Einstein College of Engineering

Unit 1 Introduction to Mechatronics Systems Mechatronics is the synergistic combination of Mechanical engineering, Electronic engineering, Computer engineering, Control engineering, and Systems Design engineering in order to design, and manufacture useful products. The term mechatronics is defined as a multidisciplinary engineering system design, that is to say it rejects splitting engineering into separate disciplines. A mechatronics engineer unites the principles of mechanics, electronics, and computing to generate a simpler, more economical and reliable system. Mechatronics is centered on mechanics, electronics, computing, control engineering, molecular engineering (from nanochemistry and biology), and optical engineering, which, combined, make possible the generation of simpler, more economical, reliable and versatile systems. The portmanteau "mechatronics" was coined by Tetsuro Mori, the senior engineer of the Japanese company Yaskawa in 1969. An industrial robot is a prime example of a mechatronics system; it includes aspects of electronics, mechanics, and computing to do its day-to-day jobs.

The development of mechatronics has gone through three stages: The first stage corresponds to the years around the introduction of word mechatronics. During this stage, technologies used in mechatronics systems developed rather independently of each other and individually.With start of eighties a synergic integration of different technologies started taking place.A notable example is opto-electronics, an integration of optics and electronics. The concept of hardware/software co-design also started in this year. The third stage, which is considered as start of Mechatronics Age, starts with the early nineties. The most notable aspect of this stage are more and more integration of different engineering disciplinesand increased use of computational intelligence in the mechatronics products and systems.Another important development in the third stage is the concept of micromechatronis, i.e., start of miniaturization the components such as microactuators and microsensors.Design of such products and processes, therefore, has to be the outcome of a multi-disciplinary activity rather than an interdisciplinary one. Hence mechatronics challenges the traditional engineering thinking, because the way it is operating, is crossing the boundaries between the traditional engineering disciplines. SENSORS A sensor is a device which receives and responds to a signal. A sensor's sensitivity indicates how much the sensor's output changes when the measured quantity changes. For instance, if the mercury in a thermometer moves 1 cm when the temperature changes by 1 C, the sensitivity is

Einstein College of Engineering 1 cm/C (it is basically the slope Dy/Dx assuming a linear characteristic). Sensors that measure very small changes must have very high sensitivities.

A good sensor obeys the following rules:

Is sensitive to the measured property Is insensitive to any other property likely to be encountered in its application Does not influence the measured property

Characteristics of sensor

The sensitivity may in practice differ from the value specified. This is called a sensitivity error, but the sensor is still linear. Since the range of the output signal is always limited, the output signal will eventually reach a minimum or maximum when the measured property exceeds the limits. The full scale range defines the maximum and minimum values of the measured property. If the output signal is not zero when the measured property is zero, the sensor has an offset or bias. This is defined as the output of the sensor at zero input. If the sensitivity is not constant over the range of the sensor, this is called nonlinearity. Usually this is defined by the amount the output differs from ideal behavior over the full range of the sensor, often noted as a percentage of the full range. If the deviation is caused by a rapid change of the measured property over time, there is a dynamic error. Often, this behaviour is described with a bode plot showing sensitivity error and phase shift as function of the frequency of a periodic input signal. If the output signal slowly changes independent of the measured property, this is defined as drift (telecommunication). Long term drift usually indicates a slow degradation of sensor properties over a long period of time. Noise is a random deviation of the signal that varies in time. Hysteresis is an error caused by when the measured property reverses direction, but there is some finite lag in time for the sensor to respond, creating a different offset error in one direction than in the other. If the sensor has a digital output, the output is essentially an approximation of the measured property. The approximation error is also called digitization error. If the signal is monitored digitally, limitation of the sampling frequency also can cause a dynamic error, or if the variable or added noise noise changes periodically at a frequency near a multiple of the sampling rate may induce aliasing errors. The sensor may to some extent be sensitive to properties other than the property being measured. For example, most sensors are influenced by the temperature of their environment. DISPLACEMENT AND POSITION SENSORS Displacement Measurement Measurement of displacement is the basis of measuring: Position Velocity Acceleration Stress Force

Einstein College of Engineering Pressure Proximity Thickness Displacement Sensors types Potentiometers displacement sensors Inductive displacement sensors Capacitive displacement sensors Eddy current displacement sensors Piezoelectric displacement sensors Ultrasonic displacement sensors Magnetostrictive displacement sensors Optical encoder displacement sensors Strain Gages displacement sensors

Resistive displacement sensors: An electrically conductive wiper that slides against a fixed resistive element. To measure displacement, a potentiometer is typically wired in a voltage divider configuration.

A known voltage is applied to the resistor ends. The contact is attached to the moving object of interest The output voltage at the contact is proportional to the displacement.

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Inductive displacement sensors The coil acts as a source of magnetomotive force that drives the flux through the magnetic circuit and the air gap. The presence of the air gap causes a large increase in circuit reluctance and a corresponding decrease in the flux. Hence, a small variation in the air gap results in a measurable change in inductance.

Linear Variable Differential Transformer (LVDT) Motion of a magnetic core changes the mutual inductance of two secondary coils relative to a primary coil Primary coil voltage: VSsin( wt) Secondary coil induced emf: V1=k1sin( wt) and V2=k2sin( wt) k1 and k2 depend on the amount of coupling between the primary and the secondary coils, which is proportional to the position of the coil. When the coil is in the central position, k1=k2; VOUT=V1-V2=0 When the coil is is displaced x units, k1 not equal to k2 ; VOUT=(k1-k2)sin(wt) Positive or negative displacements are determined from the phase of VOUT.

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Einstein College of Engineering

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Einstein College of Engineering

The linear variable differential transformer (LVDT) is a type of electrical transformer used for measuring linear displacement. The transformer has three solenoidal coils placed end-to-end around a tube. The center coil is the primary, and the two outer coils are the secondaries. A cylindrical ferromagnetic core, attached to the object whose position is to be measured, slides along the axis of the tube. An alternating current is driven through the primary, causing a voltage to be induced in each secondary proportional to its mutual inductance with the primary. The frequency is usually in the range 1 to 10 kHz. As the core moves, these mutual inductances change, causing the voltages induced in the secondaries to change. The coils are connected in reverse series, so that the output voltage is the difference (hence "differential") between the two secondary voltages. When the core is in its central position,

Einstein College of Engineering equidistant between the two secondaries, equal but opposite voltages are induced in these two coils, so the output voltage is zero. When the core is displaced in one direction, the voltage in one coil increases as the other decreases, causing the output voltage to increase from zero to a maximum. This voltage is in phase with the primary voltage. When the core moves in the other direction, the output voltage also increases from zero to a maximum, but its phase is opposite to that of the primary. The magnitude of the output voltage is proportional to the distance moved by the core (up to its limit of travel), which is why the device is described as "linear". The phase of the voltage indicates the direction of the displacement. Because the sliding core does not touch the inside of the tube, it can move without friction, making the LVDT a highly reliable device. The absence of any sliding or rotating contacts allows the LVDT to be completely sealed against the environment. LVDTs are commonly used for position feedback in servomechanisms, and for automated measurement in machine tools and many ot her industrial and scientific applications.

