INDUSTRIAL MOTOR CONTROL

BALAGHAT POLY - TECHNIC RUDDHA,

AHMADPUR
PROJECT SEMINOR = INDUSTRIAL MOTOR CONTROL

PROJECTORS STUDENT :-

KENDRE GANESH MADHAVRAO (E-J3rd SEM )

KENDRE SUBHASH MADHAVRAO (E-J3rd SEM )

NARWATE ASHISH MADHAVRAO (E-J3rd SEM )

SUPPORTI NG STAFF :-

PROF. MR. SANTOSH KONDE,

PROF. MR. AHANKARE ,

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*INTRODUCTION*
Motor control is an area of constant development. This is not
surprising with an estimated 12% of the world’s electricity
usage going to electric motors. Even modest efficiency increases
of a few percent can save millions of tonnes of CO2 over a
decade.
Additionally, the number of motors in use is booming, which,
combined with the increasing cost of copper and shipment, puts
pressure on manufacturers to minimise unit cost.
The industrial world uses electric motors to move solids,
liquids, and gases. These electric motors couldbe alternating
current or direct current. The motors range from fractional
horsepower to thousands of horsepower. For the motors to be
effective there has to be a way to turn them off and on. Motors
can also be speed controlled. about motor control, various
ways to control the speed of motors
High efficiency, reduced noise, extended lifetime, rapid time to
market. And all at optimum cost. This is the challenge
currently facing the many industries which use electric motors
Today, the demand for electronic motor control is increasing
rapidly, not only in the automotive and computer peripherals
markets, but also in industrial applications and home
appliances such as heating and ventilation systems, power tools,
vacuum
cleaners and white goods. All these mass-market applications
need cost-effective solutions without compromising reliability
CONSTRUCTION OF A DC MPTOR

notice that the shunt field and the series field both are used to make the
stator
magnet, shown in grey, stronger. The armature is shown with 4 coils.
The brushes that the A1 A2 leads
are connected to are stationary. Thus, when the armature turns, the
coils that make the rotating magnet
change. This is done by the communtator, shown in orange. The effect is
that the two magnets always
push against each other. Thus, the motor will turn and generate torque.
Another thing to note is that the
armature, as well as the series field, is a low resistance. That means that
if the motor has a voltage across
the armature a large current should flow. The current is actually limited
as the motor speeds up, but at
zero or low speed, the motor current is very large.
TYPES OF MOTORS
1)Universal motor
Universal motors may be used with an AC or DC supply current. The stator and rotor windings of the
motor are connected in series through the rotor commutator so that the mechanical force generated is
always in the same direction (as it is proportional to the square of the current flowing). Operating at
normal power-line frequencies, the maximum output of universal motors is limited and motors exceeding
a few kilowatts are rare. The advantages of universal motors are specifically high starting torque, very
compact design and high running speeds.

Main applications

1) Food processors
2)Power and garden tools

2) Brushed DC motor
Brushed DC motors are internally commutated electric motors designed to run from a DC power source.
Generally, the rotational speed of a DC motor is proportional to the voltage applied to it, and the torque
is proportional to the current. Speed can be controlled by a variable supply voltage or electronic
controls. Controlling the speed of a brushed DC motor is simple - the higher the armature voltage, the
faster the rotation. This relationship is linear up to the motor’s maximum speed. Here we address the
permanent magnet DC motor where the stator is composed of two or more permanent-magnet pole pieces
and the rotor is composed of windings that are connected to a mechanical commutator

Main applications

1)Consumer audio/video 2) Shavers 3) Toys4) Cordless tools5) Automotive body functions

6) Traction7) Servomechanisms8)Factory automation9) Machine tools

3) Single-phase induction motor

The single-phase induction motor is a brushless motor designed either with a single stator coil plus a
shaded-pole coil, or two stator coils and a phase-shift capacitor. The rotor is usually made of an
aluminum squirrel cage. Speed is controlled either by varying the motor voltage or by changing the
number of motor poles.

