Marine machinery systems

Details of machinery systems determined by role /function of vessel / platform, but can be characterised
based on services provided :-

• Propulsion – engines and propulsors

• Electrical power generation and supply

• Ship handling – rudder, anchor, winches, etc.

• Auxiliary systems for above

– Fuel

– Cooling

– Lubrication

– Starting and controls

• Other ship services

(for crew, passengers, cargo)
– HVAC

– Water production and supply

– Waste treatment

– Bilge and ballast systems

1-1
1-2
1-3
1-4
Functional blocks of an electric drive system

Power Electronic Mechanical

Motor
source converter load

controller

Study of electric drive system

• Characteristics of mechanical loads
• Behaviors of power electronic converters
Converter
• Provider motor with adjustable voltage, current and frequency
• Designer can usually select φ
• Convert electric waveform of power source to a waveform that
the motor can use
1
Primary energy Prime Movers Secondary Movers Power Transmissions
(‘fuel’) (‘engines’) Motors Actuators Fixed Ratio Variable Ratio
Mechanical Coupling
Coal Steam turbine Electric motors Fluid cylinders Mechanical coupling
(some)
Oil I/C engine Fluid motors Fluid actuators Clutch Clutch (some)
Gas Gas turbine Fluid coupling Fluid coupling (some)
Electromagnetic Electromagnetic coupling
Hydroelectric
coupling (some)
Nuclear Belt Gearboxes
Oceanographic Chain Belt drives (some)
Power Converter
Terrestrial Gears

M -1 I-2 2-L Power Transmitter

Power Source Power Sink

Prime Component Component

No. 1 Load
mover No. 2
marine power plants

1-9
 I Q ( bar )( lpm )
kw 
 600
ii 2

G V M P P M
ii 
DC Electrical Drive I Q
Hydrostatic Drive
(Ward Leonard Drive)
Typical Drives ( or transmissions)
Characteristic Power Parameters
Characteristics of Loads Type of Power Potential Parameter Flow Parameter

Mech (linear) Force , N Velocity, m/s

Nature of load has to be appreciated
before drive which couples Mech (Rotary) Torque, T Angular Velocity, rad/s
it to power source can be selected properly.
Hydraulic Head, P Discharge, Q
1. Torque-speed characteristics
Electrical Voltage, V Current, I
2. Load direction
• Some loads overhauls (loads with high inertias such as flywheels)
• PM dc motors & shunt motors change to generators if pushed fasters,
(no blocking diodes).
• Series DC & AC induction motors are poor power absorbers.

3. Cyclical torque variations

• In absence of specific information, use service factors or shock factors.
4. Inertia
• Is important for starting and stopping considerations,
• Speed change during operation.
• Either of these may turn out to be dominant factors in drive selection.
 Mechanical Load – Torque  4. Centrifugal pump:
[Dynamic (Kinetic) type]
Speed Characteristics
Torque in %
Power 
4 

2 
P = 
T 1
= 100%
TRated Constant Torque, 3.   Variable displacement axial piston 
pump: [positive displacement type
1 .
Constant HP  
3

N.
Speed in %
100% = NSync

Torque-speed characteristics
1. Constant Torque (Traction Load) ---- conveyors, crane hoist systems
2. Torque α to speed (laminar flow load) – viscous friction, magnetic brakes
3. Toque inversely α to speed (traction load) – constant horse power loads
4. Torque α to square of speed (turbulent flow) – centrifugal pumps, fans & blowers
 Range of Modern Control Applications
 Loads have widely different requirements
 Speed control process – varying degree of precision & accuracy automated process and office machinery
 Steady state operation – fan, pump drive
 Dynamic performance – robotics, tape drives and actuators. Torque/inertia ratio is an important parameter

AC Electric Motors : NEMA – inch derived units, (USA), IEC – metric units, (Europe) .
• Used in vast majority of traction drive.
• They differ in frame size, frame type, line voltage, number of phases, insulation rating, starting means,
torque-speed characteristics, duty ratings

Motor ratings & type - Tell good deal about the application. Look at both ends to find limiting criteria.
V Zero acceleration
 Selection criteria
 - determine relevant application factors and
narrow down the drive choice in most instances Speed
to a general motor type. t
 motor characteristics, Servo drives
 load requirement,
 control requirement Pump, Fan

Hoist
 Selection process
starts by defining a motion specification,
 sizing the motor, 0 Time
 defining the power requirement, Load Response Curve during Run-up
 defining the transmission
 Drive Specifications ( Power, P = 
• Input horsepower – good baseline to examine drive requirement.

