Selection of the crane duty Motor

The operating condition such as the duty cycle, startup, temperature and operation environment are
vital consideration in the motor efficiency and reliability.

Definitions Of Technical Terms

Some technical terms used frequently in intermittent duty drives and hoisting are defined as
follows:

1. Duty
Operation of the motor at the declared load(s) including starting, electric braking, no load and
rest and de-energised periods to which the motor is subjected, including their durations and
sequence in time.

2. Cyclic duration factor

The ratio of the period of energisation/loading, including starting and electric braking, to the
duration of the one complete duty cycle expressed as percentage.

Generally the values for the CDF used are 25%, 40%, 60% and 100%.

3. Starting
The process of energizing a motor to bring it up to rated speed from rest.

4. Jogging or inching

This is an incomplete start during which the motor does not attain more than 25% of the rated
speed.

5. Electric braking
A system in which a braking action is applied to an electric motor by causing it to act as a
generator.

6. DC Injection braking

A form of braking of an induction motor in which a separate dc supply is used to magnetize the
motor.

7. Plug braking
A form of electric braking of an induction motor obtained by reversing the phase sequence of its
any two lines.
Duty Type and Class Of Rating

Before going to the principle discussion, it is necessary to throw some light on two of the most
important technical requirements to be considered for better understanding.

Duty cycle assigned to the motor is one of the important factors in selection and operation of motors
for several reasons, as it depends on how often and howlong a motor operates.

In accordance with Indian Standard IS:12824-1989; Types of Duty and Classes of Rating
Assigned to Rotating Electrical Machines. The motors are to be designed for the standard duty
cycles as given in Table.1 below.

Table.1 – Types of duty for electric motors

Duty Type Motor performance requirements

Continuous running duty – The motor works at a constant load round the clock or
S1
runs for adequate time to reach thermal equilibrium.
Short-time duty – The motor works at a constant load for a definite time, but not
long enough to reach thermal equilibrium. The rest periods are long enough for the
S2 motor to cool down to the ambient temperature. The recommended values for the
short-time duty are 10, 30,60 and 90 minutes.

Intermittent periodic duty – The motor works with a sequence of identical duty
cycles comprising of period of running at a constant load and rest and de-energized
S3
period. Thermal equilibrium is never reached due to these periods being too short.
Starting current has little effect on temperature rise.
Intermittent periodic duty with starting – The motor works with a sequence of
identical duty cycles, each cycle consisting of significant periodof starting, a period
S4 of running at a constant load and rest and de-energized period. Thermal equilibrium
is never reached due to these periods being too short, but starting current affects
temperature rise.
Intermittent periodic duty with electric braking – The motor works with a sequence
of identical duty cycles, each cycle consisting of a period of starting, a period of
S5 running at a constant load, a period of rapid electric braking and rest and de-
energized period. Thermal equilibrium is never attained due to periods of operating,
rest and de-energized state being too short
Continuous operation periodic duty – The motor works with a sequence of
identical duty cycles, each cycle consisting of a period of running at a constant load
S6
and a period of running at no load without rest and de-energized period. Thermal
equilibrium is never reached due to operation period at no load is too short.
Continuous operation periodic duty with electric braking – The motor works with
S7
a sequence of identical duty cycles, each cycle consisting of a period of starting, a
 period of running at a constant load and a period of electric braking. Thermal
equilibrium is never reached, as rest and de-energized period is not there.
Continuous operation with periodic related variations in load and speed – The
motor works with a sequence of identical duty cycles, each cycle consisting of a
period of running at a constant load corresponding to a definite speed of rotation,
S8
followed by one or more periods of running at other constant loads at different
speed.Thermal equilibrium is never reached, as rest and de-energized period is not
there.
Duty with non-periodic load and speed variations – The motor works generally at a
load and speed, which are varying non-periodically within permissible operating
S9 range including frequent application of overloads that may exceed the ratingof
motor. Thermal equilibrium is never reached, as rest and de-energized period is not
there.
Classes of rating assigned to the electric motors are as given in Table.2 below. It may be noted that
while assigning classes of rating, the motors should invariably comply with the requirements of Indian
Standard referred above

