EQUATIONS

Page 1
 PC engineering tools
Cables, reactors, filters,
MASTERDRIVES MC
Motion diagram, option cards ... Ordering
Motor or SIMODRIVE 611u
mechanical specifications (brake resistor data
inverter/ converter rectifier/regenerative
feedback unit)

PATH PLUS

NCSD Configurator

Page 2
 Overview

Motion:
• Velocities
• Acceleration rates
• Distances, times
• Gearbox ratios
Mechanical system:
• Moments of inertia
n • Gearboxes
n t diagram • Motors
• Load levels, friction
t • Efficiency
Operating
cycle

M
M t diagram
t
Selecting the motor acc. to:
• Maximum speed nmax
• RMS torque MRMS
• Maximum torque Mmax
! Inter-relationships!
⇒ sometimes an iterative
procedure is required
!
+ Selecting the motor type
acc. to application:
• 1FK6, 1FT6
• 1PA6, 1PL, 1PH4, 1LA

Page 3
 Distance, velocity, acceleration
Translation:
s [m]
For const. v the For constant acceleration a the following is valid:
following is valid:
s ∆v 1 1
v= a= s= ⋅ ∆v ⋅ t s= ⋅ a ⋅t2
t t 2 2
t
Rotation: Area corresponds
For const. ω the For constant angular acceleration α the following is valid: v [m/s] to the distance
following is valid: moved
ϕ ∆ω 1 1
ω= α= ϕ= ⋅ ∆ω ⋅ t ϕ= ⋅α ⋅ t 2
t t 2 2

t
v [m/s] Velocity
a [m/s2] Area corresponds
s [m] Distance to the velocity
t [s] Time reached
a [m/s2] Acceleration
∆v [m/s] Velocity change
ϕ [rad] Angle (360° = 2⋅π⋅rad) t
ω [1/s] Angular velocity
α [1/s2] Angular acceleration r [m/s3]

∆ω [1/s] Change in the angular velocity

Conversion:
f [1/s] Frequency
n
n [RPM] Speed ω = 2π ⋅ f = 2π ⋅
s t
r [m/s3] Jerk 60
min

Page 4
28th Nov 2001
 Torque, power

Torque: M = F ⋅r F

n
Power: P = M ⋅ω with: ω = 2π ⋅ f = 2π ⋅ s
60 r
min

min 9,55 ⋅ P s
P = 0.105 ⋅ M ⋅ n ⋅ M= ⋅
s n min
M

Work, energy: W = P ⋅t Torque

at the shaft:

M [Nm], [kg m2/s2] Torque n

F [N] Force
P
r [m] Radius
P [W], [kg m2/s3] Power Mechanical
power
ω [1/s] Angular velocity
at the shaft
n [RPM] Speed (motor output):
f [1/s] Frequency
W [Ws], [kg m2/s2] Energy, work n

Page 5
 Kinetic energy

• After accelerating, all of the moved masses of the mechanical system Wkin [Ws] Kinetic energy
store a specific kinetic energy Wkin. 1
Wkin = ⋅ m ⋅ v2 m [kg] Moved mass
• This kinetic energy is decisive for the motor load when accelerating and 2
braking: v [m/s] Velocity

Examples: This is only valid for motion in a

straight line (translatory motion)!
m = 1000 kg

v = 36 km/h 2
1  m
Wkin = ⋅1000kg ⋅ 10  = 50kWs
2  s

v = 1 m/s 2 2
1  m 1  m
v = 3 m/s m=9t Wkin = ⋅ 3000kg ⋅  3  + ⋅ 9000kg ⋅ 1  = 18kWs
m=3t
2  s 2  s

Motion along circular paths can be calculated using the above

formula, if the masses are considered to be applied at a specific
point with a specific velocity.

Page 6
 Moment of inertia
Generally, no clear specific velocity can be assigned to the One solution would be to make an approximate calculation.
masses which are moved: This would finally lead to an integral calculation and is far too
complex and time consuming.

v=?

?
m=3t ??