• Input speed – establishes or confirm torque, also form baseline of life calculation.

• Torque – most important factor in sizing a drive, requires contact force,

provides tangential drive force at contact, establishes stress levels,
establishes life
Drive
- Step-up T1 > T2 (speed increaser)
Input power,
P1 = 
Motor
- Step-down T2 > T1 (speed reducer)
Load
- Adjustable* (both torque maxima
P1  P 2 Output power, have to be calculated)
P2 = 
Input coupling
 pinion ― belt drive

― chain drive
― * gear drive
 
T 1  2 N 1  2 r1 1
    
Gear wheel T 2  1 N 2 1 r 2 n

(n = N2 / N1, gear ratio)
 Constant Torque Load
V= r= 0.5 m/s
TL rad/s
Drum, = 120 rad/min = 120/2
TR 0.5m Diameter = 19 rpm

Motor

Motor, Gearbox
Acceleration = 0
1500 rpm 1000kg V
(9810N)

t
LT = Mgr
TL: Load Torque
• Torque required at drum to hoist maximum load = 9810 x 0.25  2500 Nm (load torque)
• Suppose max hoisting speed: 0.5 m/s  19 rpm
• Suitable gear ratio: 1500:19  80:1 .

TR: Reflected load Torque

• load torque reflected to motor side: 2500/80  31 Nm (full load torque)
• assume friction in gearbox :  20% of full load torque
 0.2 x 31 = 6 Nm
Therefore, max torque required for hoisting = 37 Nm

Motor power, PMAX = 37 x (2 x /60) x 1500 = 5.8 kW (at 1500rpm)
 V= r= 0.5 m/s
TL
  rad/s
Drum,
TR 0.5m Diameter = 120 rad/min = 120/2π
= 19 rpm
Motor
V
Motor, Gearbox
1500 rpm 1000kg
(9810N)
t
Suppose load is to be accelerated from rest and brought up to maximum speed in 1 sec

From manufacturer’s catalogue: Motor’s inertia = 0.02 kgm2 (Jm )

Referred inertia of drum & gear box = 0.02 kgm2 (Jg )

JL: Load inertia at drum: JL = Mr2 = 1000 x (0.25)2 = 62.5 kgm2

JR: Effective inertia of load as seen by motor: JL (EFF) = 62.5 /802 = 0.01 kgm2

Total effective inertia (JT) = JM + Jg + JL(EFF) = 0.02 + 0.02 + 0.01 =0.05 kg m2

Angular acceleration    t = [2 /60) x 1500] / 1 = 157 rad/sec2

Accelerating Torque: Tdyn = JT x  = 0.05 x 157 = 7.85 Nm

2
Check using linear power:
Force x velocity = 9810 x 0.5 = 4.9KW (power lost in gear box was ignored)

Motor power, PMAX = 37 x (2 x / 60) x 1500 = 5.8 kW (at 1500rpm)

At constant velocity, acceleration is
zero, hence accelerating toque
Torque, Nm vel diminishes, steady state torque
supports the hoisting load

Accelerating torque (7.85 Nm)

40 -

20 - Steady hoisting torque t

(37Nm)
acceleration

Speed, rev/min
0 1500
Steady state torque – speed curve of load as seen by motor

Torque requirements for motor in hoist application

• In order to meet both the steady – state and dynamic torque requirements, a drive capable of
delivering a torque of 44.85 Nm (37 Nm + 7.85 Nm) at all speed is required.

• Torque is dominated by steady – state requirement and inertia – dependent accelerating torque is
comparatively modest.