Class of Rating Philosophy for operation of motor

Maximum continuous rating
Short time rating
Equivalent continuous duty equilibrium is attained. This is considered to be equivalent to one
Periodic duty type rating
Non-periodic duty type rating overloads, assigned by the manufacturer. When applied to the
The motor may be operated continuously for unlimited period at
the load and service conditions assigned by the manufacturer.
Starting at ambient temperature, the motor may be operated
continuously for limited period at the load and service conditions
assigned by the manufacturer.
The motor may be operated at the load and service conditions
assigned by the manufacturer for the test purposes until thermal
of the periodic duty defined in duty type S3 to S8 or to the duty
type S9.
The motor may be operated for duty cycles at the load and service
conditions assigned by the manufacturer. When applied to the
motor, this class of rating corresponds to the periodic duty S3 and
S6 types maintaining time of duty cycle 10 minutes and one of the
cyclic duration factors (CDF) with values – 15, 25, 40 or 60
percent.
The motor may be operated non-periodically for dutycycles having
varying loads over varying speed and service conditions, including
motor, this class of rating corresponds to the non-periodic duty
with non-periodic load and speed variations as per duty type S9.

Designation of Duty Types and Class of Ratings

The duty types and class of ratings designated to the motor should be indicated on the nameplate
following the rated output as discussed hereunder.

1. If no designation is indicated following the rated output, then the motor should be considered
suitable for maximum continuous rating, i.e. S1 duty.

2. For the duty type S2, the duration of duty should be indicated in minutes after S2. For
example, “S2 60 minutes”.

3. For the duty type S3 and S6, indication of the cyclic duration factor (CDF) in percentage
should follow S3 or S6. For example, “S3 15 %” or “S6 60%”.
4. For the duty type S4 and S5, the indication of S4 and S5 should be followed by indication of
the CDF in percentage, the moment inertia of motor (JM) and the moment of inertia of load
(Jext), both referred to the motor shaft. For example, S4 25 %, JM= 0.15 km-m2, Jext= 0.7 km-m2.

5. For the duty type S7, the indication of S7 should be followed by indication of the moment
inertia of motor (JM) and the moment of inertia of load (Jext), both referred to the motor shaft. For
example, S7, JM= 0.15 km-m2, Jext= 0.7 km-m2.

6. For the duty type S8, the indication of S8 should be followed by indication of the moment of
inertian of the motor (JM) and the moment of inertia of the load (Jext), both referred to the motor
shaft,together with tee load, speed and cyclic duration factor for each speed condition.

Need of specifying Duty Type and Class of Rating

For the majority of applications, the motors assigned with duty types S1, S2, S3, and S6 would
be found appropriate respectively for continuous rating, short time rating, intermittent ratings or
continuous rating with intermittent loading.

However for special duties, such as cranes, the motors with equivalent continuous rating, short
time rating or intermittent rating would be required.

In case the data is insufficient, there should be an agreement by discussion between the purchaser and
the vendor for the type of motor. If the duty type and class or rating are not specified or incorrect values
are specified, the vendor may arrive at the motor rating and select a suitable motor to met the require
duty from his standard list of ratings and the purchaser may not get the correct motor and cause
problems during actual service.

Moreover, when a motor is designed for cyclic duty for crane, it should also be possible to subject the
said motor for testing for equivalent continuous, short time or intermittent rating such that the motor
would satisfactorily meet the actual duty requirements whilst complying with the specified conditions.

Types of Crane Duty Motors

Following two types of motors are widely used for crane duty applications.

 Squirrel Cage Crane Duty Motors

 Slip ring and Wound Rotor Crane Duty Motors

The crane motors are duty type rated for developing high starting torque with low starting current. The
motors are designed to withstand stresses due to frequent starts/stops and reversals. Also, a
rapid acceleration is achieved by high pull out torque/rotor inertia ratio.

The crane duty motors are specially designed to offer satisfactory performance and long lives for
service on the cranes and hoists. Generally, the motors assigned duty type S3, S4 and S5 are considered
for crane applications.
These motors may also be used for similar applications such as material handling, sluice operation on
dams/weirs, lifts of all types and in rolling mills as auxiliary motors or wherever operating drives are
required for intermittent services.