A proximity sensor is a sensor able to detect the presence of nearby objects without any physical contact. A proximity sensor often emits an electromagnetic or electrostatic field, or a beam of electromagnetic radiation (infrared, for instance), and looks for changes in the field or return signal. The object being sensed is often referred to as the proximity sensor's target. Different proximity sensor targets demand different sensors. For example, a capacitive or photoelectric sensor might be suitable for a plastic target; an inductive proximity sensor requires a metal target. The maximum distance that this sensor can detect is defined "nominal range". Some sensors have adjustments of the nominal range or means to report a graduated detection distance. Proximity sensors can have a high reliability and long functional life because of the absence of mechanical parts and lack of physical contact between sensor and the sensed object. Proximity sensors are also used in machine vibration monitoring to measure the variation in distance between a shaft and its support bearing. This is common in large steam turbines, compressors, and motors that use sleeve-type bearings.

Einstein College of Engineering A thermocouple is a junction between two different metals that produces a voltage related to a temperature difference. Thermocouples are a widely used type of temperature sensor for measurement and control[1] and can also be used to convert heat into electric power. They are inexpensive[2] and interchangeable, are supplied fitted with standard connectors, and can measure a wide range of temperatures. The main limitation is accuracy: system errors of less than one degree Celsius (C) can be difficult to achieve.[3] Any junction of dissimilar metals will produce an electric potential related to temperature. Thermocouples for practical measurement of temperature are junctions of specific alloys which have a predictable and repeatable relationship between temperature and voltage. Different alloys are used for different temperature ranges. Properties such as resistance to corrosion may also be important when choosing a type of thermocouple. Where the measurement point is far from the measuring instrument, the intermediate connection can be made by extension wires which are less costly than the materials used to make the sensor. Thermocouples are usually standardized against a reference temperature of 0 degrees Celsius; practical instruments use electronic methods of cold-junction compensation to adjust for varying temperature at the instrument terminals. Electronic instruments can also compensate for the varying characteristics of the thermocouple, and so improve the precision and accuracy of measurements. Thermocouples are widely used in science and industry; applications include temperature measurement for kilns, gas turbine exhaust, diesel engines, and other industrial processes. Resistance thermometers, also called resistance temperature detectors or resistive thermal devices (RTDs), are temperature sensors that exploit the predictable change in electrical resistance of some materials with changing temperature. As they are almost invariably made of platinum, they are often called platinum resistance thermometers (PRTs). They are slowly replacing the use of thermocouples in many industrial applications below 600 C, due to higher accuracy and repeatability.[1] There are many categories; carbon resistors, film, and wire-wound types are the most widely used.

Carbon resistors are widely available and are very inexpensive. They have very reproducible results at low temperatures. They are the most reliable form at extremely low temperatures. They generally do not suffer from significant hysteresis or strain gauge effects. Carbon resistors have been used for many years because of their advantages. Film thermometers have a layer of platinum on a substrate; the layer may be extremely thin, perhaps one micrometer. Advantages of this type are relatively low cost (the high cost of platinum being offset by the tiny amount required) and fast response. Such devices have improved performance although the different expansion rates of the substrate and platinum give "strain gauge" effects and stability problems.

Wire-wound thermometers can have greater accuracy, especially for wide temperature ranges. The coil diameter provides a compromise between mechanical stability and allowing expansion of the wire to minimize strain and consequential drift.

Einstein College of Engineering ME1402 MECHATRONICS (Common to Mechanical and Production- VI Semester) OBJECTIVE To understand the interdisciplinary applications of Electronics, Electrical, Mechanical and Computer Systems for the Control of Mechanical and Electronic Systems. 1.MECHATRONICS, SENSORS AND TRANSDUCERS 9 Introduction to Mechatronics Systems Measurement Systems Control Systems Microprocessor based Controllers. Sensors and Transducers Performance Terminology Sensors for Displacement, Position and Proximity; Velocity, Motion, Force, Fluid Pressure, Liquid Flow, Liquid Level, Temperature, Light Sensors Selection of Sensors 2.ACTUATION SYSTEMS 9 Pneumatic and Hydraulic Systems Directional Control Valves Rotary Actuators. Mechanical Actuation Systems Cams Gear Trains Ratchet and pawl Belt and Chain Drives Bearings. Electrical Actuation Systems Mechanical Switches Solid State Switches Solenoids D.C Motors A.C Motors Stepper Motors. 3.SYSTEM MODELS AND CONTROLLERS 9 Building blocks of Mechanical, Electrical, Fluid and Thermal Systems, Rotational Transnational Systems, Electromechanical Systems Hydraulic Mechanical Systems. Continuous and discrete process Controllers Control Mode Two Step mode Proportional Mode Derivative Mode Integral Mode PID Controllers Digital Controllers Velocity Control Adaptive Control Digital Logic Control Micro Processors Control. 4. PROGRAMMING LOGIC CONTROLLERS 9 Programmable Logic Controllers Basic Structure Input / Output Processing Programming Mnemonics Timers, Internal relays and counters Shift Registers Master and Jump Controls Data Handling Analogs Input / Output Selection of a PLC Problem. 5.DESIGN OF MECHATRONICS SYSTEM 9 Stages in designing Mechatronics Systems Traditional and Mechatronic Design - Possible Design Solutions Case Studies of Mechatronics Systems, Pick and place robot automatic Car Park Systems Engine Management Systems. TOTAL : 45 TEXT BOOKS W. Bolton, Mechatronics, Pearson Educat ion, Second Edition, 1999. REFERENCES Michael B. Histand and David G. Alciatore, Introduction to Mechatronics and Measurement Systems, McGraw-Hill International Editions, 2000. Bradley D. A., Dawson D., Buru N.C. and. Loader A.J, Mechatronics, Chapma n and Hall, 1993. Dan Necsulesu, Mechatronics, Pearson Education Asia, 2002 (Indian Reprint). Lawrence J. Kamm, Understanding Electro Mechanical Engineering, An Introduction to Mechatronics, Prentice Hall of India Pvt., Ltd., 2000. Nitaigour Premchand Mahadik, Mechatronics, Tata McGraw-Hill publishing Company Ltd, 2003

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Unit 2 ACTUATION SYSTEMS Pneumatic and Hydraulic Systems Directional Control Valves Rotary Actuators. Mechanical Actuation Systems Cams Gear Trains Ratchet and pawl Belt and Chain Drives Bearings. Electrical Actuation Systems Mechanical Switches Solid State Switches Solenoids D.C Motors A.C Motors Stepper Motors.

Pneumatic systems
Pneumatics is a branch of technology, which deals with the study and application of use of pressurized gas to affect mechanical motion. Pneumatic systems are extensively used in industry, where factories are commonly plumbed with compressed air or other compressed inert gases. This is because a centrally-located and electricallypowered compressor that powers cylinders and other pneumatic devices through solenoid valves is often able to provide motive power in a cheaper, safer, more flexible, and more reliable way than a large number of electric motors and actuators. Pneumatics also has applications in dentistry, construction, mining, and other areas.