• If acceleration requirement is 0.1 sec then accelerating torque is 78.5 Nm and it will be the
dominating factor.
 Electric Machines - reversible
• Mech Energy Elect Energy (Generator)
• Elect Energy Mech Energy (Motor)
• I – in electric circuit (windings)
  - in magnetic circuit (iron cores)
Interaction is the basis of
Electromechanical Energy Conversion Process

1. Incremental Motion System

2. Force Producing Mechanism
3. Continuous Energy Machines - Motors
- Generators
2 components - Field Windings (B)
- Armature Windings, E, I exists
Electrical Coupling Mechanical
System Field System
E, I B W, T
Motor Action Generator Action
F=B l I (current carrying wire) E=B l V (moving wire)
 a
shaft
b

Nr
c Rotor
Stator

Principles of Operation (Induction Motor)

Alignment of
Generation Transformer
Magnetic Field
of revolving action
Axis (Force
field (Induction)
Produced)

NSYNC = 120 x freq /no of poles

NSLIP = NSYNC - Nr

Slip, S = NSLIP / NSYNC x 100%

 Motoring Generating Plugging
NSYNC, (revolving magnetic field speed ) NSYNC

Nr ( rotor speed ) Nr
Nr NSYNC

0 ≤ N r ≤ NS ,
Nr > NS, S < 0 Nr < 0 , S > 1
1 ≥ Slip factor (S) ≥ 0

1. Synchronous speed ( NSYNC ) = 120 x frequency / number of poles. [Motors]

2. NSLIP = NSYNC - Nr 3. Slip factor ( S ) = NSLIP / NSYNC x 100%

Example: AC Motor has 4 pole, 50 Hz, and slip factor is 5% (0.05). .

∴ NSYNC = (120 x 50) /4 = 1500 rpm. ∴ Rotor speed ( Nr ) = 0.95 x 1500 =1425 rpm.



2 poles 4 poles 8 poles

 Classification of Selected Electric Motors

AC AC/DC SPECIAL DC
Motors Motors Motors Motors
 Separately
Single-phase Universal excited
induction
Self excited
Synchronous Three-  Servomotors ― Permanent
 phase 415 ~ 440v Magnet
220 ~ 240v DC Brushless ― Shunt
Synchronous ― Series
Repulsion
― Compound
start Stepper Motor
Induction
Squirrel- ―Permanent Magnet
Cage ―Squirrel-cage ―Variable Reluctance
―Split-phase ―Wound-rotor ―Hybrid
―Capacitor start
―Capacitor motor
―Permanent split-capacitor (PSC)
―Shaded-pole
 AC Motor
Star
(Starting)
Connection
Stator
Primary
*(Armature windings Delta
Windings) (Running)
Connection
Induction Motor
• Singly exited
Squirrel (Constant
• Self starting Speed)
Cage
Rotor
Secondary
*(Field windings
Windings) (External
Wound Resistor Slip
• Synchronous motor,
- doubly excited : ac in stator windings, dc supplied to rotor windings Rotor Rings)
 1. A motor with 4 pole, 50Hz,
Full load speed is 1425 rpm

NSYNC = 120xfreq / poles

= 120 x 50 / 4
= 1500 rpm

... Slip, S = 1500-1425 / 1500

= 0.05 or 5 %

2. A motorHz,
Full load speed = 1140 rpm

NSYNC = 7200 / poles

... P = 6 poles

... Slip, S = 1200 - 1140 / 1200

= 0.05 or 5 %
If slip = 0.02,

Nr = (1 – s) NSYNC
= (1 – 0.02) 1200 = 1176 rpm
Example
A 6 poles, 3phase, 60 Hz, induction motor drives a ventilating fan.
The motor torque at full-load as a function of slip is |Tma| = 4000s Nm ---------- (1)
The torque of the load as a function of the speed is TL = 10 + (16.484 x 10-3) ω2 Nm ----------- (2)
Sketch the torque-speed characteristics of the motor and load, indicating the operating points.
Determine the slip, torque and power of the motor.

Solution NSYNC = 120 x frequency / no of poles

= 1200 rpm
Ventilating Fan
ω SYNC = 2/ 60
P = 125.66 rad/sec

Equating Eq (1) & Eq (2) at operating point, P

4000s = 10 + (16.484 x 10 -3) ω 2

But ω = (1 – s) ωSYNC = (1 – s) 125.66
4000s = 10 + (16.484 x 10 -3) [(1- s)125.66] 2
Accelerating torque 260.3s2 – 4520.65 + 270.3 = 0

...
Starting torque
Solving above quadratic equation

s = 17.31 or 0.0599
... choose s = 0.0599 ≈ 0.06
P is the operating point where s = 0.06 ... Torque = 4000s = 240 Nm
Power = ω T = (1 - s) ωs T = 28.35KW
 3 phase synchronous generator (a) Salient Pole

