Documente Academic
Documente Profesional
Documente Cultură
619
100 % E
100" % I = 1.
620
d.c. series machines or the line currents of a.c. slipring and squirrel-cage motors. If the general question
is studied on this assumption, however, it is easy to
introduce corrections for the various types of machines.
These methods were adopted some 7 years ago and
have proved invaluable.
The most simple and, theoretically, the perfect form
of starter is the liquid type, because it is possible to
move the dippers or alter the level of the electrolyte
to vary the resistance at a speed which maintains a
constant accelerating torque with a minimum line
current, but so many difficulties arise in practice that
the step-by-step resistance starter holds the field except
for the very largest starters for colliery winders where
the cost of the various refinements and safeguards is
small relative to the total cost.
The chief difficulties are evaporation of the water
with creeping of the salt and resulting insulation
troubles, arcing or excessive heating with all resistance
inserted and the dippers just touching the liquid, and
heavy current-rush at the moment of short-circuiting
the plates to cut out all the resistance. No doubt
these difficulties can be wholly or partially overcome,
but the fact remains that this type constitutes a small
percentage of the total number of starters in use.
It is necessary at this point to define exactly what
is meant by starting torque, accelerating torque, and
running torque. It is surprising how loosely engineers
use these terms ; so loosely, indeed, that it is often
difficult to discover which is really meant, and the
motor makers themselves are frequently the worst
offenders. This is probably due to the fact that the
motor maker is chiefly concerned with the performance
of his motor on load and at full speed ; the starter
maker cares nothing for the performance on full load
and is concerned only with what happens while the
motor is accelerating. He requires a different set of
data from that which the motor maker is in the habit
of supplying to his customer, and he experiences very
very great difficulty in obtaining the data ; he requires
from the user a different set of data from that which
the user is in the habit of giving to the motor maker,
and again great difficulty is experienced.
There is abundance of information regarding the
power required to drive different machines on varying
loads, but one looks in vain for data regarding the
starting conditions.
Returning to the definitions : the starting torque
is obviously that iequired to start motion ; it is the
torque required to overcome static friction and may be
far in excess of the accelerating and normal running
torques ; it may vary from day to day with temperature,
and is frequently greater on Monday morning than at
any other time, on account of all the belts being stiff
and cold, and the oil squeezed out of the bearings.
Once motion-has started, the torque falls to that
required to produce steady running at a certain speed ;
this lower torque is the running torque. If it is desired
to increase the speed, a torque in excess of the running
torque has to be applied, and this is the true accelerating
torque ; it may have any value, depending on the time
in which it is desired to attain full speed. The running
torque, from the starter maker's point of view, is
TABLE 1.
2-5
5
10
15
20
25
30
40
50
60
70
80
90
100
125
150
175
200
225
250
275
300
350
400
450
500
550
600
650
400/700 r.p.m.
80
90
100
110
120
130
140
150
170
185
200
210
220
230
265
295
330
365
400
430
455
480
520
550
580
600
615
620
630
90
100
110
125
140
145
155
175
200
230
260
290
320
350
420
1300/1500 r.p.m
90
100
120
140
170
190
220
280
350
425
480
550
625
690
-
621
because no general rules apply; users sometimes complain that they have to manipulate the starter to the
half-way position before the motor starts and the
latter then rushes up to speed ; naturally this must
happen if the initial starting torque is excessive, and the
user must do what he can to reduce it.
The accelerating torque is amenable to exact calcu-
TABLE 2.
Description of work
|
I
3
4
5
6
7
8
9
10
Toothed gears
Loose pulley, as for rotor only
Shop shafting
Hoisting full load on cranes
Hoisting full load on colliery winders
Small rolls and bar-bending machines
Medium punching machines
Medium shearing machines
Large shearing machines
Large rolling mills
11
12
13
Planing machines
Disc saws for wood
Band saws for wood
14
15
16
17
18
19
20
21
22
23
24
25
26
Per cent
ft.-lb./b.h.p.
..
..
10/15
10/15
10/15
5/10/15
5/10
10/20
15/20
20/40
20/50
.. ' 1\ at start, rising to 20
at full speed
75/100
35/50 at start, rising to
75/100 at full speed
5/7 i at start, rising to
30/50 at full speed
5/7\ at start, rising to
100 at full speed
100
15/18
As in Table 1
800/1 000
6/7
500/1 000
700/1 000
2 000
3 000/3 500
14 000/18 000
500/1 000
2 000/3 000
5 000/8 000
18 000/65 000
7 000/10 000
1 900/3 800
2 500/10 000
(generally 4 000/10 000)
14 000/17 000
400
60 000/80 000
As in Table 1 for impeller
As in Table 1 for impeller,
plus, say, 70 for water
if no long, horizontal
lengths
100/200
loo
100
2\
100
100/200
300/900
1 000/2 000.