Gases used in pneumatic systems

Pneumatic systems in fixed installations such as factories use compressed air because a sustainable supply can be made by compressing atmospheric air. The air usually has moisture removed and a small quantity of oil added at the compressor, to avoid corrosion of mechanical components and to lubricate them. Factory-plumbed, pneumatic-power users need not worry about poisonous leakages as the gas is commonly just air. Smaller or stand-alone systems can use other compressed gases which are an asphyxiation hazard, such as nitrogen - often referred to as OFN (oxygen-free nitrogen), when supplied in cylinders. Any compressed gas other than air is an asphyxiation hazard - including nitrogen, which makes up approximately 80% of air. Compressed oxygen (approx. 20% of air) would not asphyxiate, but it would be an extreme fire hazard, so is never used in pneumatically powered devices. Portable pneumatic tools and small vehicles such as Robot Wars machines and other hobbyist applications are often powered by compressed carbon dioxide because containers designed to hold it such as soda stream canisters and fire extinguishers are readily available, and the phase change between liquid and gas makes it possible to obtain a larger volume of compressed gas from a lighter container than compressed air would allow. Carbon dioxide is an asphyxiant and can also be a freezing hazard when vented inappropriately.
Advantages of pneumatics

Simplicity of Design And Control

Einstein College of Engineering Machines are easily designed using standard cylinders & other components. Control is as easy as it is simple ON - OFF type control. Reliability o Pneumatic systems tend to have long operating lives and require very little maintenance. o Because gas is compressible, the equipment is less likely to be damaged by shock. The gas in pneumatics absorbs excessive force, whereas the fluid of hydraulics directly transfers force. Storage o Compressed Gas can be stored, allowing the use of machines when electrical power is lost. Safety o Very low chance of fire (compared to hydraulic oil). o Machines can be designed to be overload safe.
o

Hydraulic systems
Hydraulic machinery are machines and tools which use fluid power to do simple work. Heavy equipment is a common example. In this type of machine, high-pressure liquid called hydraulic fluid is transmitted throughout the machine to various hydraulic motors and hydraulic cylinders. The fluid is controlled directly or automatically by control valves and distributed through hoses and tubes. The popularity of hydraulic machinery is due to the very large amount of power that can be transferred through small tubes and flexible hoses, and the high power density and wide array of actuators that can make use of this power. Hydraulic machinery is operated by the use of hydraulics, where a liquid is the powering medium

Advantages of hydraulics

Liquid (as a gas is also a 'fluid') does not absorb any of the supplied energy. Capable of moving much higher loads and providing much higher forces due to the incompressibility.

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The hydraulic working fluid is basically incompressible, leading to a minimum of spring action. When hydraulic fluid flow is stopped, the slightest motion of the load releases the pressure on the load; there is no need to "bleed off" pressurized air to release the pressure on the load.

Directional control valves are one of the most fundamental parts in hydraulic machinery. They allow fluid flow into different paths from one or more sources. They usually consist of a piston inside a cylinder which is electrically controlled. The movement of the cylinder restricts or permits the flow, thus it controls the fluid flow. Directional control valves are mainly two types:

Hydraulic and Pneumatic.

Hydraulic directional control valves are for a liquid working fluid (e.g. water, hydraulic oil) and pneumatic directional control valves are for a gaseous (usually air) working fluid.
Control valves

Directional control valves route the fluid to the desired actuator. They usually consist of a spool inside a cast iron or steel housing. The spool slides to different positions in the housing, intersecting grooves and channels route the fluid based on the spool's position. The spool has a central (neutral) position maintained with springs; in this position the supply fluid is blocked, or returned to tank. Sliding the spool to one side routes the hydraulic fluid to an actuator and provides a return path from the actuator to tank. When the spool is moved to the opposite direction the supply and return paths are switched. When the spool is allowed to return to neutral (center) position the actuator fluid paths are blocked, locking it in position. Directional control valves are usually designed to be stackable, with one valve for each hydraulic cylinder, and one fluid input supplying all the valves in the stack. Tolerances are very tight in order to handle the high pressure and avoid leaking, spools typically have a clearance with the housing of less than a thousandth of an inch (25 m). The valve block will be mounted to the machine's frame with a three point pattern to avoid distorting the valve block and jamming the valve's sensitive components. The spool position may be actuated by mechanical levers, hydraulic pilot pressure, or solenoids which push the spool left or right. A seal allows part of the spool to protrude outside the housing, where it is accessible to the actuator. The main valve block is usually a stack of off the shelf directional control valves chosen by flow capacity and performance. Some valves are designed to be proportional (flow rate proportional to valve position), while others may be simply on-off. The control valve is one of the most expensive and sensitive parts of a hydraulic circuit.

Pressure relief valves are used in several places in hydraulic machinery; on the return circuit to maintain a small amount of pressure for brakes, pilot lines, etc... On hydraulic cylinders, to

Einstein College of Engineering prevent overloading and hydraulic line/seal rupture. On the hydraulic reservoir, to maintain a small positive pressure which excludes moisture and contamination. Pressure regulators reduce the supply pressure of hydraulic fluids as needed for various circuits. Sequence valves control the sequence of hydraulic circuits; to ensure that one hydraulic cylinder is fully extended before another starts its stroke, for example. Shuttle valves provide a logical or function. Check valves are one-way valves, allowing an accumulator to charge and maintain its pressure after the machine is turned off, for example. Pilot controlled Check valves are one-way valve that can be opened (for both directions) by a foreign pressure signal. For instance if the load should not be hold by the check valve anymore. Often the foreign pressure comes from the other pipe that is connected to the motor or cylinder. Counterbalance valves are in fact a special type of pilot controlled check valve. Whereas the check valve is open or closed, the counterbalance valve acts a bit like a pilot controlled flow control. Cartridge valves are in fact the inner part of a check valve; they are off the shelf components with a standardized envelope, making them easy to populate a proprietary valve block. They are available in many configurations; on/off, proportional, pressure relief, etc. They generally screw into a valve block and are electrically controlled to provide logic and automated functions. Hydraulic fuses are in-line safety devices designed to automatically seal off a hydraulic line if pressure becomes too low, or safely vent fluid if pressure becomes too high. Auxiliary valves in complex hydraulic systems may have auxiliary valve blocks to handle various duties unseen to the operator, such as accumulator charging, cooling fan operation, air conditioning power, etc. They are usually custom valves designed for the particular machine, and may consist of a metal block with ports and channels drilled. Cartridge valves are threaded into the ports and may be electrically controlled by switches or a microprocessor to route fluid power as needed.

Hydraulic rotary actuators

The hydraulic rotary actuator is a device which transform hydraulic power (pressure and flow) in rotational mechanical power (torque and speed). It is used for alternative movements with a limited rotation angle (max 280).The simplicity of construction allows to obtain very high mechanical efficiency values, close to 95%.

Mechanical actuation systems

Einstein College of Engineering Mechanical linear actuators operate by conversion of rotary motion into linear motion. Conversion is commonly made via a few simple types of mechanism:

Screw: Screw jack, ball screw and roller screw actuators all operate on the principle of the simple machine known as the screw. By rotating the actuator's nut, the screw shaft moves in a line. Wheel and axle: Hoist, winch, rack and pinion, chain drive, belt drive, rigid chain and rigid belt actuators operate on the principle of the wheel and axle. By rotating a wheel/axle (e.g. drum, gear, pulley or shaft) a linear member (e.g. cable, rack, chain or belt) moves.[1] Cam: Cam actuators function on a principle similar to that of the wedge, but provide relatively limited travel. As a wheel-like cam rotates, its eccentric shape provides thrust at the base of a shaft.

Some mechanical linear actuators only pull (e.g. hoist, chain drive and belt drive) and others only push (e.g. cam actuator).