DC field provided
Electrical through slip rings
output power

Three-Phase
voltage

-Low speed generators

-normally laminated poles
-used in hydroelectric power stations

Prime
mover

Frequency = (N sync x no poles) /120, (Generator)

Frequency = (1500 x 4) /120 =50 Hz (Generator) (b) Cylindrical
Rotor
N sync = (120 x frequency) / no of poles, (Motor)

Schematic representation of a four-pole synchronous generator -turbo-generators/ turbo-alternators

showing reversal of power circuit as compared to the dc machine. -high speed generators,readily withstand
large centrifugal forces.-often not laminated
1. Wye Connection (Star) (Start)
1

V
L1 1 1’ VL  3V
2
VL 3’ 1’
L2 2’ or 2’ I L  I
3 3’
L3
3 2

2. Delta Connection (run)

1
L1 3’
VL  V
VL
3 1’ I L  3I
L2
2’ 2
L3

3. Input power
Phase quantities: P  3V I cos 
Line quantities: P  3VL I L cos 
4. To determine output power kW of motors, when current (I),
power factor (PF) and efficiency () are known

S = apparent
IN (kW) Motor OUT (kW) power Q = reactive
power (VAR)
3VL I L cos  ) 
P = active power (watts)

OUTPUT POWER
INPUT POWER = (eff %)
VI (eff %)
For DC: kW 
1000 100
For AC: (output power)
VI (eff %) PF
1 : kW 
1000 100
VI (eff %) PF  2
2 : kW 
1000 100
VI (eff %) PF  3
3 : kW 
1000 100
 An induction motor in a fertilizer factory operating at 2300v, 3 ph, 50 Hz, has a full-load speed of 1478 rev/min.
it takes an input of 960 kVA at a power factor of 0.75 at full load, when the efficiency is 92%. The no-load
losses are known to be 34kW, half of it being due to windage and bearing friction. Find the following at the full-
load condition: 3 2300V, 50Hz
(i)the line current and the slip 3 Motor load
(ii)The output power cos   0.75,  0.92

(iii)The torque developed by the motor

( i ) power  3V L I L cos  , but 3V L I L  960 , 000 VA N sync  1478

slip 
 I L  241 amp , power input  960 , 000  0 . 75  720 , 000 watts N sync
120 f
1500  1478 N sync 
slip   0 . 01466 P
1500  P  4 poles, N sync  1500rpm
(ii )Output power , Pout  ( 3V L I L cos  )    960  0 .75  0 .92  662 .4 kW
(662.4  17)
(iii) Torque developed by Motor: T = Mechanical Power developed   4.39kNm
Angular Velocity ( 2 1478) / 60

Computation of Performance Electrical power input ( 720 Kw)

Stator core loss Power transferred across the air-

stator copper loss gap (i.e. rotor input power_

Rotor copper loss Mechanical power developed (679.4 Kw)

Power losses Rotational losses Mechanical power output

Useful power (17 Kw ) (662.4 Kw)
losses
A three phase ,four pole,30-hp,220V,60hz,Y-connected induction motor draws------
a current a current of 77 A from the line source at a power factor of 0.88. At his operating

25820

485

24302

1033

23003

1299

540
22463
30 hp
 What is electric motor efficiency?
Electric motor efficiency is measure of ability of an electric motor to convert electrical energy to
mechanical energy,

Therefore, only power absorbed by electric motor is the losses incurred in making conversion
from electrical to mechanical energy

Efficiency = Mechanical energy output x 100%

Electrical energy input

- Mechanical energy out = Electric energy input – motor losses

- Electrical energy in = Mechanical energy output + motor losses

Therefore, to reduce electric power consumption for a given mechanical energy out
 motor losses must be reduced and electric motor efficiency increased

Five components of losses in an induction motor

1. Power losses (stator)
2. Power losses (rotor)
3. Magnetic core losses (iron losses) in stator
4. Friction and windage losses
5. Stray load losses
 (heat)

Motor Efficiency → 90.5%

Good Energy Management – Entire motor load system be evaluated to minimize

energy waste
NEMA publication, MG10- makes the following recommendation
1. Motor Ratings
2. Application Analysis
3. Process and Machinery
4. First Cost versus Long range energy cost
 Single Phase Motors
Starting
capacitor
Starting winding load Starting winding
Rotor