850/1 000
50/60
7 500
20/25
300
622
100
25
Seconds
FIG. 1.Torque/time and speed/time curves for 7-notch starter passing 100 per cent current on first notch with motor
having 66*6 per cent load. Stored energy: 1000 ft.-lb./b.h.p. Motor resistance: 8'8 per cent.
it is not accurate for any particular make of motor,
and may be 50 per cent in error in places.
Accuracy is of no great importance because for an
accelerating torque of 50 per cent the accelerating
times range from about 0-6 second for 2 h.p. to 5-5
seconds for 650 h.p., and trouble would inevitably
arise if starters were designed for such short accelerating
times. In practice it is unwise to design the smallest
section of the smallest starter for less than 10 seconds.
In many cases, for example the hoisting motion of a
crane, the stored energy of the rotor is all that need
be considered, because the hoisting speeds are so low
that the stored energy of the load is negligible.
623
_
_
' ~ TT XX 5-5 X K
T3
ig speed
150
140
130
r-i
120
Ts&Is
OJ
110
-y 90
S
80
1
\
70
~
60
50
II
'g 100
'_
40
.t \
r3T+M*
Tz&Iz
\
\
/
II
^P-7
SP-6
Sp-5
_i
Sp-2
30
160
e and
20
10 /
Ste<
/
10
15
20
25
30
35
Seconds
Ratio =
~ I( total resistance \
kmotor resistance/
624
Steady running _
torque and current
12
16
20
Seconds
FIG. 3.Torque/time and speed/time curves for 7-notch
starter passing 100 per cent current on first notch,
with motor having centrifugal-pump load starting at
7J- per cent and rising to 100 per cent. Stored energy :
l"000 ft.-lb/.b.h.p. Motor resistance : 8-8 per cent.
lower, and " irregular " because the peaks are of unequal
value.
20
25
30
Seconds
FJG. 4.Torque/time and speed/time curves. Conditions
as in Fig. 1, except that motor load is 10 per cent.
625
140
130
120
110
100
Sp-6
90
80
-S-i
I-SH
70
1H
60
50
g 40
20
10
Seconds
10
15
20
25
30
35
40
45
50
Seconds
026
1 Accelerating after'
erating resistance cut-out
on starter
150
200
250
300
350
400
150
500
Seconds
550 600
FIG. 7.Speed/time and current/time curves for centrifugal hydro-extractor ; 48-inch basket.
270
240
T3
4) 2 1 0
% res. 1-61
0-775
0375
0-188
0-088
VA! = 87-03
^VA=69-18VM= 91-43
1-2
1-4
2-4 _
Seconds
FIG. 8.
electromotive force rises and the motor must slow
down to 74 per cent speed, or, alternatively, one may
say that the motor continues to run at 77 per cent
speed and the current drops at once to 92 per cent,
627
300
0-2
0-4
0-6
0-8
1-0
1-6
1-2
1-8
2-2
2-4
2-6
2-8
Seconds
FIG.
9.
300
Steady r u n n i n g speed
Steady running
I
torque
Steady running
currents
0-2
0-4"
0-6
0-6
1-0
1-2
Seconds
FIG.
10.
1-6
2-0
2-2
30
3-2
3-4
628
must be set for 3248, 69*18 and 8703 per cent pressure respectively to realize that diagram on full load,
and it would seem that there is no advantage in a
pressure setting versus a current setting; on the contrary the relays must be more difficult to standardize,
wind and adjust.
It has been assumed in Fig. 10 that the pressure
relay on notch 1 is set for 20 per cent, simply because
it must be set for less than notch 2. Again, there
seems nothing special to the advantage of a pressure
relay, because Fig. 10 would be realized by a current
relay on notch 1 set for 51 per cent current instead of
36 per cent as in Fig. 9.
The shorter accelerating period of 2"04 seconds is
not due to the use of pressure relays.
Figs. 8, 9 and 10 were drawn for a 5-notch controller
instead of the 7 or 8 notches that would be used with
a hand-operated controller, because it is customary
to give few notches on contactors on account of the
high cost and complication with many notches. Comparing Figs. 5 and 8 the peaks are 135 and 192 respectively.
Reverting to Fig. 1, it is necessary "to indicate how
the accelerating torque over the period is determined.
