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CHAPTER 7

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

INDUCTION SYNCHRONOUS MOTORS*

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

FIGURE 7.1 Induction synchronous motor lamination.

FIGURE 7.2 Four-pole induction synchronous rotor assembly.

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

FIGURE 7.3 Shaded-pole synchronous motor, permanent-magnet rotor end.

FIGURE 7.4 Shaded-pole synchronous motor, induction rotor end.

7.4

CHAPTER SEVEN

FIGURE 7.5 Shaded-pole synchronous motor showing magnetized poles.

FIGURE 7.6 Shaded-pole synchronous motor rotor showing induction motor bars and end rings.

SYNCHRONOUS MACHINES

7.5

7.2 HYSTERESIS SYNCHRONOUS MOTORS


These motors have a rotor made of a cobalt alloy or another material that can be magnetized semipermanently by the stator field. They have a rather weak secondquadrant demagnetization curve which can be easily demagnetized. The demagnetization curves of some of these materials are shown in Figs. 7.7, 7.8, and 7.9. Figure 7.10 shows a motor utilizing a wound-field distributed stator (Fig. 7.11) and a cobalt hysteresis ring rotor (Fig. 7.12). This motor is connected and run like a permanent-split-capacitor (PSC) motor. It produces a speed-torque curve like the one shown in Fig. 7.13.

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

Distributed wound stator.

SYNCHRONOUS MACHINES

7.9

FIGURE 7.12

Cobalt hysteresis ring rotor.

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.

7.3 PERMANENT-MAGNET SYNCHRONOUS MOTORS


Many of these motors are used in clocks or timing devices. Figure 7.17 shows a typical clock motor. Note that the stator portion has an uneven distribution of magnetic poles (Fig. 7.18). The purpose of this is to give the rotor a preferred starting point while providing an apparent shift in field during starting due to the uneven reluctance of the stator. Some of these motors have a spring return mechanism to reverse the rotation just in case it starts turning the wrong way. Other PM synchronous motors are essentially PM stepper motors run as PSC motors. The motor shown in Fig. 7.19 has a stator consisting of two sets of coils with the teeth offset from each other by one-half tooth pitch (Fig. 7.20). The rotor has magnetized poles along its length, as shown by magnetic viewing film (Fig. 7.21). One stator half serves as the main field winding. The other serves as the auxiliary phase. They are connected as in PSC motors, with a capacitor in series with the auxiliary winding.

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 7.14 Rhodes, Inc.)

Timer or actuator motor by Cramer Motor Company. (Courtesy of MH

FIGURE 7.15

Timer stator. (Courtesy of MH Rhodes, Inc.)

SYNCHRONOUS MACHINES

7.13

FIGURE 7.16

Timer rotor.

FIGURE 7.17

Typical clock motor.

7.14

CHAPTER SEVEN

FIGURE 7.18

Uneven distribution of magnetic stator poles.

FIGURE 7.19

Permanent-magnet synchronous motor.

SYNCHRONOUS MACHINES

7.15

FIGURE 7.20

Half-tooth-pitch offset consisting of two sets of coils with offset teeth.

FIGURE 7.21

Rotor with magnetized poles.

7.16

CHAPTER SEVEN

7.4 PERFORMANCE CALCULATION AND ANALYSIS*


P. H. Trickey suggests a method for calculating the performance of these synchronous motors which is summarized here. Generally, this method applies to motors using cobalt ring rotors. Motor parameters are calculated using the same methods as for ac induction motors, except for rotor losses. Winding resistance, iron losses, friction and windage losses, and stator leakage reactance use exactly the same methods as induction motors. Air gap leakage reactance is calculated as one-half the value of zigzag and one-third the value of belt leakage that would have been obtained using a rotor with the same number of slots as the stator. The hysteresis power is equal to the stator input power minus the stator losses, friction and windage losses, and rotor parasite losses. Stator losses include I2r1 plus core losses. Parasitic losses include hysteresis and eddy current losses of minor loops resulting from flux variation at tooth slot openings, losses resulting from harmonics of a nonsinusoidal winding distribution, and double-frequency backward field hysteresis and eddy current losses. Variables B = slot span, electrical b = slot opening C = series conductors per phase C1 = flux form coefficient Cx = correction factor Ct1 = maximum ampere-turns per inch (teeth) Cy1 = maximum ampere-turns per inch (yoke) D1 = stator ID D2 = rotor OD F = slot correction coefficient f = frequency, Hz G1 = minimum air gap HP = output power, hp h1 = straight portion of end-turn extension I = primary current (assumed) Id = direct axis current Iq = quadrature axis current kd = distribution factor kg = gap factor kp = pitch factor ks = slot leakage constant kw = total winding distribution factor kzz = zigzag leakage coefficient k1 = stator (primary) slot constant k2 = secondary slot constant Lg = physical length of air gap Lmet = mean end-turn length of coil Ls = stator stack length lg = effective length of air gap Lt1 = length of teeth Ly1 = length of yoke MTL = mean turn length m = number of phases me = length of remaining portion of coil extension Ns = synchronous speed n = coils per group Pb = belt leakage permeance factor PF = power factor p = number of poles

* 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

Slot shape B (see Fig. 7.24) k1 or k2 = F + d1 2d2 + d d + y1

Square-bottom slot constant k1 or k2: Open slot (see Fig. 7.25) k1 or k2 = d1 d + 3 d y1

Bridged slot (see Fig. 7.26)


FIGURE 7.23 Round-bottom slot, shape A.

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

Slot shape B (see Fig. 7.28) k1 and k2 = d1 d d2 + 1.5 + 3 d y1 d+r

Slot shape C (see Fig. 7.29) k1 and k2 =


FIGURE 7.24 Round-bottom slot, shape B.

d1 d 4d2 + + 3 d y1 3d + y1

Variables to Calculate Primary tooth pitch Tp1: Tp1 = D1 s1

Secondary tooth pitch Tp2: Tp2 = Total pole pitch p:


FIGURE 7.25 Square-bottom open slot.

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

Square-bottom bridged slot.

FIGURE 7.27

Flat-bottom slot, shape A.

FIGURE 7.28

Flat-bottom slot, shape B.

FIGURE 7.29

Flat-bottom slot, shape C.

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

2.03p(Ls + 2G1) G1k1Ls)

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

45.0 106 Ckw

(D1 + D2) (Ls + 2G1F2) 2p

(D1 + D2) (Ls + 2G1F2) 2p

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

FIGURE 7.31 Dimensions for end-turn leakage reactance.

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 )

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