This is the reason that the calculation is made using speed (or
angular velocity ω). However, the masses must then be evaluated
n = 5 1/min
with a different weighting:
Masses, which are a certain distance from the axis of rotation,
move quickly and have a significant effect on the kinetic energy -
!
masses, located close to the axis of rotation only have a small
effect.
J = 3 kg m2
! !
This mass, depending on its position with respect to the axis of
rotation, is known as the moment of inertia J.

The formula 1 J [kg m2] Moment of inertia

Wkin = ⋅ J ⋅ω 2
is now: 2 ω [1/s] Angular velocity
n min
Converted into speed: ω = 2π ⋅ f = 2π ⋅ ⋅
60 s

Page 7
 Moment of inertia of various bodies

Solid cylinder, disc, roll ...

1 J [kgm2] Moment of inertia
J = m⋅r2
r 2 m [kg] Body mass
r, R [m] Cylinder radius
1 ρ [kg/m3] Specific weight
J= ρ ⋅π ⋅ l ⋅ r 4
2 Aluminum: 2700 kg/m3
l Steel: 7850 kg/m3
Hollow cylinder:
1 l, b, h [m] Length, width, height
J= ⋅ m ⋅ (R2 + r 2 )
R 2
r
Steiner equation:
1
J = ⋅ ρ ⋅π ⋅ l ⋅ (R 4 − r 4 ) If the moment of inertia and mass of a body are
2 known, then they can be converted into another
l axis of rotation.
Square, bar:
1
J= ⋅ m ⋅ (l 2 + b 2 )
12
h

J=
1
ρ ⋅ l ⋅ b ⋅ h ⋅ (l 2 + b 2 ) J J * = J + m⋅r2
l b 12
Modify complex bodies and structures so that
Point-type body: Thin-walled hollow cylinder: they can be solved using these simple formulas!
Example:
r r
J = m⋅r2
+ approx. 20%

Page 8
 External moment of inertia
1
Wkin = ⋅ J ⋅ω 2
2
1
JRotor; JDisc;
Wkin = ⋅ J ⋅ω 2
2
n = 2000 RPM n = 200 RPM

JRotor; 1/100 · JDisc;

n = 2000 RPM n = 2000 RPM

Conversion
Load
(flywheel)
Gearbox 1:10

Calculated moment of inertia referred to the motor

shaft:
or
External moment of inertia JExternal
or:
Converted load moment of inertia J*Load
or:
Reduced moment of inertia Jred

Page 9
28th Nov 2001
 Gearbox as part of the mechanical system

Gearbox ratio Ratio of the moments of inertia

If the gearbox ratio i is increased, this has the following The ratio between the rotor and external moment of inertia has an
effect on the load side: effect on the dynamic performance of the speed control loop which can
be achieved, and therefore on the positioning accuracy and speed.

JRotor JExternal

Speed on
the load side

• Ideal ratio (but don’t select 2:1)

1:1 • Important for precision machine tools
• Often leads to the motor being over-dimensioned
Gearbox
ratio
• Is generally still acceptable
• Frequently used gearbox ratio for machine tools
Torque on External moment 1 : 2.5
the load side of inertia • Generally a matching motor can be found
by selecting the gearbox ratio

• For basic positioning

Additional • Price 1 : 10 in the handling area
aspects of the • Not for machine tools
• Torsional play
gearbox ratio:
• Losses (⇒temperature rise) Note: If the drive is to accelerate as quickly as possible,
• Maximum speed and positioning accuracy is not so important,
• Maximum torque on the load side then sometimes a deviation is made to the rules above (e.g.
the lowest possible JRotor for handling applications).

Page 10
 Gearbox types
Planetary gear Belt drive Cycloid gearbox

Motor shaft
(the speed is Motor shaft
reduced)

Belts or
toothed-belts
(also chain)
Drive-out Motor shaft

Drive-out
Harmonic drive gearbox
Worm-gear spindle
Motor shaft

Motor shaft

Drive-out
Drive-out

Page 11
 Conversion for axial gearboxes

Speed: n Motor side = i ⋅ n Load side

1 M Load side
Torque: M Motor side = ⋅
η i
MMotor side MLoad side
J Load nMotor side nLoad side Gearbox ratio for
Moment of inertia:
*
J Load = belt drives
i2
rLoad side
i=
rMotor side
nMotor side [RPM] Speed at the motor side
i [-] Gearbox ratio
nLoad side [RPM] Speed at the load side
rLoad side [m] Radius of the pulley on the load side
rMotor side [m] Radius of the pulley on the motor side Efficiencies:

MMotor side [Nm] Torque at the motor side Planetary gearbox (single-stage)η ≈ 0.95
η [-] Gearbox efficiency Gearbox η ≈ 0.95
MLoad side [Nm] Torque at the load side Cycloid gearbox (single-stage) η ≈ 0.92
J*Load [kgm2] Moment of inertia of the load Belt drive η ≈ 0.90
converted to the motor side Harmonic Drive gearbox η ≈ 0.60 - 0.80
JLoad [kgm2] Load moment of inertia Worm drive η ≈ 0.45 - 0.9

Page 12
28th Nov 2001
 Converting racks, conveyor belts, winders
FLoad side
vLoad side
v Load side
Speed: n Motor side =
2π ⋅ r

MMotor side
1 nMotor side
Torque: M Motor side = ⋅ FLoad side ⋅ r
η

Moment of inertia:
*
J Load = m⋅r2

nMotor side [RPM] Speed at the motor side

vLoad side [m/min] Velocity at the load side
(rack, conveyor belt ...)
r [m] Radius of the driving wheel/pulley
(gear, pinion, roll ...)
MMotor side [Nm] Torque at the motor side
η [-] Gearbox efficiency
FLoad side [N] Force at the load side
(friction, force due to weight ...)
J*Load [kgm2] Moment of inertia of linearly moved masses Efficiencies:
referred to the rack (pinion, roll)
Pinion and rack η ≈ 0.90
m [kg] Total linearly moved masses
(incl. belts, conveyor belt, cable ...) Belt drive η ≈ 0.90

Page 13
 Converting leadscrews

FLoad side
v Load side
Speed: n Motor side = vLoad side
hSp

1 hSp
Torque: M Motor side = ⋅ ⋅ FLoad side
η 2π MMotor side
nMotor side
2
 hsp 
Moment of inertia: J *
= m ⋅  
 2π
Load


nMotor side [RPM] Speed at the motor side

vLoad side [m/min] Velocity at the load side
(machine table)
hSp [m] Pitch (movement of the machine
table for one revolution)
MMotor side [Nm] Torque at the motor side
η [-] Worm-gear spindle efficiency
FLoad side [N] Force at the load side
(machining forces, force due to weight) Efficiencies:

J*Load [kgm2] Moment of inertia of the mass Circulating worm-gear spindle

referred to the worm-gear spindle (high quality version with ball bearings) η ≈ 0.70 ... 0.95
m [kg] Total linearly moved masses Trapezoidal worm-gear spindle
(workpiece and machine table) (favorably-priced design w/o ball bearings) η ≈ 0.30 ... 0.70

Page 14
 Forces

FR
Force due to FG = m ⋅ g
weight

g [m/s2] Gravitational force

g = 9.81 m/s2 FG

Frictional force FR = µ ⋅ FG

µ [-] Friction coefficient

Inclined forces Fparallel = FG ⋅ sin α Fparallel

Fvertical

FG
Fvertical = FG ⋅ cos α
α

Page 15
 Acceleration time, acceleration t o rque
n
1 1
Acceleration torque ( J Rotor + ⋅ J external ) ⋅ ∆n or: ( J Rotor + ⋅ J External ) ⋅ ∆ω ∆n
and acceleration time: η min η
M Accel. = ⋅ M Accel. =
9.55 ⋅ t Accel. s t Accel.
t
tAccel

This is only valid, if a constant

Braking torque ( J Rotor + η ⋅ J External ) ⋅ ∆n min
and braking time: M Brake = ⋅ torque is available over
9.55 ⋅ t Brake s the complete acceleration phase

! (for AC servomotors and

induction motors in the
constant-torque range)
!

