1. 8. Februar 2012TCS Internal MOTORS

2. March 28, 2012 What is an Electric Motor? Electromechanical device that converts electrical energy to mechanical energy Mechanical energy used to e.g.  Rotate pump impeller, fan, blower  Drive compressors  Lift materials Motors in industry: 70% of electrical load Electric Motor Basic Principles 2

3. March 28, 2012 How Does an Electric Motor Work? 3

4. March 28, 2012 How Does an Electric Motor Work? 4

5. March 28, 2012 Three types of Motor Load 5 Motor loadsDescriptionExamples Constant torque loads Output power varies but torque is constant Conveyors, rotary kilns, constant-displacement pumps Variable torque loads Torque varies with square of operation speed Centrifugal pumps, fans Constant power loads Torque changes inversely with speed Machine tools

6. March 28, 2012 Type of Electric Motors Classification of Electric Motors 6

7. March 28, 2012 Type of Electric Motors DC Motors Fundamental characteristics of DC Motors 7 End view Time 0 End view Time 0+ Shifting magnetic field in rotor causes rotor to be forced to turn.

8. March 28, 2012 DC Motors.... Nature of commutation 8 Power is applied to armature windings through brush, commutator and armature winding Rotation of the armature moves the commutator, switching the armature winding connections Stator may be permanent or electromagnet

9. March 28, 2012 DC motor wiring topologies...

10. March 28, 2012 DC Motors.... Series Wound DC motors Armature and field connected in a series circuit. Useful for high breakaway torque loads. locomotives, hoists, cranes, automobile starters Starting torque 300% to as high as 800% of full load torque. Load increase results in both armature and field current increase Therefore torque increases by the square of a current increase. 10 Constant speed motor Industrial use: Lathes Drills Boring mills Shapers Spinning and Weaving machines

11. March 28, 2012 DC Motors.... Shunt wound DC motors Field coil in parallel (shunt) with the armature. Current through field coil is independant of the armature. Result = excellent speed control. Apply where starting loads are low fans, blowers, centrifugal pumps, machine tools Starting torque 125% to 200% full load torque (300 for short periods). 11 Variable speed motor Industrial Uses: Electric traction Cranes Elevators Air compressor Vacuum cleaner Hair drier Sewing machine

12. March 28, 2012 DC Motors.... Compound wound DC motors Performance is roughly between series-wound and shunt-wound Moderately high starting torque Moderate speed control Inherently controlled no-load speed safer than a series motor where load may be disconnected e.g. cranes 12 Industrial uses: Presses Shears Reciprocating machine

13. March 28, 2012 DC Motors Common Applications: –Small/cheap devices such as toys, electric tooth brushes, small drills Pros: –Cheap, simple –Easy to control - speed is governed by the voltage and torque by the current through the armature Cons: –Mechanical brushes - electrical noise, arcing, sparking, friction, wear, inefficient, shorting 13

14. March 28, 2012 Brushless DC Motors Essential difference - commutation is performed electronically with controller rather than mechanically with brushes 14

15. March 28, 2012 Brushless DC Motor Commutation 15 Commutation is performed electronically using a controller (e.g. HCS12 or logic circuit) Similarity with stepper motor, but with less # poles Needs rotor positional closed loop feedback:  hall effect sensors, back EMF, photo transistors

16. March 28, 2012 BLDC (3-Pole) Motor Connections Has 3 leads instead of 2 like brushed DC Delta (greater speed) and Wye (greater torque) stator windings 16 Delta Star

17. March 28, 2012 Brushless DC Motors Applications CPU cooling fans CD/DVD Players Electric automobiles Pros (compared to brushed DC) Higher efficiency Longer lifespan, low maintenance Clean, fast, no sparking/issues with brushed contacts Cons Higher cost More complex circuitry and requires a controller 17

18. March 28, 2012 AC Motors Electrical current reverses direction Two parts: stator and rotor –Stator: stationary electrical component –Rotor: rotates the motor shaft Speed difficult to control Two types –Synchronous motor –Induction motor 18

19. March 28, 2012 AC Motors 19 Induction Motors  Supply power to the stator coils, and rely on induction to generate torque.  Use poly-phase (usually 3) AC current to create a rotating magnetic field on the stator  This induces a magnetic field on the rotor, which tries to follow stator - slipping required to produce torque  Workhorses of the industry - high powered applications Synchronous motors  Supply power to both the rotor and the stator.  This allows for precise control (stepper motors), but requires mechanical brushes or slip rings to supply DC current to the rotor.  There is no slip since the rotor does not rely on induction to produce torque.

20. March 28, 2012 AC Motors – Induction motor Components Rotor Squirrel cage: conducting bars in parallel slots Wound rotor: 3-phase, double-layer, distributed winding Stator Stampings with slots to carry 3-phase windings Wound for definite number of poles 20

21. March 28, 2012 AC Motors – Induction motor How induction motors work Electricity supplied to stator Magnetic field generated that moves around rotor Current induced in rotor Rotor produces second magnetic field that opposes stator magnetic field Rotor begins to rotate

22. March 28, 2012 AC Motors – Induction motor 22 Single-phase induction motor  One stator winding  Single-phase power supply  Squirrel cage rotor  Require device to start motor  3 to 4 HP applications  Household appliances: fans, washing machines, dryers Three-phase induction motor  Three-phase supply produces magnetic field  Squirrel cage or wound rotor  Self-starting  High power capabilities  1/3 to hundreds HP applications: pumps, compressors, conveyor belts, grinders  70% of motors in industry!