If the running torque is 66 per cent the excess torque
in the time available for acceleration is represented by
the area of the peaks, and roughly it will be found
that the average over the period works out at onequarter of the excess of the peak over the valley, giving
in this case
100 - 66
= 85 per cent
629
200
600
700
Units
100
43
630
Unit horizontal
Temp.-iise of element/Temp.-rise
Unit horizontal
.-rise of element/Temp.-rise at
vertical
/
horizontal
Unit vertical
osite top
of element
0-25
1-0
1-25
60
80
100
120
Temperature-rise in degs.F.
FIG. 12.
components at the two temperatures, and quite different
results are obtained if the element is horizontal instead
of vertical, even when the total wire surface swept
by the air is equal in both positions.
Calculations based on the formulae accepted for
natural draught in chimneys or ventilating shafts in
mines would appear to apply, but this is not the case,
and a curious effect occurs for which as yet there is no
explanation.
It is shown in Fig. 11 ; a number of resistance
elements 1\ inches long over all, and about 6 inches
wound length, were assembled vertically on a central
iron rod and centred by means of stamped steel spiders,
631
B was placed
as close as
possible to C
TABLE 3.
Heating.
Ratio of Watts to obtain the same Temperature-rise of the
Element at the Hottest Part.
Air-cooled
In asbestos
cover
In black iron
cover
In bright iron
cover
10
0-56
0-45
0-35
Cooling.
Ratio of Times for Temperature of the Element at the
Hottest Part to fall from 400 degrees F. Rise to
100 degrees F. Rise.
Air-cooled
In asbestos
cover
In black iron
cover
In bright iron
cover
1-0
1-48
1-9
2-4
The table shows that if a correctly rated aircooled resistance is enclosed in a black iron cover
45 per cent of the watts rating may be put on it, and,
if the starting is cyclic, the cooling period must be
extended 90 per cent.
The temperature-rise of the cover at the hottest part
is equal to that of the element at its hottest part,
multiplied by the ratio of resistance wire surface to
cover surface.
It might be mentioned, as an instance of the difficulty
in getting consistent results, that if small holes inch
diameter are drilled in the enclosure opposite the
bottom, middle and top of the element, and a thermometer is hung in a small aperture into which the
G32
so, and heating for one short period with cooling for
a different period makes the problem one of the most
difficult that can be imagined.
An intermittent rating depends on the watts which
will raise the temperature of the unit during the heating
period the same number of degrees that it cools during
the cooling period.
An element with high thermal storage, i.e. specific
heat multiplied by weight, is a desideratum for infrequent starting, say once every 4 hours, and the
ability to get rid of the heat is not very important.
Consequently, resistances embedded in ceramic material are attractive at first sight, and experimental
resistances have been made which will absorb a large
number of watts for 10 seconds with a current far
beyond the fusing current.
Some of the earliest forms with wire embedded in
enamel are still in use, but they have never become
very popular.
It seems going rather far to have one type with low
thermal capacity and high dissipating capacity for
continuous rating, another with high thermal capacity
and poor dissipating capacity for infrequent starting,
and a third intermediate type for running on a consecutive cycle. The element already described is a
satisfactory compromise; it dissipates heat readily
because the spirals are scrubbed by the air or oil, yet
it has a high thermal capacity because the spirals are
in close contact with the stoneware. The intermittent
rating of such an element constitutes a very interesting
problem, but it would be of no general utility to go
deeply into this as all the results would apply only
to this particular form.
The following figures show the degree of accuracy
which can be obtained in the more simple case of the
heating of totally-enclosed direct-current brake magnets.
A single heating and cooling test was made on an
experimental magnet; a method of calculating was
developed and the final designs were rated from the
drawings.
Shunt Magnets.
Size
3
2
1
15
30
60
sec.
14 58-3/5
30 55
70
Series Magnets.
Size
3
2
3
min.
min. sec.
15
30
60
13 5
28 45
60 20
633
180
50
55
60 Minutes
9 Inches from top surface of oil
FIG. 14.Heating tests on oil-immersed resistances arranged as shown in Fig. 13.
634
100
^*
ho 80
3
/
/
% 60
/
40
5 20
0
1
20
60
80
100
120
WO
160
180
Seconds
Fro. IT).Heating tests on oil-immersed resistance elements.
Tests 1 to 4 : 68-turn pot filled with 21 S.W.G. Heckaum.
(1) 3 520 watts 67 watts/in.Surface.
(2) 3 910
^75
3) 9 200 .* 175
(4) 20 769 ---* 410
Tests 5 and : 31-turn pot filled with 11 S.W.G. Hecknum.