M Simplified torque characteristic

for estimation purposes

If required, the acceleration time in

the field-weakening range can be ½M
estimated as a multiple of the acceleration
time in the constant-torque range ¼M

nn 2·nn 3⋅nn 4⋅nn n

Acceleration Acceleration Acceleration Acceleration

= th ≈ 2 ·th ≈ 4 ·th ≈ 4 ·th

Total acceleration ≈ 11 ·th

Page 16
 Speed-torque diagram
upwards
n
downwards

Torque required When braking moving upwards and

M
for acceleration accelerating downwards the torque acts in
the same direction! This is best illustrated
by using this simple diagram.

+
Torque required to oppose
t

Frictional forces always act against the direction of

M
frictional torques and motion! Enter with the same sign as the speed!
possible machining forces t Some machining forces can have the inverse sign,
i.e. the "push" from behind.

+
Torque required
M
The force due to weight is the same when moving and
when stationary! (except if a holding brake is closed)
to compensate the Observe additional load and unload conditions!
force due to weight t

= Add all of the torques with the

Sum of all of correct sign!
the torques t

Page 17
 RMS torque

RMS torque: Average speed:

1 operating cycle 1 operating cycle

M n
M max
M eff
t

t1 t2 t3 t4 t5 t6 t7 t8 t9 t
Simplification

M 12 ⋅ t1 + M 22 ⋅ t 2 + M 32 ⋅ t 3 ...
M RMS =
t1 + t 2 + t 3 + ...
t1 t2 t3 t4 t

The RMS value is calculated by extracting the square root. Contrary

to generating the arithmetic average, the higher torques are more
heavily weighted due to the power of 2. This is required, as the n1 ⋅ t1 + n2 ⋅ t 2 + n3 ⋅ t3 + ...
power loss PV in the motor increases to the square of the current: n=
t1 + t 2 + t3 + ...
with U = R ⋅ I and R = const.
PV = U ⋅ I PV ∼ I 2

Page 18
 Selecting an AC servomotor

The rated speed may be exceeded, however

1. Speed nmax < nn the maximum torque decreases significantly
When required,
above the rated speed.
intermediate values
can be estimated
M0
2. RMS torque M rms < M n If the average
speed is high
(n ≈ n )
n
Mn
Note: A flanged gearbox can
result in a reduction
M RMS < M 0 (100 K ) If the average
speed is low
( n < 10% ⋅ n )
n
of the permissible
torque.
nn n

Maximum M max < approx.4 ⋅ M 0 (100 K ) Shaft heights 03, 04, 06

3. torque Observe the
For approx. 10 s possible
with motor in the cold condition
M max < approx.3.3 ⋅ M 0 (100 K ) Shaft heights 08, 10, 13 !
overload capacity
Catalog DA 65.3, Section 2 of the drive converter
!
or Catalog NC 60.1 section 5

M max < approx.2.5 ⋅ M 0 (100 K ) Forced-ventilated

motors + In the range n > 0.7⋅nn :
(voltage limiting characteristic)
M max < 2 M 0 (100 K )

Ratio of the
Machine tools
4. moments of J External
= 1 ... 2.5 Processing machines with
inertia J Motor the highest dynamic performance This is also the simplest
assignment. Any motor can achieve
2·M0(100K) - at any speed
J External General positioning with low
< 10 demands placed on the
J Motor dynamic performance

Page 19
 Selecting a drive converter for an AC servomotor

Motor > drive converter assignment according to the Catalog:

Assumption:
The drive converter can provide If the motor is not fully utilized,
M0 of the motor is fully utilized.
I0, motor is required
the required current.
In, converter ≥ I0, motor
! then a smaller drive converter
may be able to be used.
!
Assumption:
Overload capacity of the converter: If the full overload capacity of the motor
The motor is operated with no more
than the same overload condition
1.6⋅In for all MC drive converters
approx. 3⋅In for Compact Plus
! is utilized, then it maybe necessary to
use a larger drive converter.
!
as the drive converter permits.
Imax = 1.6 * In

Calculating the matching drive converter for other load situations:

The required current is
calculated with torque Shaft heights
constant kTn : 4·M0 03, 04, 06
Requirement: Shaft heights
08, 10, 13
M RMS
I RMS = I n ,converter ≥ I RMS Forced-ventilated
k Tn 2·M0 motors

M max This interrelationship

I max =
kTn
I max,converter ≥ I max
! is only valid up to 2⋅M0
(self-cooled motors) ! 2·I0 4·I0
kTn = 1,22 Nm