Cams
A linear actuator is an actuator that, when driven by a non-linear motion, creates linear motion (as opposed to rotary motion, e.g. of an electric motor). Mechanical and hydraulic actuation are the most common methods of achieving the linear motion. A cam is a rotating or sliding piece in a mechanical linkage used especially in transforming rotary motion into linear motion or vice-versa.[1][2] It is often a part of a rotating wheel (e.g. an eccentric wheel) or shaft (e.g. a cylinder with an irregular shape) that strikes a lever at one or more points on its circular path. The cam can be a simple tooth, as is used to deliver pulses of power to a steam hammer, for example, or an eccentric disc or other shape that produces a smooth reciprocating (back and forth) motion in the follower, which is a lever making contact with the cam.

Gear train
A gear train is a set or system of gears arranged to transfer rotational torque from one part of a mechanical system to another. Gear trains may consist of:

Driving gears - attached to the input shaft Driven gears/Motor gears - attached to the output shaft Idler gears - interposed between the driving and driven gear in order to maintain the direction of the output shaft the same as the input shaft or to increase the distance between the drive and driven gears. A compound gear train refers to two or more gears used to transmit motion.

Einstein College of Engineering Types of gear trains include:

Simple gear train Compound gear train Epicyclic gear train Reverted gear train

A gear train is two or more gear working together by meshing their teeth and turning each other in a system to generate power and speed. It reduces speed and increases torque. To create large gear ratio, gears are connected together to form gear trains. They often consist of multiple gears in the train. The smaller gears are one-fifth of the size of the larger gear. Electric motors are used with the gear systems to reduce the speed and increase the torque. Electric motor is connected to the driving end of each train and is mounted on the test platform. The output end output end of the gear train is connected to a large magnetic particle brake that is used to measure the output torque. Types of Gear Trains

Simple Gear Train - The most common of the gear train is the gear pair connecting parallel shafts. The teeth of this type can be spur, helical or herringbone. The angular velocity is simply the reverse of the tooth ratio. The main limitation of a simple gear train is that the maximum speed change ratio is 10:1. For larger ratio, large size of gear trains are required. The sprockets and chain in the bicycle is an example of simple gear train. When the paddle is pushed, the front gear is turned and that meshes with the links in the chain. The chain moves and meshes with the links in the rear gear that is attached to the rear wheel. This enables the bicycle to move. Compound Gear Train - For large velocities, compound arrangement is preferred. Two keys are keyed to a single shaft. A double reduction train can be arranged to have its input and output shafts in a line, by choosing equal center distance for gears and pinions. Epicyclic Gear Train - It is the system of epicyclic gears in which at least one wheel axis itself revolves around another fixed axis. Planetary Gear Train - It is made of few components, a small gear at the center called the sun, several medium sized gears called the planets and a large external gear called the ring gear. The planet gear rolls and revolves about the sun gear and the ring gear rolls on the planet gear. Planetary gear trains have several advantages. They have higher gear ratios. They are popular for automatic transmissions in automobiles. They are also used in bicycles for controlling power of pedaling automatically or manually. They are also used for power train between internal combustion engine and an electric motor. Applications Gear trains are used in representing the phases of moon on a watch or clock dial. It is also used for driving a conventional two-disk lunar phase display off the day-of-the-week shaft of the calendar.

Ratchet & pawl

Einstein College of Engineering A ratchet is a device that allows continuous linear or rotary motion in only one direction while preventing motion in the opposite direction. Because most socket wrenches today use ratcheting handles, the term "ratchet" alone is often used to refer to a ratcheting wrench, and the terms "ratchet" and "socket" are closely associated in many users' minds. A ratchet consists of a round gear (see Figure 1) or linear rack with teeth, and a pivoting, springloaded finger called a pawl (or click[1]) that engages the teeth. The teeth are uniform but asymmetrical, with each tooth having a moderate slope on one edge and a much steeper slope on the other edge. When the teeth are moving in the unrestricted (i.e., forward) direction (see Figure 2), the pawl easily slides up and over the gently sloped edges of the teeth, with a spring forcing it (often with an audible 'click') into the depression between the teeth as it passes the tip of each tooth. When the teeth move in the opposite (backward) direction, however, the pawl will catch against the steeply sloped edge of the first tooth it encounters, thereby locking it against the tooth and preventing any further motion in that direction.

Backlash
Because the ratchet can only stop backward motion at discrete points (i.e., at tooth boundaries), a ratchet does allow a limited amount of backward motion. This backward motionwhich is limited to a maximum distance equal to the spacing between the teethis called backlash. In cases where backlash must be minimized, a smooth, toothless ratchet with a high friction surface such as rubber is sometimes used. The pawl bears against the surface at an angle so that any backward motion will cause the pawl to jam against the surface and thus prevent any further backward motion. Since the backward travel distance is primarily a function of the compressibility of the high friction surface, this mechanism can result in significantly reduced backlash.

Belt drives
A belt is a loop of flexible material used to link two or more rotating shafts mechanically. Belts may be used as a source of motion, to transmit power efficiently, or to track relative movement. Belts are looped over pulleys. In a two pulley system, the belt can either drive the pulleys in the same direction, or the belt may be crossed, so that the direction of the shafts is opposite. As a source of motion, a conveyor belt is one application where the belt is adapted to continually carry a load between two points.

Einstein College of Engineering Belts are the cheapest utility for power transmission between shafts that may not be axially aligned. Power transmission is achieved by specially designed belts and pulleys. The demands on a belt drive transmission system are large and this has led to many variations on the theme. They run smoothly and with little noise, and cushion motor and bearings against load changes, albeit with less strength than gears or chains. However, improvements in belt engineering allow use of belts in systems that only formerly allowed chains or gears.
Pros and cons

Belt drive, moreover, is simple, inexpensive, and does not require axially aligned shafts. It helps protect the machinery from overload and jam, and damps and isolates noise and vibration. Load fluctuations are shock-absorbed (cushioned). They need no lubrication and minimal maintenance. They have high efficiency (90-98%, usually 95%), high tolerance for misalignment, and are inexpensive if the shafts are far apart. Clutch action is activated by releasing belt tension. Different speeds can be obtained by step or tapered pulleys. The angular-velocity ratio may not be constant or equal to that of the pulley diameters, due to slip and stretch. However, this problem has been largely solved by the use of toothed belts. Temperatures ranges from 31 F (35 C) to 185 F (85 C). Adjustment of center distance or addition of an idler pulley is crucial to compensate for wear and stretch.
Flat belts

The drive belt: used to transfer power from the engine's flywheel. Here shown driving a threshing machine. Flat belts were used early in line shafting to transmit power in factories.[1] It is a simple system of power transmission that was well suited for its day. It delivered high power for high speeds (500 hp for 10,000 ft/min), in cases of wide belts and large pulleys. These drives are bulky, requiring high tension leading to high loads, so vee belts have mainly replaced the flat-belts except when high speed is needed over power. The Industrial Revolution soon demanded more from the system, and flat belt pulleys needed to be carefully aligned to prevent the belt from slipping off. Because flat belts tend to climb towards the higher side of the pulley, pulleys were made with a slightly convex or "crowned" surface (rather than flat) to keep the belts centered. Flat belts also tend to slip on the pulley face when heavy loads are applied and many proprietary dressings were available that could be applied to the belts to increase friction, and so power transmission. Grip was better if the belt was assembled with the hair (i.e. outer) side of the leather against the pulley although belts were also often given a half-twist before joining the ends (forming a Mbius strip), so that wear was evenly distributed on both sides of the belt (DB). Belts were joined by lacing the ends together with leather thonging,[2][3] or later by steel comb fasteners.[4] A good modern use for a flat belt is with smaller pulleys and large central distances. They can connect inside and outside pulleys, and can come in both endless and jointed construction.