Test 5 : 11 500 watts =- 133 watts/in. 8 surface.
,, 6: 20 000 ,, 1 =- 293
10
40
22
6
38
33
44-5
44
53
59
70
77
26
35
49
39
12
34
12
22
37
42
65
3
32
18
64/96
(swinging)
36
35
19
37-5
32
33
25
10
80
5-5
6-8
10-5
14
14-5
15
16
16-3
18
19
22
23-5
6-2
7-5
10/13
6-2
7-4
10/13
(swinging)
(swinging)
15
15-8
16
16-9
17
18-8
20
22-6
24-5
14-5
15
15
16-5
16-7
18-8
20
22-5
24-5
Stator : delta-connected.
Rotor : star-connected.
Rotor resistance : star-connected.
Full-load stator current: 30 amperes.
635
Per cent
i2x
R2
i?3
Ri
#5 =
RQ =
R7 =
i?8 =
= 100
= 72
= 51-9
= 37-3
26-9
19-4
13-9
10 (rotor winding)
the formula on page 623 being used, and the ratio working
out at 1-39.
" Suppose now that in the rotor phases D, E and F,
resistances of values Rit i?2> a n d R3 respectively were
inserted. As shown above, results equivalent to using
resistances R2 in each phase would be obtained, with
an out-of-balance ratio of 1-39. If resistance RL were
then changed to value Rit results equivalent to using
resistances i?3 in each phase would occur, still with an
out-of-balance ratio of 1 39. Similarly, by successively changing the highest resistance value to that
below the lowest in use, a starter giving results equivalent to those of an equally-cut-out type will be obtained.
Obviously, to obtain the effects of resistances of value
R1 in each phase, values of 139, 100, and 72 per cent
resistance will be necessary.
" The last notches require a little further remark.
If, for reasons of manufacturing convenience or the
like, it is desirable to cut out one section at a time
throughout, the last 3 notches will be cut out thus :
Notch
(a)
(b)
(0)
Phase D
Phase E
Phase F
Per cent
Per cent
Per rent
19-4
10*
10*
13-9
13-9
10*
10*
10*
10*
5.
Notch Number
Stator Current
Expected
Obtained
Rotor CurrentExpected
Obtained
Speed
Expected
Obtained
Torque
Expected
Obtained
44-0
44-6
Per cent
55
55
Per cent
66
66
Per cent
73-5
73-1
Per cent
92
91-5
30-5
30-5
10
10
40
40
66
66
3175
31-75
10
9-85
59 , 75-1
59 75
51-9
52
10
9-85
60
60
94
94
56
55-2
5
Per cent
113-5
l]2-5
99
99
132
132
58
57-9
10
10
9-85
9-85
1
40
40
51-9
51-9
67
68-5
87
95
112
121
125
125
Resistance specification.
Values in ohms.
Rotor volts between rinps 1 3 8.
Motor: 25h.p., 440 V., 3 ph.,
25 ~ , 750 r.p.m., synchronous
speed.
636
winding. In consequence the dimensions become considerable ; the iron, surrounded as it is by the coil,
is in a bad position for heat dissipation.
Another trouble, more apparent with infrequent
starting and non-reversing motors where the choking
coil is short-circuited at full speed is that, if the choking
coil is small, as it may be for infrequent service, the
copper voltage-drop is considerable and the currentrush on short-circuiting is very high if there is an appreciable load on the motor.
It would seem that a better result would be obtained
equivalent resistance
by the use of a true auto-transformer, with more or
Ratio = n~2i
rotor resistance per phase
less laminated cores, which would supply current at
and a specification drawn up as for the phase resistance low voltages to a massive resistance element capable
of an equally-cut-out type as shown in Fig. 16, noting of being run at a high temperature, say 600 F., without
that the equivalent resistance is used on the second risk of damage to the windings ; the auto-transformer
step [hence the term (n 2) in the formula]. The could be designed for any convenient loss, and the
required torque obtained by adjusting the resistance.
first step is given by
At standstill the choking coil is subjected to full
Equivalent resistance X ratio
rotor pressure at line frequency ; at full-load speed the
" If the notch (b) above is dropped, as suggested, the voltage and frequency are those due to slip, say 3 per
cent, and on reversal of the stator at full speed the
formula becomes
frequency and voltage are double the normal values ;
equivalent resistance
as the eddy-current losses are proportional to the
Ratio =
.se/
<rotor resistance per phase/
square of the frequency and square of the induction,
The values obtained are then allocated to the phases and the hysteresis losses to the l-6th or l-7th power
in cyclic order, as shown in the figure, the last value of the induction, a very interesting series of calculations
Notches
%Resistance 139
Phases
Notches
100
51-9
I
E
37-3
26-9
19-4
13-9
10
D
2
4'
Shortcircuited
Notch. 8 is not e s s e n t i a l
FIG.