Page 20
 Selecting an induction motor - operation in the constant torque range

1. Speed nmax,required < nn For continuous operation with n<nn:

Torque of non-ventilated
1LA motors must be reduced
M [Nm]

2. RMS torque M RMS ,required < M n Mn

approx.70% Mn
P1:2 = M red . ⋅ nn
Observe the
! speed control
range for 1LA
! P1:5 = M red . ⋅ nn

nn n [RPM]
(If the speed range is only passed through once
when the motor is powered-up, then the Speed control range 1:2
drive system can be dimensioned for the operating point) 1500 3000
Speed control range 1:5
600 3000

Observe the
3.
Maximum
torque
M max,required < 0.77 ⋅ M Stall ( nn ) Fed from
EE, ERE M Stall = 2 ⋅ M n 1PH, 1PL ! overload capacity !
of the drive converter

M max, required < M Stall ( nn ) Fed from

M Stall = approx.2.5 ⋅ M n 1LA
AFE
More detailed information
is provided in Catalog M11

Page 21
 Selecting an induction motor - operation in the constant power range

1. Speed n n < n max, required < n1 1PA, 1PH, 1PL Catalog DA 65.3 (or Catalog NC 60.1)

n max, required < 1.4 ⋅ nn 1LA

For higher nmax,required, the stall torque can even mean some
restrictions. This must be checked.
Also refer to “Checking the stall torque”

2. Power PRMS , required < Pn

Max.

P [kW]
! field-weakening range
VC control: 1:5
MC control: 1:2
!
Pn
Note: Limited by Mstall
For self-ventilated 1LA motors, Required
at 100 Hz, i.e. 2x the rated speed, output
the output (power) must be reduced
by approx. 10 %
nn n1 n [RPM]

Constant-power range

Page 22
 Selecting an induction motor - checking the stall torque
Max. Observe the
The safety margin to the stall 1LA motors at nLoad point > 1.4·nn
torque should be checked for: 1PH motors at nLoad point > n1.
! field-weakening range
VC control: 1:5
MC control: 1:2
! max. drive
converter output
frequency
!
1. Speed n Load po int < n max, motor
Limited by MStall
P [kW]
More detailed information
Pn Load point
in Catalog DA 65.3 and M11
1LA

Stall torque < 0.77 ⋅ M Stall ,load Prequired

2. at nLoad point
M Load po int po int

Fed from EE, ERE nn n1 nmax,motor

nLoad point

M Load po int < M Stall ,load po int

2
 nn 
1LA: M Stall ,load po int = M Stall ( nn ) ⋅  
Fed from AFE n 
 Load po int 
2 1PH
M [Nm]  n1 
In comparison to 1LA motors, 1PH motors have a
Mn 1PH: M Stall ,load po int = M Stall ( n1 ) ⋅  
significantly higher field-weakening range.  n Load po int 
Generally, they are operated at speeds less than n1.  
If the stalling torque has to be checked,
then the stalling torque must first be determined Mrequired
at n1 using the catalog data:

9.55 ⋅ Pn
M Stall ( n1 ) = nn n1 nmax,motor
n1 nLoad point

Page 23
 Selecting an induction motor - optimization using the pole number

As for DC motors, the High nn > low Mn

following interrelationship also Low nn > high Mn
is valid for induction motors: at the same current Overload capacity
(for heavy-duty starting),
a higher pole number
is more favorable
M [Nm]
6 pole
The following aspects should be observed if a motor
with a higher pole number is operated in the field-
weakening range: 4 pole
• The required current is lower, so that generally a
2 pole
smaller drive converter can be used.
• The motor is generally somewhat larger; under
Required
unfavorable conditions, this could mean the next
torque
shaft height . e.g. traversing
• Motors with higher pole numbers are generally drive
more expensive.
1000 1500 Required 3000 n [RPM]
• Higher fan noise. torque
• The safety margin to the stall torque must be e.g. pump
checked!
• If the motor is to be used directly online (bypass
operation) if the drive converter develops a fault,
then the motor does not reach its full speed or
output.