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Round belts

Round belts are a circular cross section belt designed to run in a pulley with a circular (or near circular) groove. They are for use in low torque situations and may be purchased in various lengths or cut to length and joined, either by a staple, gluing or welding (in the case of polyurethane). Early sewing machines utilized a leather belt, joined either by a metal staple or glued, to a great effect.
Vee belts

Belts on a Yanmar 2GM20 marine diesel engine.

A multiple-V-belt drive on an air compressor. Vee belts (also known as V-belt or wedge rope) solved the slippage and alignment problem. It is now the basic belt for power transmission. They provide the best combination of traction, speed of movement, load of the bearings, and long service life. The V-belt was developed in 1917 by John Gates of the Gates Rubber Company. They are generally endless, and their general cross-section shape is trapezoidal. The "V" shape of the belt tracks in a mating groove in the pulley (or sheave), with the result that the belt cannot slip off. The belt also tends to wedge into the groove as the load increases the greater the load, the greater the wedging action improving torque transmission and making the V-belt an effective solution, needing less width and tension than flat belts. V-belts trump flat belts with their small center distances and high reduction ratios. The preferred center distance is larger than the largest pulley diameter, but less than three times the sum of both pulleys. Optimal speed range is 10007000 ft/min. V-belts need larger pulleys for their larger thickness than flat belts. They can be supplied at various fixed lengths or as a segmented section, where the segments are linked (spliced) to form a belt of the required length. For high-power requirements, two or more vee belts can be joined side-by-side in an arrangement called a multi-V, running on matching multi-groove sheaves. The strength of these belts is obtained by reinforcements with fibers like steel, polyester or aramid (e.g. Twaron or Kevlar). This is known as a multiple-V-belt drive (or

Einstein College of Engineering sometimes a "classical V-belt drive"). When an endless belt does not fit the need, jointed and link Vbelts may be employed. However they are weaker and only usable at speeds up to 4000 ft/min. A link v-belt is a number of rubberized fabric links held together by metal fasteners. They are length adjustable by disassembling and removing links when needed.
Multi-groove belts

A multi-groove or polygroove belt [5] is made up of usually 5 or 6 "V" shapes along side each other. This gives a thinner belt for the same drive surface, thus is more flexible, although often wider. The added flexibility offers an improved efficiency, as less energy is wasted in the internal friction of continually bending the belt. In practice this gain of efficiency is overshadowed by the reduced heating effect on the belt, as a cooler-running belt lasts longer in service. A further advantage of the polygroove belt, and the reason they have become so popular, stems from the ability to be run over pulleys on the ungrooved back of the belt. Although this is sometimes done with vee belts and a single idler pulley for tensioning, a polygroove belt may be wrapped around a pulley on its back tightly enough to change its direction, or even to provide a light driving force. [6] Any vee belt's ability to drive pulleys depends on wrapping the belt around a sufficient angle of the pulley to provide grip. Where a single-vee belt is limited to a simple convex shape, it can adequately wrap at most three or possibly four pulleys, so can drive at most three accessories. Where more must be driven, such as for modern cars with power steering and air conditioning, multiple belts are required. As the polygroove belt can be bent into concave paths by external idlers, it can wrap any number of driven pulleys, limited only by the power capacity of the belt. [6] This ability to bend the belt at the designer's whim allows it to take a complex or "serpentine" path. This can assist the design of a compact engine layout, where the accessories are mounted more closely to the engine block and without the need to provide movable tensioning adjustments. The entire belt may be tensioned by a single idler pulley.
Ribbed belt

A ribbed belt is a power transmission belt featuring lengthwise grooves. It operates from contact between the ribs of the belt and the grooves in the pulley. Its single-piece structure it reported to offer an even distribution of tension across the width of the pulley where the belt is in contact, a power range up to 600 kW, a high speed ratio, serpentine drives (possibility to drive off the back of the belt), long life, stability and homogeneity of the drive tension, and reduced vibration. The ribbed belt may be fitted on various applications : compressors, fitness bikes, agricultural machinery, food mixers, washing machines, lawn mowers, etc.[7]
Film belts

Though often grouped with flat belts, they are actually a different kind. They consist of a very thin belt (0.5-15 millimeters or 100-4000 micrometres) strip of plastic and occasionally rubber. They are generally intended for low-power (10 hp or 7 kW), high-speed uses, allowing high efficiency (up to 98%) and long life. These are seen in business machines, printers, tape recorders, and other lightduty operations.

Einstein College of Engineering

Timing belts

Timing belt

Belt-drive cog on a belt-driven bicycle Timing belts, (also known as Toothed, Notch, Cog, or Synchronous belts) are a positive transfer belt and can track relative movement. These belts have teeth that fit into a matching toothed pulley. When correctly tensioned, they have no slippage, run at constant speed, and are often used to transfer direct motion for indexing or timing purposes (hence their name). They are often used in lieu of chains or gears, so there is less noise and a lubrication bath is not necessary. Camshafts of automobiles, miniature timing systems, and stepper motors often utilize these belts. Timing belts need the least tension of all belts, and are among the most efficient. They can bear up to 200 hp (150 kW) at speeds of 16,000 ft/min. Timing belts with a helical offset tooth design are available. The helical offset tooth design forms a chevron pattern and causes the teeth to engage progressively. The chevron pattern design is selfaligning. The chevron pattern design does not make the noise that some timing belts make at idiosyncratic speeds, and is more efficient at transferring power (up to 98%). Disadvantages include a relatively high purchase cost, the need for specially fabricated toothed pulleys, less protection from overloading and jamming, and the lack of clutch action.

Einstein College of Engineering

Specialty belts

Belts normally transmit power on the tension side of the loop. However, designs for continuously variable transmissions exist that use belts that are a series of solid metal blocks, linked together as in a chain, transmitting power on the compression side of the loop.
Rolling roads

Belts used for rolling roads for wind tunnels can be capable of 250 km/h.[8]
Flying rope

For transmission of mechanical power over distance without electrical energy, a flying rope can be used[9]. A wire or manila rope can be used to transmit mechanical energy from a steam engine or water wheel to a factory or pump which is located a considerable distance (10 to 100s of meters or more) from the power source. A flying rope way could be supported on poles and pulleys similar to the cable on a chair lift or aerial tramway. Transmission efficiency is generally high.

Chain drives
Chain drive is a way of transmitting mechanical power from one place to another. It is often used to convey power to the wheels of a vehicle, particularly bicycles and motorcycles. It is also used in a wide variety of machines besides vehicles. Most often, the power is conveyed by a roller chain, known as the drive chain or transmission chain,[1] passing over a sprocket gear, with the teeth of the gear meshing with the holes in the links of the chain. The gear is turned, and this pulls the chain putting mechanical force into the system. Sometimes the power is output by simply rotating the chain, which can be used to lift or drag objects. In other situations, a second gear is placed and the power is recovered by attaching shafts or hubs to this gear. Though drive chains are often simple oval loops, they can also go around corners by placing more than two gears along the chain; gears that do not put power into the system or transmit it out are generally known as idler-wheels. By varying the diameter of the input and output gears with respect to each other, the gear ratio can be altered, so that, for example, the pedals of a bicycle can spin all the way around more than once for every rotation of the gear that drives the wheels.