L1 Centrifugal L1
Rotor starting Rotor
switch
L2 L2
running running
winding winding
L1 L2
Split-phase motor Permanent-split
capacitor motor Shaded pole motor

Starting Main winding current

capacitor
Starting winding Starting winding current

L1 Centrifugal
Rotor starting current time
switch
L2
running
winding

Capacitor-start motor Phase shift between main winding current and

starting winding current
Performance curves of four types of single-phase electric motors

Permanent-split
Split-phase motor
capacitor motor
100
Capacitor-start motor

80
Rotational Shaded
pole
speed (% of
60 motor
synchronous
speed) Centrifugal
40 switch-opens

20

0
100 200 300 400
Torque (% of full-load torque)
 Torque
Motor A

Motor B

Disc sander

Speed
Motor A
• sander will start very quickly and accelerate to operating speed.

• machine will not easily stall if operator uses excessive thrust. The excess torque, especially at start-up might
surprise the unwary operator, as there is a tendency for machine to jerk out of operators hands on start-up.

Motor B
• There will be no violent jerk on start-up, but motor may stall if the sander is presses too heavily against the
surface.

• Operator may have to lift sander clear of surface on start-up to allow machine to run up to operating speed.
Example 8
An AC motor is required for a surface grinding operation. The diameter and the thickness of the designated
grinding wheel as shown in figure are 400 mm and 70 mm respectively.

The wheel rotates at a speed of 480 rev per min, the contact angle between the wheel and the workpiece
is about 1.430 and the grinding force is taken as 0.15 N per mm2 of contact surface.

If the motor is coupled to the grinding wheel through 3:1 reduction gearing, select a suitable type of motor,
giving:

(i) The kilowatt rating (~ 0.6 kw)

(ii) number of poles required for the 50 Hz operation (4 poles)
(iii) slip in per cent (0.04)
(iv) input current from a 220 – V line – to – neutral supply at 0.75 p.f. ( 5 amps )

Assume a gearing efficiency of 87% and a motor input/output efficiency of 0.73

400 mm 70 mm

Grinding wheel

1.430
Side view End view

Work-piece
 Solution s=r
i. Contact area = (arc length x 7 ) cm2 = { (20 x 1.43 x  ) / 180 } x 7 = 3.5 cm2
a. Grinding force = constant pressure x area = 15 x 3.5 = 52.5 N
b. Torque = Fr = 52.2 x 0.2 = 10.5 Nm
c. Power required for surface grinding,
Power = ω T = {(2 x 480) / 60} x 10.5
= 528 watts P in = 832

528 / motor output = 87 % 87%

Therefore motor output = 528 / 0.87
Motor Load=528
= 607 watts
Grinding
Pout / P in = 73 %, thus P in = Pout / 0.73
73% wheel
= 607 / 0.73 = 832 watts P out= 607

ii. Motor speed = 480 x 3 = 1440 rpm

N SYNC = 120 f / p, therefore p = (120 x 50) / 1440 = 4.167, thus p = 4 poles

iii. N SYNC = (120 x 50)/ 4 = 1500 rpm, therefore slip = (1500 – 1440)/1500 = 0.04 (4%)

iv. Power = IV cos , therefore I = 832 / 220 x 0.75 ) = 5 amps

v. Select: Single phase induction motor, Capacitor start motor or split phase motor
 DC Motors
• Speed adjustable, quick response (high ration of torque to inertia)

• Direction of rotation reversible

• Dynamic braking – eliminate need for brakes

• Speed – torque – motoring/regeneration

• High starting torques (~ x3 to ~ x5)

• DC power batteries  mobile application  115V, 230V  SCR, ripples  overheating

ω
Forward
regenerative Forward
2 1
braking motoring

Reverse Reverse
3 4 regenerative
motoring
braking
 DC Motors

Stator
(Field windings)
• Pole pieces
• Frame Carbon
DC Motors Commutators brushes
Rotor
(Armature windings)
• Lap
• Wave
 Speed
SHUNT IL Ia No
Motor
VT
If Nf l
ω, T
VT T Ia
Eb – back emf Torque T/TR
1.0
Speed
SERIES IL Ia
Motor
If ω, T
T Ia2
VT
Torque T/TR
Eb – back emf