Page 24
2001
 Selecting a drive converter for induction motors (1)

Motor > drive converter assignment according to the Catalog:

As for AC servomotors, it is assumed that the motor will be fully

! utilized (In,converter ≥ In,motor ), and that the overload capacity of

the drive converter is not exceeded (VC: 136%; MC: 160%)
!
Calculating the matching drive converter for other load situations:

Operation at the rated operating point:

Adjacent side
Rated current In I n ⋅ cos ϕ = I w (cos ϕ = )
Magnetizing Hypotenuse
The drive converter ϕ current Iµ or
must provide this
Active current Iw
I n2 = I w2 + I µ2 (Pythagoras )

Operation with any torque:

?? ? ? ? ?? ? ?
ILoad point Iµ ILoad point ILoad point ILoad point
Iµ Iµ Iµ
ϕ ϕ ϕ
Iw = 0 Iw Iw Iw

No-load condition Weak load Rated load Overload

Page 25
 Selecting a drive converter for induction motors (2)

Magnetizing 1PH, 1PL Refer to Catalog DA 65.3 (or Catalog NC 60.1)

current at the
1. rated operat. Iµ Refer to Catalog M11
ϕ 1LA I µ = I n ⋅ 1− cos ϕ
point
Note: (cosϕ)2 should have been obtained using these formulas.
However, this change comes very close to
the actual interrelationships, for example, that cosϕ
is load-dependent.
Active current
2. at the rated Iµ I w, rated po int = I n2 − I µ2
operating point
Iw,rated op. point

Active current
3. at the load M Load po int
Iµ I w,load po int = ⋅ I w,rated po int
point Mn
Iw, load point

For overload:
Additional factor due
2
 M Load po int 
4.
Current
required at the
ILoad point
Iµ
I Load po int t = 
 Mn
⋅ I w,rated po int  + I µ2

! to saturation effects
at 1.5⋅Mn: 5% !
load point at 2⋅Mn:10%
Iw, load point This formula is valid for the constant
torque range = constant flux range!

Page 26
28th Nov 2001
 Selecting a drive converter for induction motors (3)

Operation in However, with the weaker magnetic field,

The magnetizing current decreases
5. the field-
in field-weakening operation
the active current must be increased in
weak. range order to achieve the same torque

ILoad point
ILoad point ILoad point
Iµ Iµ Iµ

Iw, load point Iw, load point Iw, load point

2 For overload:
 
  2 Additional factor due
 M Load po int   nn 
I Load po int = 

nn
Mn
⋅ I w,rated po int  +
n
  Load po int
⋅ Iµ 


! to saturation effects:
at 1.5⋅Mn: 5% !
n  at 2⋅Mn:10%
 Load po int 

The torque, which can be achieved at the The magnetizing current

rated operating point with the active current, decreases proportionally with the speed.
decreases, above the operating point, proportionally
with the speed.

Page 27
 Overload capacity of MASTERDRIVES MC
Standard load duty cycle (also for Compact Short-time behavior for Compact Plus
Plus)
300% In
300% In for
I [A] I [A] I [A]
Compact Plus
for 0.25s

160% In
Imax = 3 * In

In In In

91% In 91% In

30 300 t [s] t [s] 0,25 1 t [s]

Any load duty cycle - determining the base load time with a Overload Base load
nomogram
1.1 In 0.9 In
140% In 0.7 In
1.4 In
? In
1.6 In
0.4 In

?? 40% In 0.0 In

30 ? t [s] t [s] 30 t [s]

!!!

Page 28
2001
 Derating the rated current

Increased pulse frequency: Installation altitude: Ambient temperature:

100%
In In

100%
In
!
100%

f [kHz] 1000 4000 20 40 50

Standard setting dependent
on the type of construction Altitude above sea level [m] Ambient temperature [°C]
and drive converter output

(Alternative:
Sinusoidal filter)

Page 29
 Regenerative power / braking power
1 operating cycle T
Maximum PBrake, max = 0.105 ⋅ M ⋅ n
1. braking power
The maximum braking power
n
In this case, the drive converter and motor efficiencies are occurs at the start of braking!
not taken into account. Any losses help to dissipate the
energy when braking so that we are on the safe side
t
anyway.
This calculation should be made for each individual braking
operation within an operating cycle, M
especially if M and n differ.