Table.1 Standards applicable to motors

Indian Standard Title Applicability

Dimension of Three Phase Foot
IS:1231-1974 For dimensions of motor
Mounted Induction Motors
Dimension of Flange Mounted
IS :2223-1983 For dimensions motor
AC Induction Motors
Three Phase Induction Motors –
IS:325-1996 For specification and performance of motor
Specification
Specification for Thermal
IS:1271-985 Evaluation and Classification of For insulation of stator and rotor windings
Electrical Insulation
Types of Duty and Classes of
IS:12824-1989 Rating Assigned to rotating For duty class and assigned rating for motors
Electrical Machines
Degrees of Protection Provided
IS:4691-1985 by Enclosures for Rotating For protection to enclosures
Electric Machines
Designation of Methods of
IS:6362-1995 Cooling for Rotating Electrical For cooling of motors
Machines
Designations for Types of
Construction and
IS:2253-1974 For type of mounting and frame size
Mounting Arrangements of
Rotating Electrical Machines
Permissible Limits of Noise
IS:12065-1987 Levels for Rotating Electrical For noise level
Machines
Mechanical Vibration of
Rotating Electrical Machines
with Shaft Heights 56 mm and
IS:12075-1987 For vibration level
Higher – Measurement,
Evaluation and Limits of
Vibrations Severity
Guide for Testing of Three
IS:4029-1967 For testing of motors
Phase Induction Motors
Code of Practice for Electric
overhead Travelling Cranes and
IS :3177–1977 For understanding requirements of cranes
Gantry Cranes other than
Steelworks Cranes
Standard operating conditions
In accordance with the provisions made in the applicable Indian Standard, the motors should be
able to perform satisfactorily for the power supply parameters, site conditions and insulation
class as provided in Table.2, unless specific parameters are furnished.

Table.2 – Power supply parameters, site conditions and insulation class for AC
motors

Supply voltage with permissible variation 415 volts ±10%, 3 phase

Supply frequency with permissible variation 50 Hz + 5%
Combined voltage and frequency variation ±10% (absolute sum)
Standard motors capable to operate under unbalance
supply conditions, wherein negative and zero
Unbalance sequence voltage components not to exceed
individually 2% of positive phase sequence
component
Ambient temperature -10°C to 40°C
Altitude Up to 1000 m
Humidity Up to 100%
Class “F” in Squirrel cage motors
Insulation Class “F/F” for both stator and rotor in slip ring
motors

Ambient temperature

The rated output of motor specified by the vendor is generally at 40°C ambient temperature. For
temperatures other than 40°C, a duration factor should be applied as indicated Table.3.

Table.2 – Ambient temperature and deration factors for AC motors

Ambient temperature Deration factor

45°C 0.95

50°C 0.88

55°C 0.83

60°C 0.75
The technical and constructional features of crane duty motors as follows are more or less
similar to that are found in the standard continuous duty motors.

 Material and construction of stator frame and end shields

 Material and construction of stator and rotor cores
 Bearings at non-drive and drive ends
 Material of construction of shaft
 Earthing to stator frame and terminal box
 Mounting of motor – foot mounted or flange mounted
 Material, construction and position of terminal box

Specific technical and constructional features required to be incorporated in the specification for
the crane duty motors are listed hereunder so that the motors provide desired trouble free,
predetermined and optimum performance.

The motor rating should be decided based on its thermal capability taking into consideration few
or all factors listed hereunder as per duty requirements.

1. Optimised nos. of starts and frequency of starts for all the motors should be
specified for the design purpose (Starting class);
2. Percentage of time during each operating cycle the motor is energised, i.e. Cyclic
duty factor (CDF);
3. The intermittent duty type S3, S4 or S5 should be defined correctly based on
exact operational requirements of cranes. The number and type of cycle per hour
should be (Duty class) should be considere

The motors should have higher than normal pullout torques. As the motors are supposed to experience
large no. of starts, it is necessary that the accelerating time of the system should be as small as possible.
The higher pull out torque ensures rapid acceleration irrespective of drop in effective torque due to
stepped rotor resistance.

The motors should be able to withstand 1.5 times the rated current for 2 minutes without suffering
damage. This feature makes the motor suitable for intermittent and severe duties experienced on the
crane or similar applications.

All 4, 6, 8, and 10 pole motors should be designed for withstanding an overspeed of 2.5 times rated
synchronous speed or minimum 2000 rpm, whichever is less.