Speed
COMPOUND
IL Ia
Motor
If ω, T

VT
Eb – back emf Torque T/TR
 Speed
SHUNT
IL Ia No
Ra VT
Motor Nf l
If ω, T
VT T Ia
Eb – back emf Torque T/TR
1.0

N o  N fl
VT = Eb + IaRa ---- (1) Speed Regulation 
N fl
VT = k ω + IaRa Shunt Motor: T = k Ia

VT I a Ra VT  I a Ra VT  E b
   Starting Current Ia
K K  K Ra
• Additional notes
 Permanent Magnet DC Motor
Ia Voltage equation:
V = RaIa + KE 
Ra
Armature current:
V Eb = KE
Ia = ( V - KERa 
Torque:
Equivalent circuit of a DC motor KT
T  KT Ia  (V  K E  )    ( 3 )
Ra
Torque T
KT K E
K T V1 slope  From Eq (3)
Ra Ra Starting torque: TS= (KTV)/Ra  
V1 Independent of
No load speed:  V/KE  
V and 
V2 KT = torque constant (1 Nm A-1)
B
KE = Back emf constant (1 Vs rad-1)
A
Using the above units
Speed 
KT = KE = K (motor constant)
(141.6 oz in A-1 = 104/7 VK rmp-1)
Torque vs speed characteristics of a DC motor
The given motor has the speed-torque characteristics shown in Fig, Ra= 2 ohms
(a) If VT = 5V, calculate the motor no-load speed.
(b) Calculate the speed of the motorExample
for VT = 5 V and TL = 7 oz.-in
(c) What must be the input VT to restore the motor speed calculated in part (a)
assuming that the 7 oz-in. load is applied?
KT (a) At no load speed,
T  KT I a  (VT  K E )    (3)
Ra
0 = 1000 rpm, VT = 4V
Starting torque: TS= (KTV)/Ra --- (4) KE = 4/1000, [ Ω0 = VT /KE ]
If vT = 5V, then 0 = (5 x 1000)/4 = 1250 rpm
Torque T KT K E
(b) From Eq (3), slope  = 20/1000
Ra
From Eq (4) TS / VT= KT /Ra = 20 / 4 = 5
5V
20 Using Eq (3) 7 = 5 x 5 – (20/1000) 
6.4V rpm
4V (c) Using (3) and (4)
7
Speed  7 = 5 x VT – [(20/1000) x 1250]
1000 1250 VT = 6.4V
900
 DC Motor Power flow diagram of
the DC motors
Ia
Pin = VtIL
Ra
developed
VT mechanical
Ea = KEm power

Ia2 (Ra + Rs) Pmech = EaIa = Tmech

Prot Pout = To

developed
output
power
A small dc motor has a armature resistance of, Ra = 178 mΩ ,= 0.178 Ω.
The terminal voltage, VT = 9 V
The no load speed = 14600 rpm, and the motor is drawing a current of 0.437A.

Determine
-the rotational losses – [Ans:3.9 w]
-the motor constant, KE –[Ans: 5.84 x 10-3 V/rad]

Solution:

Ea = VT – IaRa = 9 – 0.437 (0.178) = 8.922 V

Rotational losses = EaIa = 3.9 w

Ea 8 .922
Motor constant, KE  
m 2 (14600 ) / 60
 5.84 x 10  3 v /( rad / sec)
 Step: 300 ~ 600
DIR
DIR LOG 300 ~400 step/s
DRIVER AMP Permanent magnet type
-rotor is a permanent magnet
WIND DRIVER AMP
-rotor is large, has high polar
CLOCK SEQ moment of inertia.
LOG DRIVER AMP -exhibit a high holding torque even
without sustained stator energization
DRIVER AMP

Logic and drive circuitry
Step: 150
700 ~800 step/s
Variable reluctance type
-rotor made from unmagnetised
soft iron.
-rotor can be small & light.

