm

Features of an AC Motor Classification of an AC Motor

• Higher the frequency Æ Fast speed • Single-
Single-phase [Low-
[Low-power requirements]
– Induction
• Varying frequency to a number of robot
axes has been impractical till recently – Synchronous

• Electromagnetism
Elect omagnetism is used
sed for
fo • Poly-
Poly-phase (typically 3-
3-phase) [High-
[High-
regenerative braking (also for DC) Æ power requirements]
Reduces deceleration time and overrun – Induction

• Motor speed cannot be predicted (same – Synchronous

for DC) Æ Extra arrangements required • Induction motors are cheaper Æ Widely
used

Single--phase AC Induction Motor

Single Single--phase AC Induction Motor
Single
• Squirrel cage rotor (Cu or Al bars into • Auxiliary starting winding
slot in the end) Æ Circuit is complete
• Motor speed ≅ Frequency
• Stator has windings Æ Alternating
current Æ Alternative magnetic field • 50 rev/sec ≅ 50 Hz

• EM forces induces current in the rotor • No exact match

conductors • Slip: 1 to 3%
• When rotor is stationary no resultant
torque (not self-
self-starting)

DC & AC Motors 4
Prof. S.K. Saha

Three--phase AC Induction Motor

Three
• Three windings in stator at 120o apart
• Each winding is connected to one of the
three lines of the supply
• Rotation of field is much smoother
• Self-
Self-starting
• Direction reversal Å Interchange any of
two line connections
AC Synchronous Motor
• Stator is same as induction motor
• Rotor is permanent magnet
• Since stator magnetic field rotates Æ
Rotor rotates
• Speed is same as supply frequency
• Used for precise speed requirement
• Not self
self--starting

AC vs. DC Motors
Questions/Doubts?
• Cheaper, rugged, reliable, maintenance
free
• Speed control is more complex
• Speed-
Speed-controlled DC drive (stator
voltage) is cheaper than speed
speed--controlled
AC drive (V
(Variable Frequency Drive)
• Price of VFD is steadily reducing

Motor Selection Motor Selection (contd.)

• For robot applications • Hydraulics can generate more power in
– Positioning accuracy, reliability, speed of compact volume
operation, cost, etc.
• Capable of high torque + Rapid
• Electric is clean + Capable of high operations
precision
• Power for electro
electro--hydraulic valve is small
• Electronics is cheap but more heat but expensive

• Pneumatics are not for high precision for • All power can be from one powerful
continuous path hydraulic pump located at distance

DC & AC Motors 5
Prof. S.K. Saha

Thumb Rule for Motor Selection Simple Calculation

• Rapid movement with high torques (>
3.5 kW): Hydraulic actuator
• < 1.5 kW (no fire hazard): Electric
motors
2 m robot arm to lift 25 kg mass at 10 rpm
• Force = 25 x 9.81 = 245.25 N
• Torque = 245.25 x 2 = 490.5 Nm

• 1-5 kW: Availability or cost will 2π x 10/60 = 1.047 rad/sec

• Speed = 2π rad/sec
determine the choice • Power = Torque x Speed = 0.513 kW
• Simple but sufficient for approximation

Practical Application Accelerations & Torques

• Ang. accn. during t1:
Trapezoidal
Trajectory • Ang. accn. during t2: Zero (Const. Vel.)

• Ang. accn during t3:

Ang accn.

• Torque during t1: T1 =

• Torque during t2: T2 =

Subscript l for load; m for motor;
• Torque during t3: T3 =
G = ωl/ωm (< 1); η: Motor + Gear box efficiency

RMS Value Motor Performance

DC & AC Motors 6
Prof. S.K. Saha

Summary
Final Selection
• DC motors
• Peak speed and peak torque – Permanent Magnet (PM)
requirements , where TPeak is max of – Brushless PM
(magnitudes) T1, T2, and T3 – Their construction + advantages,
g , etc.
• Use individual torque and RMS values + • AC motors
Performance curves provided by the
– Single-
Single-phase: Induction vs. Synchronous
manufacturer.
– Three-
Three-phase
• Check heat generation + natural
frequency of the drive. • Selection of motors in practical applications

Thank You
saha@mech.iitd.ac.in
sahaiitd@gmail.com

http://web.iitd.ac.in/~saha

DC & AC Motors 7