Electric motors

KON-C2004 Mechatronics Basics

Tapio Lantela, Nov 7nd, 2016
Applications
 Power range http://www.dmaeuropa.com/Clients/Sulzer/News/tabid/3546/itemid/3334/Default.aspx

From milliwatts

to megawatts

http://small-generator.com/buy/index.php?main_page=product_info&cPath=2&products_id=44&zenid=7am2ohqmufajn06bafie386007
Speed range http://www.celeroton.com/en/products/motors.html

From a couple hundred rpm

to hundreds of
thousandsof rpm
http://www.ebikes.ca/learn/hub-motors.html
Electric motors

DC
- Brushed
- Brushless
AC
- Synchronous
• Permanent magnet motor
• Field excitation
• Reluctance
- Asynchronous (Induction)
• Squirrel cage
• Wound rotor
Physics of a generic electric motor
Magnetic flux density B
Current I
Magnetic flux Length l
Stator Current -I
density B Number of turns N
Radius r
Force F = BlI
Torque T = 2rF
2rFcos(ϑ)

Force F
Torque T
= 2NrBlI = KtI
Force F

Angle ϑ Induced voltage = Blv

Rotor =2NBlv
Blrω =2NBlrω = Keω

Current I
DC motor working principle

Simple two pole example

- In practise motors have three or more poles

http://www.pcbheaven.com/wikipages/How_DC_Motors_Work/

https://en.wikipedia.org/wiki/Brushed_DC_electric_motor
Brushed DC motor construction

http://www.electrical-knowhow.com/2012/05/classification-of-electric-motors.html
DC motor commutator
DC motor field generation

Permanent magnet
- Permanent magnet rotor (Brushless) Material saturation
- Permanent magnet stator (Brushed) limits field magnitude
Field coils (Brushed)
- Series wound
- Parallel (shunt) wound
- Separately excited

http://www.electrical4u.com/dc-servo-motors-theory-and-working-principle/
Electrical models of a DC motor

Equivalent circuit

http://ctms.engin.umich.edu/CTMS/index.php?example=MotorSpeed&section=SystemModeling

Mathematical model
Mechanical models of an electric motor

Physical model

Mathematical model
Time constants of a motor

Winding
inductance & Rotor & load
resistance inertia
Power losses

Resistive losses
- Proportional to the square of the current (torque)
- Resistance depends on temperature (0.4%/K)
Core losses
- Proportional to the rotating speed
Mechanical losses
- Bearing friction
• proportional to the rotating speed
- Damping (air etc.)
• proportional to the square of rotating speed

Additional losses
- Variable frequency drive harmonics etc.
Motor equations

Input power Pin = UI

Output power Pout = Tω
Resistive loss in windigs Pres = RI2
Back electromagnetic force Vbemf = Keω
Characteristics of a PMDC motor

Maximum torque and efficiency are speed dependent

Operating limits of a PMDC motor

http://www.electrocraft.com/products/pmdc/DPP720/
Field weakening

Reduce magnetic field flux density B

- Smaller B -> smaller torque constant Kt and BEMF constant Ke
- Smaller Kt -> less torque
- Smaller Ke -> more angular velocity
Field weakening

http://ecomodder.com/forum/showthread.php/bsfc-chart-thread-post-em-if-you-got-1466-26.html
Operating limits of a motor

Temperature
- Winding insulation melting temperature
- Permanent magnet demagnetization temperature
Voltage
- Winding insulation breakdown voltage
Mechanical strength
- Rotor breakdown speed
Commutation speed
- Drive/controller speed
Characteristics of a DC motor
Motor data
Assigned power rating 12 W
1 Nominal voltage 12 V
2 No load speed 12100 rpm
3 No load current 155 mA
4 Nominal speed 8060 rpm
5 Nominal torque 10.1 mNm
6 Nominal current 1.25 A
7 Stall torque 31.3 mNm
8 Starting current 3.47 A
9 Max. efficiency 63 %
10 Terminal resistance 3.46 Ω
11 Terminal inductance 0.121 H
12 Torque constant 9.02 mNm / A-¹
13 Speed constant 1060 rpm / V-¹
14 Speed / torque gradient 406 rpm / mNm-1
15 Mechanical time constant 9.56 ms
16 Rotor inertia 2.25 gcm²

Source: Maxon corp.

Four quadrant operation
Brushed DC motor velocity control

The torque is proportional to the current in the winding

Current is controlled by voltage

- Or usually with pulse width modulation, PWM
- If the PWM frequency is high enough, the current stays almost constant (small
fluctuations)
Brushed DC motor control

Motor needs large currents

- E.g. microcontroller signal not powerful enough for running the motor
- A separate motor drive circuit controls the motor current according to the
microcontroller signal
One signal for PWM, one for direction

M M
Brushless DC motor (BLDC)

Permanent magnet rotor

Stator with windings
External commutation
- integrated position sensosr,
usually hall sensors

Almost service free

Withstands well short term overloading
- heat is transported effectively from the stator into the environment
More complex control system
BLDC commutation

http://www.mpoweruk.com/motorsbrushless.htm
BLDC commutation
AC motor

Two categories
- Asynchronous
- Synchronous

Input usually three phase sinusoidal AC voltage

Only bearings need service
Control with variable frequency drive

http://www.pump-zone.com/topics/motors/ac-motors-part-two-three-phase-operation/page/0/1
AC field generation
Three field coils (per pole)
- 120 °phase difference

http://tdflashzone.net23.net/1_6_Physics-Flashes.html
Synchronous AC: Permanent magnet

Permanent magnet AC motor is almost the same as BLDC.

Synchronous AC: Permanent magnet

https://www.ecnmag.com/article/2009/10/comparing-motor-control-techniques
Asynchronous AC: Induction

Stator field induces current in the bars which causes torque

- Requires slip to create induced currents
Types
- Squirrel cage
• Rotor made of conducting short circuited bars in steel frame
- Wound rotor

http://www.nidec.com/en-IN/technology/motor/basic/00026/?prt=1
AC motor control

Rotational speed is determined

by the frequency of the input voltage
Frequency is controlled with variable frequency drive/inverter
(taajuusmuuttaja in Finnish)
- Rectification of the three phase voltage to DC voltage
- The rectified DC voltage is converted e.g. with pulse width
modulation (PWM) to AC voltage with the needed frequency
- The AC voltage is fed to one of the three coils of the stator
according to the sensors of the control system.
Rated values of an induction motor

Rated values are for continuous duty

- Rated voltage – winding insulation
- Rated current – ohmic resistive losses
- Rated field – magnetic saturation of the material
- Rated power = T*omega

For a dimensioning a motor for a variable load, it is possible to

calculate an equivalent constant load or simulate the system
Motors for servo systems

Many designs: DC (brushed or brushless), AC

Integrated feedback sensors
Ability to tolerate short term overloads
Low inductance
- Small electric time constant
Low rotor inertial mass
- Small mechanical time constant
http://www.ustudy.in/node/5789

http://www.exlar.com/press_releases/1868
Summary

Electric motors can be found anywhere and for any power rating
They have excellent efficiency at proper loading conditions
- Usually this means a large enough rpm
Output power limited by temperature
- Can be overloaded for a short while
Maximum rotating speed limited by back emf / supply voltage
Questions?

More info on electric drives

- Advanced courses
• ELEC-E8407 – Electromechanics
• ELEC-E8405 - Electric Drives