Step: 0.50 ~ 150

150 ~200 step/s
Hybrid type
-slotted soft iron rotor but
include a permanent magnet
in its magnetic circuit
 Torque vs pulse rate curves

Torque T Slew range -motor speed can follow input pulse rate
without losing steps, but cannot start, stop or reverse on
command

Maximum pull-in torque

pull-in characteristic
torque curve
pull-out torque
characteristic
curve

Start range

Maximum Slew Maximum

pull-in range pull-out
pulse rate pulse rate

10 Pulse rate (pps)

 Example
Figure shows part of a mechanism which is driven by a stepper motor through a belt and pulley
transmission system. The pulleys have an effective diameter of 240 mm. the belt conveys a
mass of 500 kg which has to be accelerated uniformly up to a velocity of 0.1 m/s in a period
of 2 s. This maximum velocity is then held constant for 4 s before being decelerated uniformly
back to zero velocity in 2 s. Friction in the system requires a constant force of 100 N acting
effectively through the mass. On completing the cycle, the motion is reversed through the same
velocity-time history to return the mass the original starting position. The stepper motor operates
with 200 pulses per revolution and is directly coupled to the driven pulley. Determine:-
(a) The pull-in torque at start up
(b) The pull-out torque at constant velocity
(c) The stepping rate required for the constant velocity
(d) The power required at constant velocity.

Velocity (m/s)
Friction = 100 N
500kg 0.1 acc = 0

Motor slide way

200
pulses/rev
driven Idler Time (s)
pulley pulley 2 4 2
 Solution
(a) The force required has to overcome friction in the mechanism and accelerate the mass.
At start-up:- force = ( m x a ) + friction force
force = mass x accel + friction = 500 x (0.1/2) + 100 = 125 N
Starting torque required is therefore:- 125 x 0.12 = 15 Nm

(b) This is the minimum torque, or pull-in torque required at start-up. As the system
accelerates, this torque will be constantly required until the steady velocity is reached.
During steady motion, there is no force required for acceleration.
Running torque during steady motion is:- 100 x 0.12 = 12 Nm

(c) This lower value of torque is the minimum value allowable which the motor must
be capable of providing without losing synchronism when running at the constant speed,
i.e. the pull-out torque. Since the peripheral velocity of the pulley is v = DN, then the

Rotational speed of the pulley is N = v / (D) = 0.1 / (0.24) = 0.133 rev/s

Required stepping rate is 200 x 0.133 = 26.5 steps/s

(d) The power required at this speed is 2 NT = 2 x  x 0.133 x 12 = 10 W

 25,820 w

(485) (24,302)
(1033)

(23003)
(1299)

(540)
(22,463)
NEMA
 NEMA Motor frame size
In 1952,new frame assignment is “U Frame”, designed for use with Class A insulation, temperature rating of
105° C. In 1964,”T Frames” were introduced ,designed for use with Class B insulation, with a temperature
rating of 130 ° C. Increase in temperature capability made it possible to pack more horsepower into same
size frame . Eg : 254 frame, 5hp,1800 rpm, 1 1/8 “ shaft diameter, 254 U frame, 7.5hp,1800 rpm, 1 3/8 “
shaft diameter, 254T frame, 15hp,1800 rpm, 1 5/8 “ shaft diameter. To accommodate larger mechanical hp,
shaft & bearing sizes has to be increased.
 Starting & running induction motors on engine –generator
power.
KVA Code
Indicate locked rotor kilovolt ampere per hp. Eg: N- max
locked rotor kVA/hp of 12.49. If motor is rated 1/3 hp, Max
locked rotor kVA is 4.163, Max locked rotor ampere at 115V
is 4.183/115 = 36.2 .

-For 3Ø motor, code letter determined by locked rotor

kVA/hp/phase.
-Most frequently classifies is Code F on NEMA Design B
motors,

-If problem occurs during start of motor, some suggestions

:
1.specify an oversized generator & improve system power
factor.
2.Use reduced voltage starters. It reduces KVA required to
start a given motor.
3.Use wound rotor motors. Require lower starting current.
4.Provide clutches so that motor may be started before load
applied to them.
5.Change starting sequence. Start largest load first.
6.Use motor generator set. Start largest motor first which in
turn supplies power to motor to be started ,eg: elevator
services.
Temperature Ratings

Insulation system
Insulation is a major element that has
greatest effect on motor life. It undergoes
more design change than any other part of
the motor, when equipment size seem to
be shrinking &motor subject to higher
operating temperature.
Temperature is vital. Rule of thumb,
every 10°C rise in insulation temp, Its
life is halved, and every 10°C decrease
in temperature ,its life is doubled.
Motor operating in typical plant where air is
clean & dry, motor abuse absent, a class B
or F insulation system in standard off the
shelf motor is adequate