The squirrel cage motors should be provided single cylindrical shaft extension and the wound rotor (slip
ring) motors should be provided double cylindrical shaft extension

The stator and rotor windings should be impregnated with Class ‘F’ thermosetting varnish insulation. In
stringent cases, Class ‘H’ insulation may also be considered.

Additionally, the rotor windings should be braced with resin-glass banding to give protection against
centrifugal forces experienced by overhang during overspeed and frequent reversals. Gel-coat may be
painted on the winding overhang for better consolidation and protection from vibration.
Size of the terminal box should be adequate for to facilitate splitting of power cables cores and
terminate comfortably. In slip ring motors, the cables for main power supply and from slip rings
are usually accommodated in the same terminal box for simplifying wiring and maintenance.

Hence in case of slip ring as well as squirrel cage motors, if required, the cable box size may be
increased by providing an attachment of cable splitter box (generally of trapezoidal shape) to the
main terminal box.

It should be preferred to use the metallic cooling fans in the wound rotor motors. PVC or plastic fans
are likely to be deformed due to high temperature in housing due to slip rings and get damaged.

As the motor would generate more heat due to intermittent switching operations, the painting
should be heat resistant, specifically able to withstand higher temperatures.

The standard crane duty motors should be provided IP55 Degree of protection as per IS:4691.
The cooling code of motor should be IC411 as per IS:6362.

The insulation resistance of the slip-ring unit should be high enough ensuring minimum wear and
breakdown. The brush holders, made as a complete unit, should be easily replaceable. The slip-
ring should be large enough to encounter starting currents and for proper installation of brushes
in slip ring motors.

Derivation Of Cyclic Duration Factor From Different Duty Cycles

S3 – Intermittent Periodic Duty

N = Duration of motor operation under rated conditions
R = Duration of motor at rest and de-energised
ØMax = Maximum temperature attained during Duty cycle

Unless otherwise specified, the duration of the duty cycle is 10 minutes. The recommended
values for CDF are 25, 40 and 60 percent.

S4 – Intermittent Periodic Duty with starting

S4 - Intermittent Periodic Duty with starting

D = Duration of starting
N = Duration of motor operation under rated conditions
R = Duration of motor at rest and de-energised
ØMax = Maximum temperature attained during Duty cycle
S5 – Intermittent Periodic Duty with starting and breaking

S5 – Intermittent Periodic Duty with starting

and breaking

D = Duration of starting
N = Duration of motor operation under ratedconditions
R = Duration of motor at rest and de-energised
F = Duration for electric braking
ØMax = Maximum temperature attained during Duty Cycle

Starting Of Crane Duty Motors

The squirrel cage motors are started with direct-on-line starters in most of the cranes. Few
cranes, operated more or less on continuous basis, are found operated through a variable voltage
variable frequency (VVVF) drive.

For intermittent duty cranes, provision of VVVF would be costly affair.

The slip-ring or wound rotor motors are usually started by means of variable resistance in the
rotor circuit to get required starting torque at reduced starting current. The value of external
starting resistance can be calculated as under.
K = Constant depends on line voltage drop; varies from 0.6 to 1.0. Generally a value 0.8 can
be considered.
VR = Rotor voltage (Volts)
IR = Rotor Current
TFL = Full load torque (kg-m)
TLR = Locked Rotor (Starting) Torque
Rrt = Rotor resistance in Ohms per phase
Rext = External rotor resistance per phase to be added (Ohms) to get torque TLR at stand still

Rrt is generally small compared to Rext and may be neglected. However, if required, approximate
Rrt can be calculated by following relation:

The starting torque can be increased up to the value of maximum torque available for that
particular design. Usually, it is possible to obtain the starting torque as high as 2.5 times the
normal torque.

Choice of cage and wound motors may be based on the following criteria.

Squirrel Cage Motors may be used for various applications as follows:

 The driven equipment is to be accelerated rapidly with a fixed sequence of operation and
uniform load conditions, e.g. mechanical workshop crane.
 If the load conditions are almost identical for both directions of rotation, e.g. long travel
or cross travel of gantry crane.
 In the cranes, which are running at single speed without speed control.
 If site conditions are dusty, corrosive, these motors with totally enclosed fan cooled
construction would be robust and would provide services with least maintenance.
 Where the cost factor is to be considered, as cost of cage motor is less than that of slip-
ring motor;
 The squirrel cage motors for crane duty are available normally up to 250M frame size.