Main applications

1)Washing machines
2) Fridges and washing machines
3)Window and door openers
4)Three-phase induction mO tor

The three-phase induction motor is a brushless motor. Its stator is copper wound and the
rotor is typically an
aluminum squirrel cage. The motor is supplied with three alternating voltages which
produce a rotating stator field
while speed varies with the field frequency. The rotor follows this field with a lag called
the slip

Main applications

1)Washing machines 2) Heating, ventilation and air conditioning 3 ) Blowers, fans and
pumps
4)Industrial control

5) Stepper motor
stepper motor has windings only on the stator, while the rotor usually features
permanent magnets. A stepper motor converts digital pulses into fixed angular steps and,
for this reason, is normally used in an open loop configuration and is the most cost-
effective solution in many positioning applications

Main applications

1)Traction
2)Industrial and automotive actuators
3) Home appliances
CONTROLLING DEVICES USED TO CONTROL MOTORS

Microcontrollers
high-performance, real-time, low-power and low-voltage operation, while maintaining full
integration and ease of development; six PWM advanced control timers with embedded deadtime
generation; numerous PWM outputs allowing multiple motor drives

Power transistors
they come in a large variety of SMD and through-hole packages. For high-voltage low-current
applications, the standard high-voltage technologies can be useful

Fast rectifiers
Available at 300 V and 600 V, Turbo 2 diodes feature ultra-fast recovery while maintaining a low
dropout voltage. They significantly cut losses in both the diode and the transistor at turn-on.

Smart power ICs

motor drivers can be conveniently used in applications where the input voltage does not exceed a
few dozen volts and the current feeding the motor windings is limited to a few amps. These parts
may include just the power stage or include the control section.
ST has developed several types of power ICs, suited to different application requirements. Some
operate in linear and some in switch mode

Gate drivers
Half-bridge gate drivers are high-voltage monolithic circuits which include a bootstrap diode for the
floating driver, deadtime circuitry, two UVLO circuits and an uncommitted comparator for
protection functions. Signal and power grounds are separated to ensure high noise immunity.

Amplifiers and comparators

Operating at low voltage with rail-to-rail input and output capability, new op-amps bring innovation
with very high merit factors and consumption below 1 mA, while offering high slew rate, 10 V/μs
and large product gain bandwidth (up to 20 MHz). For high-voltage operation, standard CMOS or
bipolar op-amps and comparators offer single-supply operation, with adequate speed

Power factor corrections

Used to reduce the low-frequency AC harmonics of the motor
drive, power factor correction (PFC) circuits now use boost
topologies and run in either continuous or discontinuous PWM
conduction modes. Covering the 20 to 1,500W range, ST
offers a comprehensive semiconductor kit to deliver this
functionality. This consists of continuous or discontinuous
PWM
control ICs (L4981 & L6561), PowerMESH™ or MDmesh
MOSFETs and Turboswitch™ rectifiers.
Auxiliary supply
As a standalone system, the motor drive typically requires a
supply of up to 10W to feed the controller and the power
switch drive. ST offline monolithic circuits, such as the VIPer
and FIPS PWM regulator, address this function with
compact, reliable and low standby power solutions.
Protection devices
diodes are designed to protect against over-voltage by
clamping against electrostatic discharge (ESD) and electrical
overstress (EOS). They protect the DC line power bus from 5V
to 200Vdc or force triac triggering or FET transistor clamping
against any over-voltage. Uni- or bi-directional Transil™ diodes
are available as axial and surface mount
devices, with a power range of up to 5,000W (10/1000μs pulse)
and stand-off voltages from 3.3 to 376V

Intelligent Motor Control

Intelligent Motor Control gives eyes and ears to the plant floor, using sensors and control
devices with a high degreeof embedded local intelligence to feed critical data back into
programmable automation controllers (PACs), plant-floor condition monitoring units and
higher-level monitoring systems. The increased efficiency of motor communication and
monitoring allows you to make informed decisions about your
processes. Rather than simple on/off information, it gives you the data you need to help
improve production by preventing downtime, increasing productivity and boosting
profit.
The Intelligent Motor Control solution can be readily tailored for many applications. The
solution is fully scalable for projects ranging from an individual motor to a complete
plant operation. Typical systems integrate drives, intelligent relays, motor control
centers (MCCs) and sensors and other monitoring devices on a common data-driven
communications network. This delivers precise motor control intelligence as part of a
strategic maintenance program. As applicable to stand-alone drives as it is to panel
upgrades and networks of distributed motor starters, Intelligent Motor Control can help
reduce downtime by potentially alerting you to motor problems long before failure
occurs. Motor control devices have long provided users with data about motor
performance. Intelligent Motor Control transforms this data into improved information,
with the networked frastructure allowing engineers to gather information from
the drives from any location on the network, and potentially from anywhere in the world.
This allows a faster response to flagged motor problems, helping to prevent process
disruption or motor damage. Overload relays with embedded intelligence can provide you
with greater diagnostic information than traditional devices. These diagnostic parameters
assist in pinpointing problems with trip and warning identification. The inputs can be
used to monitor a variety of signals, including auxiliary contacts of branch protection
circuit breakers and contactors. Information provided by the electronic overloads can
allow engineers to act well before motor or associated electrical issues become a
problem. Further, as part of Intelligent Motor Control, higher-levelcontrollers and PCs
can take inputs from condition monitoring system. Programmable automation
controllers (PACs) can take inputs directly from sensors on the plant floor, such as
vibration sensors that monitor motor bearing condition. PACs also monitor the operating
conditions of sensors (for dirt, misalignment, etc) to avoid false trips and unwanted stop
commands on the system