23. March 28, 2012 Stepper Motor Working principle –Stepper motors consist of a permanent magnet rotating shaft, called the rotor, and electromagnets on the stationary portion that surrounds the motor, called the stator. When a phase winding of a stepper motor is energized with current, a magnetic flux is developed in the stator. The direction of this flux is determined by the “Right Hand Rule”. 23 A stepper motor is an electromechanical device which converts electrical pulses into discrete mechanical movements. The shaft or spindle of a stepper motor rotates in discrete step increments when electrical command pulses are applied to it in the proper sequence.

24. March 28, 2012 Stepper Motor At position 1, the rotor is beginning at the upper electromagnet, which is currently active (has voltage applied to it). To move the rotor clockwise (CW), the upper electromagnet is deactivated and the right electromagnet is activated, causing the rotor to move 90 degrees CW, aligning itself with the active magnet. This process is repeated in the same manner at the south and west electromagnets until we once again reach the starting position.

25. March 28, 2012 Two phase stepper motors 25 Two phase of winding arrangements in stepper motor : Unipolar & Bipolar. Unipolar stepper motor has two windings per phase, one for each direction of magnetic field. In this arrangement a magnetic pole can be reversed without switching the direction of current. Bipolar motors have a single winding per phase. The current in a winding needs to be reversed in order to reverse a magnetic pole. Bipolar motors have higher torque but need more complex driver circuits.

26. March 28, 2012 Types of Stepper Motors There are three main types of stepper motors: 26 Variable Reluctance stepper motor Permanent Magnet stepper motor Hybrid Synchronous stepper motor

27. March 28, 2012 Variable Reluctance motor This type of motor consists of a soft iron multi-toothed rotor and a wound stator. When the stator windings are energized with DC Current, the poles become magnetized. Rotation occurs when the rotor teeth are attracted to the energized stator poles. 27

28. March 28, 2012 Permanent Magnet motor The rotor no longer has teeth as with the VR motor. Instead the rotor is magnetized with alternating north and south poles situated in a straight line parallel to the rotor shaft. These magnetized rotor poles provide an increased magnetic flux intensity and because of this the PM motor exhibits improved torque characteristics when compared with the VR type. 28

29. March 28, 2012 Hybrid Synchronous motor The rotor is multi-toothed like the VR motor and contains an axially magnetized concentric magnet around its shaft. The teeth on the rotor provide an even better path which helps guide the magnetic flux to preferred locations in the air gap. 29

30. March 28, 2012 Stepper Motor Applications These include printers plotters medical equipment fax machines automotive and scientific equipment etc. 30 Stepper motors can be a good choice whenever controlled movement is required. They can be used to advantage in applications where you need to control rotation angle, speed, position and synchronism. When to Use a Stepper Motor

31. March 28, 2012 Stepper Motor Applications Film Advance 31 TCS Internal Product Solutions: Drive/Indexer Motor SX S57-51-MO Optical Scanner Product Solutions: Indexer Drive Motor Model 4000 LN Drive LN57-51 Application Type: Feed-to-Length Motion: Linear Application Type: X-Y Point- to-Point Motion: Rotary

32. March 28, 2012 Stepper Motor Applications Telescope Drive 32 Product Solutions: Indexer Drive Motor AT6200-AUX1* S Drive S106-178 Application Type: Metering/Dispensing Motion: Rotary

33. March 28, 2012 Stepper Motor Applications Labelling Machine 33 Product Solutions: Controller Motor APEX6152* APEX604 Application Type: Following Motion: Linear

34. March 28, 2012 Stepper Motor Applications 34 Fluted-Bit Cutting Machine Product Solutions: Indexer Drives Motor Model 4000* S Drives S83-135 Application Type: Contouring Motion: Linear

35. March 28, 2012 Linear Motors Analogous to Unrolled DC Motor Force (F) is generated when the current (I) (along vector L) and the flux density (B) interact F = LI x B

36. March 28, 2012 Main Types of Linear Motors 36 Linear Motor Linear Synchronous Motor Linear Induction Motor Linear Stepper Motor Permanent Magnet Wound Secondary Type Single-Sided Double-Sided or Sandwich Long-primary & Short Secondary Short-primary & Long-Secondary

37. March 28, 2012 Linear Motors Applications Large Linear Induction Machines (3 phase) Materials handling Extrusion presses Transportation (Trains) Robotics & Material Handling Elevators Compressors & Pumps Catapults and Launchers Sliding Doors Closer Cartain pullers 37

38. March 28, 2012 Linear Motors Applications 38 Small Linear Motors Packaging and Material Handling Automated Assembly Reciprocating compressors and alternators Textile machinery Packaging machines Handling machinery Robot applications Laboratory automation and others...

39. March 28, 2012 Linear Motors Applications Linear Stepper Motors Applied in Robotics 39 MEGAmation has over 350 Linear XY stepper motor robot heads in use throughout the world Pharmaceutical Automation Automotive drive train assembly Electronic PCB Maker Mechanical Pick & Place Assembly

40. March 28, 2012 Linear Motors Applications Linear Motor Drive Men's shaver 40 Triple Blade shaving System 1 Hour Charge Universal Voltage 12,000 Blade strokes a minute Linear Motors used for sliding doors and various similar actuators create rotary motion for accelerating cars for crash tests.

41. 8. Februar 2012TCS Internal THANK YOU