Slip-ring motors may be used for various applications as follows:

 Where very precise speed control is required for the crane, e.g. inching, slow and fast
handling of load during hoisting and lowering, alignment of crane over a furnace
opening, etc.
 In case of non-uniform loading conditions and operation is to be carried out in nos. of
sequences.
  The cranes are required to perform large number of starting and reversals during
operation.
 The cranes are required starting torque of more than 2.5 times the rated torque in general.

Selection
The crane duty motors are always supposed to operate under varying load conditions and
sequential switching due to requirement of handling materials of varied weights (i.e. loads).

Many continuous duty motors even operate under varying load conditions due to chemical
process requirements

As a common practice, where such variable loads are to be operated, a motor rating is selected based
on the highest anticipated load. However, more efficient and cost effective approach is to select the
motor with optimum rating on the basis of the load duration curve for the particular application.

Selection made on this basis also provides equally effective and satisfactory operation.

Thus as an alternative, it is better to select the motor having rating slightly lower than the peak
anticipated load and let it be operated at overload for a short time duration, rather than selecting
the motor of high rating that would operate at full capacity for only a short period providing
optimum efficiency only for that much duration. Only concern for motors operating at higher
than its rating is the thermal capacity of motor, which determines the speed of degradation of
the winding insulation.

CONCLUSION
Most vital and primary technical consideration for selection of the motor for any particular
application is the torque required by the load during starting and acceleration periods, especially
the relationship between the maximum torque or breakdown torque generated by the motor and
the start-up torque or locked rotor torque for both periods.

The thermal capability of motor is determined based on the duty / load cycle. Additionally,
where the totally enclosed fan cooled (TEFC) motor is operated with speed variations, the
cooling may be insufficient when the motor is operated at speeds below its rated value.

If the ambient temperature is more than 40°C, deter rating factor would affect the selection of
motor. Good estimate of the switching frequency can help in selecting the appropriate motor for
the proposed duty cycle.

Reliability is of prime importance in all the services, however, it is general practice to grossly
oversize the motor unnecessarily for better reliability, which results into sub-optimal energy
performance. Better understanding of the power system and knowledge of operating parameters
can certainly aid in reducing over sizing with no adverse effect on reliability.
References:

1. Efficient Electric Motor Systems Handbook, by Todd Litmann

2. IS:12824-1989; Types of Duty and Classes of Rating Assigned to Rotating Electrical Machines
3. The Technical Literature of Indian Motor Manufacturers

is.3177.1999.pdf

is.12824.1989_1.pdf

Selection of the Motor

1. Selection of the Motor sizes.
The selection of the motor for any crane motion is selected so that the temperature do not
exceed the permissible limits(Specified by IS 325 for three phase induction motor) for the given
class of insulation and ambient temperature. The cooling temperature not exceeding 40oC.
Motor intended or service with a cooling medium temperature other than 40oC are covered.
DC motor should be series wound and ac motors should be squirrel cage or slip ring induction
type.
2. Enclosures
All crane motor shall be totally enclosed with or without fan cooling arrangement. The
enclosure shall suit the specified service conditions as shall be stipulated with the order. If not
specified by the purchaser the motor enclosure shall be minimum IP44 for the indoor
applications and IP55 for the outdoor application of the ac motor and IP23 for the dc motors.
For the outdoor purpose separate canopy shall be provided for the motors.
3. Torque Rating
The pull out torque of the motor at the rated voltage and the frequency should not be less than
2 times the rated torque for the all mechanism from M1 to M8 as corresponding to compute
motor power without service factor.
4. Electrical Braking
When the electrical braking is used, provision shall be made to limit the current on the reversal
to a safe value. Effective means shall be provided for stopping the motion in the event of a
power failure and in the case of an emergency.
Shunt brakes shall be so connected that it will be applied when the main circuit breaking device
is open irrespective of the position of the controller. If required by the purchaser. Each control
circuit shall be electrically interlocked with all associated shunt breaks to prevent power being
applied to the motion when the brakes are not energized.
Brake magnets: the terminal of the brake magnets shall be protected from the accidental
contact. The connections and windings shall be effectively protected from the mechanical
damage. Where necessary the magnets shall be provided with the efficient cushioning.