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SYNCHRONOUS MACHINES
Chapter Contributors
Chris A. Swenski William H. Yeadon
This chapter covers some of the ac synchronous motors commonly encountered in the industry. While it could be said that the electronically commutated motors discussed in Chap. 5 are also synchronous motors, this chapter is confined to the typical ac versions. While larger polyphase machines are well covered by others, little information is available on these smaller motors.
7.1
These motors are built in a manner very similar to that for induction motors. They may have polyphase windings or be designed as single-phase motors, such as capacitor-start, split-phase, or shaded-pole types. The rotors have a dual construction that allows for induction motor starting characteristics and salient-pole synchronous running conditions. These rotors may be made from induction motor stampings with some of the teeth removed, as shown in Fig. 7.1. They are then die-cast in the same manner as an induction motor rotor (Fig. 7.2). Some motors use a permanent magnet in conjunction with an induction motor rotor. Figures 7.3 and 7.4 show such a motor. This is a four-pole shaded-pole motor. Here the field coils are connected such that they directly produce two like poles and induce two opposite poles at 90 in the unwound space between the coils. In these
* Sections 7.1 to 7.3 contributed by William H. Yeadon, Yeadon Engineering Services, PC.
7.1
7.2
CHAPTER SEVEN
figures, the rotor is shown to be enclosed by the stator. Figure 7.3 shows the permanent-magnet part of the rotor, while Fig. 7.4 shows the induction rotor end. The rotor is shown alone in Figs. 7.5 and 7.6, with a piece of magnetic viewing film over the permanent-magnet portion. Figure 7.5 demonstrates the position of the magnetic poles, of which there are four on the rotor. Figure 7.6 shows that the induction rotor portion is a laminated structure with copper-wire bars swedged over copper-plate end rings.
SYNCHRONOUS MACHINES
7.3
7.4
CHAPTER SEVEN
FIGURE 7.6 Shaded-pole synchronous motor rotor showing induction motor bars and end rings.
SYNCHRONOUS MACHINES
7.5
FIGURE 7.7 0.32-MGOe hysteresis material. BR = 10.4 kG, BD = 7.0 kG, HC = 88 Oe, HD = 45 Oe, BHmax = 0.315 MGOe, BD/HD = 155.6. (Courtesy of Arnold Engineering Company.)
7.6
CHAPTER SEVEN
FIGURE 7.8 0.054-MGOe hysteresis material: hardened A151050. BR = 37.00 kG, BD = 2.0 kG, HC = 56 Oe, HD = 27 Oe, BHmax = 0.054 MGOe, BD/HD = 24.1. (Courtesy of Arnold Engineering Company.)
SYNCHRONOUS MACHINES
7.7
FIGURE 7.9 0.36-MGOe hysteresis material. BR = 9.5 kG, BD = 6.0 kG, HC = 116 Oe, HD = 60 Oe, BHmax = 0.360 MGOe, BD/HD = 100.0. (Courtesy of Arnold Engineering Company.)
7.8
CHAPTER SEVEN
FIGURE 7.10
Wound-field motor.
FIGURE 7.11
SYNCHRONOUS MACHINES
7.9
FIGURE 7.12
Many timer motors and value actuators use a hysteresis ring but use the shadedpole type of stator to provide starting torque. Figures 7.14, 7.15, and 7.16 show a timer motor which utilizes this principle. The shaded-pole stator provides the starting torque, but it also makes the motor unidirectional.
7.10
(a) (b) (c)
FIGURE 7.13 Synchronous motor speed-torque curves: Oz in versus (a) rpm, (b) Win, (c) PF, (d) amps, (e) horsepower, and (f) efficiency.
7.11
(d) (e) (f)
FIGURE 7.13 (Continued) Synchronous motor speed-torque curves: Oz in versus (a) rpm, (b) Win, (c) PF, (d) amps, (e) horsepower, and (f) efficiency.
7.12
CHAPTER SEVEN
FIGURE 7.15
SYNCHRONOUS MACHINES
7.13
FIGURE 7.16
Timer rotor.
FIGURE 7.17
7.14
CHAPTER SEVEN
FIGURE 7.18
FIGURE 7.19
SYNCHRONOUS MACHINES
7.15
FIGURE 7.20
FIGURE 7.21
7.16
CHAPTER SEVEN
* Section contributed by Chris A. Swenski, and William H. Yeadon, Yeadon Engineering Services, PC.
SYNCHRONOUS MACHINES
7.17
Rs = rotor skew, in r1 = resistance per phase, Sp = span (average coil throw) SF = saturation factor SFd = direct axis saturation factor SFq = quadrature axis saturation factor Str = number of strands of wire in parallel s1 = stator (primary) slots s2 = rotor (secondary) slots T = torque, ozin Tp1 = primary tooth pitch Tp2 = secondary tooth pitch Tf1 = width of primary tooth face Tf2 = width of secondary tooth face Vph = volts per phase Win = total input, W WL = Loss, W Wout = output, W
Wph = watts per phase w = total series conductors w2 = axial rotor stack length Xd = total direct axis reactance Xfctr = reactance factor Xpc = primary end reactance Xps = primary slot reactance Xq = total quadrature axis reactance X1 = total leakage reactance X1d = primary direct axis reactance X1q = primary quadrature axis reactance Y = end-winding length coefficient p = total pole pitch pd = direct axis pole pitch pq = quadrature axis pole pitch = efficiency 2 = flux factor
Note: See figures for those variables not listed here, but used in the following equations. Calculation of Constants Pitch factor kp: kp = sin (pitch 90) where pitch is expressed as a fraction of the full pitch, such as 56, etc. Distribution factor kd: kd = Total winding distribution factor kw: kw = kpkd Slot correction coefficient F: F = 0.28 0.14 Slot leakage constant ks: ks = F + d1 2d2 + d d + y1 y1 y2 + d3/y2 + 0.08 2.87(y1/y2) + 0.08 sin (B/2) n sin (B/2n)
7.18
CHAPTER SEVEN
Gap factor kg (see Fig. 7.22): Semiclosed slot kg = Open slot kg = Tunnel slot kg = 1.03 Effective gap length lg: lg = Lgkg Zigzag reactance correction factor Cx: Cx = Tp1Ls 1 Tf1lg p(5G1 + b) p(5G1 + b) b2 p(4.4G1 + 0.75b) p(4.4G1 + 0.75b) b2
Primary and Secondary Slot Constant Calculations k1 and k2 Note: See figures for variable descriptions. k1 represents the primary (stator) slot constant, while k2 represents the secondary (rotor) slot constant. They are found using the same set of equations, being careful to use the equation which most closely resembles that of the slot in question. Round-bottom slot constant k1 or k2 (note that F is different for the two constants): Slot shape A (see Fig. 7.23) k1 or k2 = F + d1 2d2 + d d + y1
(a)
(b)
(c)
FIGURE 7.22
Gap factor variables: (a) semiclosed, (b) open, and (c) tunnel.