Chains versus belts

Drive chains are most often made of metal, while belts are often rubber, plastic, or other substances. Although well-made chains may prove stronger than belts, their greater mass increases drive train inertia. Drive belts can often slip (unless they have teeth) which means that the output side may not rotate at a precise speed, and some work gets lost to the friction of the belt against its rollers. Teeth on toothed drive belts generally wear faster than links on chains, but wear on rubber or plastic belts and

Einstein College of Engineering their teeth is often easier to observe; you can often tell a belt is wearing out and about to break more easily than a chain. Chains are often narrower than belts, and this can make it easier to shift them to larger or smaller gears in order to vary the gear ratio. Multi-speed bicycles with derailleurs make use of this. Also, the more positive meshing of a chain can make it easier to build gears that can increase or shrink in diameter, again altering the gear ratio. Both can be used to move objects by attaching pockets, buckets, or frames to them; chains are often used to move things vertically by holding them in frames, as in industrial toasters, while belts are good at moving things horizontally in the form of conveyor belts. It is not unusual for the systems to be used in combination; for example the rollers that drive conveyor belts are themselves often driven by drive chains. Drive shafts are another common method used to move mechanical power around that is sometimes evaluated in comparison to chain drive; in particular shaft drive versus chain drive is a key design decision for most motorcycles. Drive shafts te

Bearing
A bearing is a device to allow constrained relative motion between two or more parts, typically rotation or linear movement. Bearings may be classified broadly according to the motions they allow and according to their principle of operation as well as by the directions of applied loads they can handle.

Plain bearings use surfaces in rubbing contact, often with a lubricant such as oil or graphite. A plain bearing may or may not be a discrete device. It may be nothing more than the bearing surface of a hole with a shaft passing through it, or of a planar surface that bears another (in these cases, not a discrete device); or it may be a layer of bearing metal either fused to the substrate (semi-discrete) or in the form of a separable sleeve (discrete). With suitable lubrication, plain bearings often give entirely acceptable accuracy, life, and friction at minimal cost. Therefore, they are very widely used. However, there are many applications where a more suitable bearing can improve efficiency, accuracy, service intervals, reliability, speed of operation, size, weight, and costs of purchasing and operating machinery.

Einstein College of Engineering Thus, there are many types of bearings, with varying shape, material, lubrication, principal of operation, and so on. For example, rolling-element bearings use spheres or drums rolling between the parts to reduce friction; reduced friction allows tighter tolerances and thus higher precision than a plain bearing, and reduced wear extends the time over which the machine stays accurate. Plain bearings are commonly made of varying types of metal or plastic depending on the load, how corrosive or dirty the environment is, and so on. In addition, bearing friction and life may be altered dramatically by the type and application of lubricants. For example, a lubricant may improve bearing friction and life, but for food processing a bearing may be lubricated by an inferior food-safe lubricant to avoid food contamination; in other situations a bearing may be run without lubricant because continuous lubrication is not feasible, and lubricants attract dirt that damages the bearings.

Principles of operation
There are at least six common principles of operation:

plain bearing, also known by the specific styles: bushings, journal bearings, sleeve bearings, rifle bearings rolling-element bearings such as ball bearings and roller bearings jewel bearings, in which the load is carried by rolling the axle slightly off-center fluid bearings, in which the load is carried by a gas or liquid magnetic bearings, in which the load is carried by a magnetic field flexure bearings, in which the motion is supported by a load element which bends. angular contact bearing

Motions
Common motions permitted by bearings are:

Axial rotation e.g. shaft rotation Linear motion e.g. drawer spherical rotation e.g. ball and socket joint hinge motion e.g. door, elbow, knee

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electrical actuators Relay

A solid state relay (SSR) is an electronic switching device in which a small control signal controls a larger load current or voltage. It comprises a voltage or current sensor which responds to an appropriate input (control signal), a solid-state electronic switching device of some kind which switches power to the load circuitry either on or off, and some coupling mechanism to enable the control signal to activate this switch without mechanical parts. The relay may be designed to switch either AC or DC to the load. It serves the same function as an electromechanical relay, but has no moving parts.

Operation
An SSR based on a single MOSFET, or multiple MOSFETs in a paralleled array, works well for DC loads. There is an inherent substrate diode in all MOSFETs that conducts in the reverse direction. This means that a single MOSFET cannot block current in both directions. For AC (bi-directional) operation two MOSFETs are arranged back to back with their source pins tied together. Their drain pins are connected to either side of the output. The substrate diodes then are alternately reverse biased in order to block current when the relay is off. When the relay is on, the common source is always riding on the instantaneous signal level and both gates are biased positive relative to the source by the photo-diode. It is common to provide access to the common source so that multiple MOSFETs can be wired in parallel if switching a DC load. There is also commonly some circuitry to discharge the gate when the LED is turned off, speeding the relay's turn-off.

Advantages over mechanical relays

Most of the relative advantages of solid state and electromechanical relays are common to all solidstate as against electromechanical devices.

SSRs are faster than electromechanical relays; their switching time is dependent on the time needed to power the LED on and off, of the order of microseconds to milliseconds Lower (if any) minimum output current (latching current) required Increased lifetime, particularly if activated many times, as there are no moving parts to wear o Output resistance remains constant regardless of amount of use Clean, bounceless operation Decreased electrical noise when switching No sparking, allowing use in explosive environments where it is critical that no spark is generated during switching Totally silent operation Inherently smaller than a mechanical relay of similar specification (if desired may have the same "casing" form factor for interchangeability). Much less sensitive to storage and operating environment. For example much less sensitive to mechanical shock and vibration, humidity.

Einstein College of Engineering

Solenoid
solenoid[nb 1] is a coil wound into a tightly packed helix. In physics, the term solenoid refers to a long, thin loop of wire, often wrapped around a metallic core, which produces a magnetic field when an electric current is passed through it. Solenoids are important because they can create controlled magnetic fields and can be used as electromagnets. The term solenoid refers specifically to a magnet designed to produce a uniform magnetic field in a volume of space (where some experiment might be carried out). In engineering, the term solenoid may also refer to a variety of transducer devices that convert energy into linear motion. The term is also often used to refer to a solenoid valve, which is an integrated device containing an electromechanical solenoid which actuates either a pneumatic or hydraulic valve, or a solenoid switch, which is a specific type of relay that internally uses an electromechanical solenoid to operate an electrical switch; for example, an automobile starter solenoid, or a linear solenoid, which is an electromechanical solenoid.

AC motor
An AC motor is an electric motor that is driven by an alternating current. It consists of two basic parts, an outside stationary stator having coils supplied with alternating current to produce a rotating magnetic field, and an inside rotor attached to the output shaft that is given a torque by the rotating field. (There are examples, such as some Papst motors, which have the stator on the inside and the rotor on the outside to increase the inertia and cooling. They were common on high quality tape and film machines where speed stability is important.) There are two types of AC motors, depending on the type of rotor used (not including eddy current motors also AC/DC mechanically commutated machines in which speed is dependent on voltage and winding connection). The first is the synchronous motor, which rotates exactly at the supply frequency or a submultiple of the supply frequency. The magnetic field on the rotor is either generated by current delivered through slip rings or by a permanent magnet. The second type is the induction motor, which runs slightly slower than the supply frequency. The magnetic field on the rotor of this motor is created by an induced current.