FEATURE ARTICLE
All these inputs can be combined as part of Intelligent Motor Control, with the data from
mechanical monitoring of the motor transmitted on the same network as the electronic
control information to higher-level systems. There, the data can be interpreted and
presented to users as meaningful operational information. That level of integration of the
real-time condition monitoring processes can play a key role in the modern strategic
maintenance approach, helping you to effectively predict to equipment problems to
minimize costly downtime

A Proven, Scalable Solution

As an intrinsic element of the Rockwell Automation Integrated Architecture, Intelligent
Motor Control is an established technology, delivering proven results across a range of
industries. It is a key tool in managing one of manufacturing’s most essential assets, but
most importantly it is a fully scalable solution, as viable and useful to the smallest
manufacturer as to the largest.Recognizing that the most important motor in maintaining
your production is just as likely to be the smallest, Intelligent Motor Control is also cost-
effective to implement across the spectrum of applications, from a single, fractional
horsepower motor to a factory wide network of discrete high-power motors and high-
density motor controlcenters. With its tailored approach, a typical Intelligent Motor
Control system generally costs 10-15% lower than the installed cost of aconventional
system, yet offers far greater benefits in improved machine productivity, quality and
availability — all key parameters in boosting OEE In addition, Intelligent Motor
Control-based predictive maintenance strategies offer huge benefits compared to reactive
maintenance programs, helping reduce maintenance times and costs by up to 50%.
Intelligent Motor Control also offers benefits all through the motor’s life cycle in its
given application, providing an easily quantifiable
return on investment. Intelligent Motor Control as part of Integrated Architecture can
help to provide faster design times through a flexible design concept. It can result in
lower installation times, quicker set-up times and faster commissioning.
Intelligent Motor Control is a proven asset during maintenance. For example, it allows up
to 250 parameters to be held on a PC and downloaded directly to a new drive, thus
getting a machine running again in the shortest possible time.
Finally, the simplified design make upgrades easier and more predictable.
Protection, performance and ease of use are the hallmarks of Intelligent Motor Control.
Delivering on the requirement to make data-driven decisions, Intelligent Motor Control
helps you meet the challenge of efficiently controlling motors to improve plant
performance, reduce power consumption and protect your
motor investments.