SYNCHRONOUS MACHINES
7.19
k1 or k2 =
d1 d + 3 0.02 y1
Flat-bottom slot constant k1 or k2: Slot shape A (see Fig. 7.27) k1 and k2 = d1 d + 3 d y1
d1 d 4d2 + + 3 d y1 3d + y1
D2 s2
p =
(D1 + D2) 2p
Zigzag leakage coefficient kzz: Open slot kzz = (Tf 1 Tf 2 )2 4(Tp1 + Tp2)
7.20
CHAPTER SEVEN
FIGURE 7.26
FIGURE 7.27
FIGURE 7.28
FIGURE 7.29
Closed slot kzz = Direct axis pole pitch pd (see Fig. 7.30): pd = 20pks + s1 20pCx 4D1Sp(1.1 + 0.1p) kzz + + Pb s1 2s1Ls 1.063Wph G1s1
where belt leakage permeance factor Pb is Pb = 0 Pb = 0.95 for three-phase D1 pmk1 for two-phase
SYNCHRONOUS MACHINES
7.21
FIGURE 7.30 Rotor cross section showing pd and pq. Dimensions in inches, not degrees, measured along the circumference of the rotor.
Quadrature axis pole pitch pq (see Fig. 7.30): pq = 20pks + 1.25 s1 4D1Sp(1.1 + 0.1p) (sin 1.5)[(Sp + p)/s1] 20pCx kzz + + s1 2s1Ls kp +Q where Q=1 Saturation Calculations Saturation factor SF: SF = total ampere turns airgap ampere turns sin (Rs/2) Rs/360
2
and
Rs =
Rs p
180
7.22
CHAPTER SEVEN
Flux factor 2: 2 =
{[ I2 (Win/Vphm)2 r1] (Win/Vph) X1}2 + {(Vph (Win/Vphm) r1) [I2 (Win/Vphm)2 X1]}2
Area of the Air Gap: Direct axis area Agd Agd = Quadrature axis area Agq Agq = pq p pd p
Direct axis saturation factor SFd: SFd = Cy1Ly1 + Ct1Lt1 + 491.41(F2/Agd)lg 491.41(F2/Agd)lg
Quadrature axis saturation factor SFq: SFq = Cy1Ly1 + Ct1Lt1 + 491.41(F2/Agq)lg 491.41(F2/Agq)lg
Direct and Quadrature Axis Reactances Reactance factor Xfctr: Xfctr = Total direct axis reactance Xd: Xd = Xfctr[(CmC1/SFd) + pd] Total quadrature axis reactance Xq: Xq = Xfctr[(Cf/SFq) + pq] Primary direct axis reactance X1d: X1d = Xfctrpd Primary quadrature axis reactance X1q: X1q = Xfctrpq f(Ckw)2w2m p(108)
SYNCHRONOUS MACHINES
7.23
Primary Resistance Mean turn length MTL: MTL = 2Ls + 2Lmet Primary resistance r1: r1 = Reactances Primary slot Xps Xps = Primary end Xpc (see Fig. 7.31): Xpc = Zigzag Xzz: Xzz = w2f D1Lsks 108 s1(s1 + s2)G1kg w2f (h1 + 0.5me)k2 p 108 p w2f Lsk1ks) s1 108 (C)(MTL)(resistance/1000 ft) 12,000Str
Primary Leakage Reactance. The primary leakage reactance X1 is the sum of the preceding reactances: X1 = Xps + Xpc + Xzz Friction and Windage Losses. Friction and windage losses are obtained by testing similar machines (same frame size, bearing size, rpm, enclosure and cooling fan).
7.24
CHAPTER SEVEN
Output Calculations Speed Ns: Ns = Losses WL WL = (I2mr1) + (Fe loss) + (F + W) Output power HP: HP = Input Win: Win = HP(745.7) + losses Torque T: T= Output Wout: Wout = HP(745.7) Efficiency : = Power factor PF: PF = HP(745.7) + losses mVphI HP(745.7) HP(745.7) + (I2mr1) + (Fe loss) + (F + W) HP(1,008,000) rpm ozin inputs losses 745.7 120f p
Variables for direct and quadrature axis current calculations ,,: = cos1 PF = tan1 PF + (r1/xq) sin sin + (Vph/Ixq) (r1/xq) cos =+ where = torque angle Direct axis current Id: Id = I(sin ) Quadrature axis current Iq: Iq = I(cos )