Squirrel-cage rotors
Most common AC motors use the squirrel cage rotor, which will be found in virtually all domestic and light industrial alternating current motors. The squirrel cage refers to the rotating exercise cage for pet animals. The motor takes its name from the shape of its rotor "windings"- a ring at either end of the rotor, with bars connecting the rings running the length of the rotor. It is typically cast aluminum or copper poured between the iron laminates of the rotor, and usually only the end rings will be visible. The vast majority of the rotor currents will flow through the bars rather than the higher-resistance and usually varnished laminates. Very low voltages at very high currents are typical in the bars and end rings; high efficiency motors will often use cast copper to reduce the resistance in the rotor. In operation, the squirrel cage motor may be viewed as a transformer with a rotating secondary. When the rotor is not rotating in sync with the magnetic field, large rotor currents are induced; the large rotor currents magnetize the rotor and interact with the stator's magnetic fields to bring the

Einstein College of Engineering rotor almost into synchronization with the stator's field. An unloaded squirrel cage motor at rated noload speed will consume electrical power only to maintain rotor speed against friction and resistance losses. As the mechanical load increases, so will the electrical load - the electrical load is inherently related to the mechanical load. This is similar to a transformer, where the primary's electrical load is related to the secondary's electrical load. This is why a squirrel cage blower motor may cause household lights to dim upon starting, but doesn't dim the lights on startup when its fan belt (and therefore mechanical load) is removed. Furthermore, a stalled squirrel cage motor (overloaded or with a jammed shaft) will consume current limited only by circuit resistance as it attempts to start. Unless something else limits the current (or cuts it off completely) overheating and destruction of the winding insulation is the likely outcome. To prevent the currents induced in the squirrel cage from superimposing itself back onto the supply, the squirrel cage is generally constructed with a prime number of bars, or at least a small multiple of a prime number (rarely more than 2). There is an optimum number of bars in any design, and increasing the number of bars beyond that point merely serves to increase the losses of the motor particularly when starting. Virtually every washing machine, dishwasher, standalone fan, record player, etc. uses some variant of a squirrel cage motor.
Calecon Effect

If the rotor of a squirrel runs at the true synchronous speed, the flux in the rotor at any given place on the rotor would not change, and no current would be created in the squirrel cage. For this reason, ordinary squirrel-cage motors run at some tens of rpm slower than synchronous speed, even at no load. Because the rotating field (or equivalent pulsating field) actually or effectively rotates faster than the rotor, it could be said to slip past the surface of the rotor. The difference between synchronous speed and actual speed is called slip, and loading the motor increases the amount of slip as the motor slows down slightly.
Two-phase AC servo motors

A typical two-phase AC servo-motor has a squirrel cage rotor and a field consisting of two windings: 1. a constant-voltage (AC) main winding. 2. a control-voltage (AC) winding in quadrature (i.e., 90 degrees phase shifted) with the main winding so as to produce a rotating magnetic field. Reversing phase makes the motor reverse. An AC servo amplifier, a linear power amplifier, feeds the control winding. The electrical resistance of the rotor is made high intentionally so that the speed/torque curve is fairly linear. Two-phase servo motors are inherently high-speed, low-torque devices, heavily geared down to drive the load.
Single-phase AC induction motors

Three-phase motors produce a rotating magnetic field. However, when only single-phase power is available, the rotating magnetic field must be produced using other means. Several methods are commonly used:

Einstein College of Engineering

Shaded-pole motor

A common single-phase motor is the shaded-pole motor and is used in devices requiring low starting torque, such as electric fans or the drain pump of washing machines and dishwashers or in other small household appliances. In this motor, small single-turn copper "shading coils" create the moving magnetic field. Part of each pole is encircled by a copper coil or strap; the induced current in the strap opposes the change of flux through the coil. This causes a time lag in the flux passing through the shading coil, so that the maximum field intensity moves across the pole face on each cycle. This produces a low level rotating magnetic field which is large enough to turn both the rotor and its attached load. As the rotor picks up speed the torque builds up to its full level as the principal magnetic field is rotating relative to the rotating rotor. A reversible shaded-pole motor was made by Barber-Colman several decades ago. It had a single field coil, and two principal poles, each split halfway to create two pairs of poles. Each of these four "half-poles" carried a coil, and the coils of diagonally-opposite half-poles were connected to a pair of terminals. One terminal of each pair was common, so only three terminals were needed in all. The motor would not start with the terminals open; connecting the common to one other made the motor run one way, and connecting common to the other made it run the other way. These motors were used in industrial and scientific devices. An unusual, adjustable-speed, low-torque shaded-pole motor could be found in traffic-light and advertising-lighting controllers. The pole faces were parallel and relatively close to each other, with the disc centred between them, something like the disc in a watthour meter. Each pole face was split, and had a shading coil on one part; the shading coils were on the parts that faced each other. Both shading coils were probably closer to the main coil; they could have both been farther away, without affecting the operating principle, just the direction of rotation. Applying AC to the coil created a field that progressed in the gap between the poles. The plane of the stator core was approximately tangential to an imaginary circle on the disc, so the travelling magnetic field dragged the disc and made it rotate. The stator was mounted on a pivot so it could be positioned for the desired speed and then clamped in position. Keeping in mind that the effective speed of the travelling magnetic field in the gap was constant, placing the poles nearer to the centre of the disc made it run relatively faster, and toward the edge, slower. It is possible that these motors are still in use in some older installations.
Split-phase induction motor

Another common single-phase AC motor is the split-phase induction motor,[5] commonly used in major appliances such as washing machines and clothes dryers. Compared to the shaded pole motor, these motors can generally provide much greater starting torque by using a special startup winding in conjunction with a centrifugal switch. In the split-phase motor, the startup winding is designed with a higher resistance than the running winding. This creates an LR circuit which slightly shifts the phase of the current in the startup winding. When the motor is starting, the startup winding is connected to the power source via a set of spring-loaded contacts pressed upon by the stationary centrifugal switch. The starting winding is

Einstein College of Engineering wound with fewer turns of smaller wire than the main winding, so it has a lower inductance ( L) and higher resistance (R). The lower L/R ratio creates a small phase shift, not more than about 30 degrees, between the flux due to the main winding and the flux of the starting winding. The starting direction of rotation may be reversed simply by exchanging the connections of the startup winding relative to the running winding. The phase of the magnetic field in this startup winding is shifted from the phase of the mains power, allowing the creation of a moving magnetic field which starts the motor. Once the motor reaches near design operating speed, the centrifugal switch activates, opening the contacts and disconnecting the startup winding from the power source. The motor then operates solely on the running winding. The starting winding must be disconnected since it would increase the losses in the motor.
Capacitor start motor

Schematic of a capacitor start motor. A capacitor start motor is a split-phase induction motor with a starting capacitor inserted in series with the startup winding, creating an LC circuit which is capable of a much greater phase shift (and so, a much greater starting torque). The capacitor naturally adds expense to such motors.
Resistance start motor

A resistance start motor is a split-phase induction motor with a starter inserted in series with the startup winding, creating capacitance. This added starter provides assistance in the starting and initial direction of rotation.
Permanent-split capacitor motor

Another variation is the permanent-split capacitor (PSC) motor (also known as a capacitor start and run motor).[6] This motor operates similarly to the capacitor-start motor described above, but there is no centrifugal starting switch,[6] and what correspond to the start windings (second windings) are permanently connected to the power source (through a capacitor), along with the run windings. [6] PSC motors are frequently used in air handlers, blowers, and fans (including ceiling fans) and other cases where a variable speed is desired. A capacitor ranging from 3 to 25 microfarads is connected in series with the "start" windings and remains in the circuit during the run cycle. [6] The "start" windings and run windings are identical in this motor,[6] and reverse motion can be achieved by reversing the wiring of the 2 windings, [6] with the capacitor connected to the other windings as "start" windings. By changing taps on the running winding but keeping the load constant, the motor can be made to run at different speeds. Also, provided all 6 winding connections are available separately, a 3 phase motor can be converted to a

Einstein College of Engineering capacitor start and run motor by commoning two of the windings and connecting the third via a capacitor to act as a start winding.