D&F
D^E&F
Shortcircuited
16.
637
95-5 per cent speed (4-5 per cent slip), and the current
will rise at change-over to 285 per cent and fall to 120
per cent; if all the resistance is now cut out the motor
will run up to 97 per cent speed (3 per cent slip),
and the current will rise to 150 per cent and fall to
100 per cent.
Results of calculations worked out from Figs. 17
and 18 are conveniently recorded as shown in Fig. 19,
the arrangement of which is due to Mr. Fox.
If the load torque during acceleration is constant at
40 per cent, a glance shows that a current not less
than 350 per cent must be passed on the first notch,
270
60
10
30
20
120
110
240
1:00
Seconds
FIG. 17.Rhcostatic stator starter. Line resistance passing about 250 per cent current. Drawn for a stored energy of
10 000 ft.-lb./b.h.p. At 20 per cent friction load the average and R.M.S. currents are about 95 per cent of initial
current. Small kick on finally cutting out line resistance not shown.
038
that it will not start with 250 per cent current; and that
with 300 per cent current on the first notch and a
suitable starter it can be made to run up in 79 seconds
with 5 000 ft.-lb. per b.h.p. stored energy. 1 000 ft.-lb.
would be a high figure, and 16 seconds more than a
normal time.
There is an apparent discrepancy between these
figures and those used when discussing Fig. 18 ; the
explanation is that the latter figure is drawn for a
starter properly proportioned to give current-rushes
equal to the initial current on changing from notch to
notch.
Intermediate curves should be drawn and the set
750
375
700
350
650
325
600
300
550
275
500
250
7 25%/
/
/
/
/I
5 30%/
# 450 225
5
y
-_
g 350 S 175
250
300 125
150
200
100
725'
3 50%/
li
/ /
//A
Lfife*
75
100
50 w
m
25
^=
ZJ50%/
""
A A sA
150
50
^ ^
d ^00.3 200
*--.
500%/
150%/
^-Fanloa dris
"
^-Fauioaa rising ~
35Oc
T - ..
250'
ISO1}
10
15
20
25
30
35
-iO 45
50
55
60
65
70
75
80
85
90
95 100
Torque and current curves with various amounts of resistance in line. Light lines
represent driving torques for fan loads.
repeated for motors having, say, 400, 500 and 600 per
cent short-circuited current, and then the whole series
should be re-calculated for auto-transformers with
various tap voltages.
The auto-transformer curves also serve for stardelta and series-parallel starters because these act like
an auto-transformer with one tap and without the
voltage-drop in the transformer windings.
The starter maker has, then, a means of tackling
intelligently and quickly any starting problem.
It is common practice to use these starters on any
machine requiring low starting torque without special
attention to the accelerating time; if the average
current over the period is 80 to 95 per cent of the initial,
639
TABLE 6.*
Col. 2
Col. 3
Taps in phase
A
05
05
075
0-5
0-6
0-6
06
0-75
06
0-75
075
0-75
0-75
075
Col. 4
Sees, to
run to
83 %
speed
Does not
start
0-5
6
05
5
0-6
4-5
0-6
4-0 +
05
30 0-75 2-0 +
0-5
Col. 5
Col. 6
Col. 7
25
25
25
33
34-8
36
37-5
42
51
336
37-6
36
41
42 3
51
25
36
36
36
25
56-25
20
100
40
60
80
100
120
140
160
400
500
600
700
800
PROOF
Field has sliown that the voltage-drop in three starconnected unequal resistances connected to a three-
640
phase supply may be determined graphically by drawing an equilateral triangle whose sides represent to
scale the voltage between lines, and imagining the
values of the conductance of each phase as a weight at
each corner of the triangle; the centre of gravity of
the triangle is then the position of the neutral point,
and lines drawn to each corner of the triangle from this
point will represent in phase and magnitude the voltagedrop in the resistances concerned.
Fig. 20 shows such a construction for resistances in
A, B, and C having the relative values R, Rk, and Rlc2.
InB,
InC,
DISCUSSION.
- k + 1)
AC
k + 1)
InB,
InC,
Total,
AC 2
AC?
kR
AO
CO =
&AC
+ 1)
1922.