THE NEXT GENERATION OF SAFE-SPEED CONTROL

The safe control of motion, whether linear, rotary or positioning, is a key concern for
many automation users and equipment suppliers. The benefits associated with this type of
control are many, such as safe control of potentially hazardous movement, performance
enhancements when total power removal is not necessary to carry out tasks and the
efficient maintenance of an application while powered up. With automation and safety
experience, Rockwell Automation helps you achieve the control you need and recognizes
the need for safe control of motion across different platforms. The result is a standard
core technology that helps give you a Safe-Speed control solution, independent of the
product chosen
With Safe-Speed monitoring functionality, you can safely monitor and control the speed
of your application allowing operators to perform tasks under safe conditions such as the
removal of jams, and perform other similar maintenance work without stopping the
application completely. This can help increase operating availability and help avoid
uncecessary wear due to frequent stop/start procedures which can ultimately help
increase productivity
The Safe Speed control core technology gives you:
1)Safe-Speed Control: Allows personnel to enter
hazardous areas only when the system is at Safe-Speed.
2) Versatility: Available as a dedicated unit in the MSR57P Relay
or options to integrate into PowerFlex 750 Series AC Drive
and in future releases of Kinetix 6000 Servo Drive.
3) Encoder inputs: Supports all encoder types
(Sin/Cos and TTL).
4) Diagnostics and LEDs Quickly identify a problem
and reduce machine downtime.
5) TÜV certified: For use in applications up to SIL CL3 / Cat. 4 / PLe.
6) Easy Configuration: Common programming tools for
simplified configuration and trouble shooting.
7)Flexibility: Supports diverse input types such as e-stops,
light curtains, interlock switches, guardlocking switches,
enabling switches.
Energy efficiency is a gem in the crowning glory of operational efficiency.
Intelligent Motor Control is the key to finding that gem.
􀀁􀀴 domestic manufacturers
spend more than $33 billion on electricity each year? Motors
consume 64% of that total. More than half of those motors run
pumps and fans, and pumps account for 20% of worldwide
electrical demand.
Much of that cost is caused by inefficient systems. Those
unnecessary costs negatively affect your bottom line, and energy
waste sabotages any energy conservation efforts that are part of
a sustainable production program for environmental and social
responsibility. Without the proper motor control systems and
components, corporate sustainability goals and plant-floor uptime goals remain mutually
exclusive􀁐
intelligent decisions that more efficiently use equipment􀀁􀁖 Energy efficiency is
becoming an increasingly important benefit of
installing soft starters and VFDs because energy costs are impacted
by the efficiency of how energy is delivered to start and run motors.
Bringing motors up to speed in a controlled manner, limiting wear
on the motor and other mechanical components, and protecting the
automation equipment are key motor control functions􀁑
􀀁􀁕􀁐􀀁􀀓􀀁􀁆􀁏􀁄􀁐􀁅􀁆􀁓􀁔
􀁴 A vital function to increase energy efficiency is to monitor and
manage the energy, including methods such as:
􀁴Load profiling measures and records energy use, then stores that information in a
central database. By tracking energy consumption patterns over time, your facility can
use historical data to verify electric bills, negotiate a better rate structure and identify
opportunities for demand management. Users often can reduce energy costs by up to 10%
after accurately profiling their energy load.
􀁴This method identifies
equipment that may be approaching failure, such as alarming for near overheat or
overload conditions. As a result, the system reconfigures electrical system topology and
manually limits demand by shedding loads or increasing generator output.
􀁴 Power quality monitoring pinpoints the cause of failures of motors, drives and
sensitive equipment. It can be used to negotiate better service from utilities and identify
the need for power factor correction. Intelligent Motor Control solutions provide energy
monitoring, control and reporting tools that help slash energy consumption. Logix
controllers provide a common collection point for data from
Intelligent Motor Control devices such as motor controllers, switches and protective
relays. The controllers work with the PCs running the􀀁 human machine interface and
logging software to automate data collection and concentrate power monitoring data. This
lets you model your energy profiles by measuring peak demands and power quality
parameters; determining demand patterns; correlating energy consumption to weather
patterns; aggregating loads; and calculating energy costs by businessgroup, department or
site. This modeling approach saves a significant amount of money because solutions can
be verified before committing capital expenditures for new systems or􀀤 􀁂
equipment.􀁕􀀏􀀁􀀕􀀁􀁑􀁆􀁓􀀁􀀦􀀯􀀚􀀖􀀕􀀎􀀒􀀍􀀁􀁍􀁊􀁏􀁈􀀁􀁔􀁘􀁊􀁕􀁄􀁉􀀁􀁔􀁖􀁑􀁑􀁐􀁓􀁕􀁆􀁅􀀁􀁕􀁐
􀀁􀁂􀁍􀁍􀁐􀁘􀀁􀁂􀁄􀁄􀁆􀁔􀁇􀁆􀁕􀁚􀀁􀀰􀁖􀁕􀁑􀁖􀁕􀁔􀀁􀁂􀁏􀁅􀀁􀀕􀀁􀀢􀁖􀁙􀁊􀁍􀁊􀁂􀁓􀁚􀀁􀀰􀁖􀁕􀁑􀁖􀁕􀁔
􀁴􀀁􀀧􀁍􀁆􀁙􀁊􀁃􀁍􀁆􀀁􀁇􀁖􀁏􀁄􀁕􀁊􀁐􀁏􀁂􀁍􀁊􀁕􀁚􀀁􀁊􀁏􀁄􀁍􀁖􀁅􀁊􀁏􀁈􀀛
- Safe Stop (Stop Category 0, 1 and 2)
- Safe Limited Speed monitoring
- Safe Maximum Speed
- Safe A
SAFE-