Wound rotors
An alternate design, called the wound rotor, is used when variable speed is required. In this case, the rotor has the same number of poles as the stator and the windings are made of wire, connected to slip rings on the shaft. Carbon brushes connect the slip rings to an external controller such as a variable resistor that allows changing the motor's slip rate. In certain high-power variable speed wound-rotor drives, the slip-frequency energy is captured, rectified and returned to the power supply through an inverter. With bidirectionally controlled power, the wound-rotor becomes an active participant in the energy conversion process with the wound-rotor doubly-fed configuration showing twice the power density. Compared to squirrel cage rotors and without considering brushless wound-rotor doubly-fed technology, wound rotor motors are expensive and require maintenance of the slip rings and brushes, but they were the standard form for variable speed control before the advent of compact power electronic devices. Transistorized inverters with variable-frequency drive can now be used for speed control, and wound rotor motors are becoming less common. Several methods of starting a polyphase motor are used. Where the large inrush current and high starting torque can be permitted, the motor can be started across the line, by applying full line voltage to the terminals (direct-on-line, DOL). Where it is necessary to limit the starting inrush current (where the motor is large compared with the short-circuit capacity of the supply), reduced voltage starting using either series inductors, an autotransformer, thyristors, or other devices are used. A technique sometimes used is (star-delta, Y) starting, where the motor coils are initially connected in star for acceleration of the load, then switched to delta when the load is up to speed. This technique is more common in Europe than in North America. Transistorized drives can directly vary the applied voltage as required by the starting characteristics of the motor and load. This type of motor is becoming more common in traction applications such as locomotives, where it is known as the asynchronous traction motor. The speed of the AC motor is determined primarily by the frequency of the AC supply and the number of poles in the stator winding, according to the relation: Ns = 120F / p where Ns = Synchronous speed, in revolutions per minute F = AC power frequency p = Number of poles per phase winding Actual RPM for an induction motor will be less than this calculated synchronous speed by an amount known as slip, that increases with the torque produced. With no load, the speed will be very close to synchronous. When loaded, standard motors have between 2-3% slip, special motors may have up to 7% slip, and a class of motors known as torque motors are rated to operate at 100% slip (0 RPM/full stall).

Einstein College of Engineering The slip of the AC motor is calculated by: S = (Ns Nr) / Ns where Nr = Rotational speed, in revolutions per minute. S = Normalised Slip, 0 to 1. As an example, a typical four-pole motor running on 60 Hz might have a nameplate rating of 1725 RPM at full load, while its calculated speed is 1800 RPM. The speed in this type of motor has traditionally been altered by having additional sets of coils or poles in the motor that can be switched on and off to change the speed of magnetic field rotation. However, developments in power electronics mean that the frequency of the power supply can also now be varied to provide a smoother control of the motor speed.
Three-phase AC synchronous motors

If connections to the rotor coils of a three-phase motor are taken out on slip-rings and fed a separate field current to create a continuous magnetic field (or if the rotor consists of a permanent magnet), the result is called a synchronous motor because the rotor will rotate synchronously with the rotating magnetic field produced by the polyphase electrical supply. The synchronous motor can also be used as an alternator. Nowadays, synchronous motors are frequently driven by transistorized variable-frequency drives. This greatly eases the problem of starting the massive rotor of a large synchronous motor. They may also be started as induction motors using a squirrel-cage winding that shares the common rotor: once the motor reaches synchronous speed, no current is induced in the squirrel-cage winding so it has little effect on the synchronous operation of the motor, aside from stabilizing the motor speed on load changes. Synchronous motors are occasionally used as traction motors; the TGV may be the best-known example of such use. One use for this type of motor is its use in a power factor correction scheme. They are referred to as synchronous condensers. This exploits a feature of the machine where it consumes power at a leading power factor when its rotor is over excited. It thus appears to the supply to be a capacitor, and could thus be used to correct the lagging power factor that is usually presented to the electric supply by inductive loads. The excitation is adjusted until a near unity power factor is obtained (often automatically). Machines used for this purpose are easily identified as they have no shaft extensions. Synchronous motors are valued in any case because their power factor is much better than that of induction motors, making them preferred for very high power applications. Some of the largest AC motors are pumped-storage hydroelectricity generators that are operated as synchronous motors to pump water to a reservoir at a higher elevation for later use to generate electricity using the same machinery. Six 350-megawatt generators are installed in the Bath County Pumped Storage Station in Virginia, USA. When pumping, each unit can produce 563,400 horsepower (420 megawatts).[7]

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Universal motors and series wound motors

AC motors can also have brushes. The universal motor is widely used in small home appliances and power tools.
Repulsion motor

Repulsion motors are wound-rotor single-phase AC motors that are similar to universal motors. In a repulsion motor, the armature brushes are shorted together rather than connected in series with the field. By transformer action ,the stator induces currents in the rotor, which create torque by repulsion instead of attraction as in other motors. DC MOTOR A DC motor is an electric motor that runs on direct current (DC) electricity.

Stepper motor
A stepper motor (or step motor) is a brushless, synchronous electric motor that can divide a full rotation into a large number of steps. The motor's position can be controlled precisely without any feedback mechanism (see Open-loop controller), as long as the motor is carefully sized to the application. Stepper motors are similar to switched reluctance motors (which are very large stepping motors with a reduced pole count, and generally are closed-loop commutated.)

Fundamentals of operation
Stepper motors operate differently from DC brush motors, which rotate when voltage is applied to their terminals. Stepper motors, on the other hand, effectively have multiple "toothed" electromagnets arranged around a central gear-shaped piece of iron. The electromagnets are energized by an external control circuit, such as a microcontroller. To make the motor shaft turn, first one electromagnet is given power, which makes the gear's teeth magnetically attracted to the electromagnet's teeth. When the gear's teeth are thus aligned to the first electromagnet, they are slightly offset from the next electromagnet. So when the next electromagnet is turned on and the first is turned off, the gear rotates slightly to align with the next one, and from there the process is repeated. Each of those slight rotations is called a "step", with an integer number of steps making a full rotation. In that way, the motor can be turned by a precise angle.

Unit 3.SYSTEM MODELS AND CONTROLLERS Building blocks of Mechanical, Electrical, Fluid and Thermal Systems, Rotational Transnational Systems, Electromechanical Systems Hydraulic Mechanical Systems. Continuous and discrete process Controllers Control Mode Two Step mode Proportional Mode Derivative Mode Integral Mode PID Controllers Digital Controllers