Braking The braking energy is

2. energy calculated for each braking
operation: t

1
The following applies for W Brake = ⋅ PBrake,max ⋅ t Brake
braking with a constant torque: 2
When lowering a load with constant
velocity and when braking in the WBrake = PBrake ⋅ t Brake Rule: The braking power occurs
field-weakening range, the following when the speed and torque
applies: have different signs!
PBrake
PBrake, max
Average ΣW Brake
3. P=
braking power T

The energy of all of the braking operations is added and is t

divided by the cycle time. The area corresponds
to energy W

Page 30
 BACK UP ONLY
Selecting a braking unit
Maximum
1. braking power C P [kW]
P3 = 6⋅PD With external
brake resistor
PBrake, max ≤ P3
P20 = 4 ⋅ PD

This calculation is sufficient for individual

braking operations (emergency off, end of shift,...)
PD
For load duty cycles, the continuous
load must also be determined: D 3 20 30 90 t [s]

Average
2. braking power P [kW]
With integrated
C P3 = 6⋅PD brake resistor
P ≤ PD
P20 = 4 ⋅ PD

Note: For longer braking sequences

in the field-weakening range, P20
PD
is favorable when making calculations:

PBrake ≤ P20 0.4 4 90 t [s]

2.5
This allows for a safety margin for the D
remaining braking travel in the constant-torque
range.

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 Load characteristics

1
M ∼ const. M ∼n M ∼ n2 M∼
n
Speed-torque diagram

M M M M
Pmax Pmax Pmax

Starting
torque?

n n n n

• Feed drives • Calendar drives • Fans and pumps • Winders

Example

• Positioning drives (=which are used to smooth • Main spindle drives on

• Elevators, hoisting equip. and emboss for paper and machine tools
• Extruders, mixing units plastic-producing/finishing
machines)
Engineered/dimensioned

• Overload / base load • Load point • Load point • Constant-power range

according to

or or or

• Load duty cycle • (Load duty cycle) • Overload / base load

Note: When commissioning
or
select a square law characteristic.
⇒ energy-saving! • Load duty cycle

Page 32
 Duty types according to VDE 0530
Temperature ϑ
P,ϑ Continuous duty S1

The motor reaches the maximum permissible temperature for

continuous duty with rated output PN

t
Mechanical power P
at the motor shaft Short-time duty S2
P,ϑ
The motor can be briefly overloaded but it must be allowed to cool
down completely

t
Intermittent duty S3

P,ϑ The motor can be overloaded for a specific time in any 10 min cycle.
For example:
4 min operation, 6 min no-load interval (=neither subject to an electrical
nor mechanical load).
Data for a shorter cycle time, e.g. S3-40% 1 min.
t
10 min

Intermittent duty S6
P,ϑ
Contrary to duty type S3, during the no-load interval, the motor
continuous to rotate but under no-load conditions. This is also a typical
condition for an induction motor fed from a drive converter/inverter, if
the magnetic field excitation is to be continuously maintained.
t
Although no mechanical output is generated, electrical power is drawn.
This generates losses.

Page 33
 Mechanical system equations

Const. velocity: Const. acceleration: Point-type body, J = m⋅r2

thin-walled hollow cylinder:

v=
s ∆v s=
1 1 Solid 1
J=
1
ρ ⋅π ⋅ l ⋅ r 4
a= ⋅ ∆v ⋅ t s= ⋅a ⋅t2 J= m⋅r2
t t 2 2 cylinder: 2 2
1 1
Axial gearboxes (planetary, belt, cycloid gearboxes): Hollow cylinder: J = ⋅ m ⋅ (R2 + r 2 ) J= ⋅ ρ ⋅π ⋅ l ⋅ (R 4 − r 4 )
2 2
J Load
n Motor side = i ⋅ n Load side M Motor side = 1 ⋅ M Load side *
J Load = 1
η i i2 ( J Rotor + ⋅ J External ) ⋅ ∆n
η
rLoad side Accelerating torque: M Accel. =
Gearbox ratio for belt drives: i= 9.55 ⋅ t Accel.
rMotor side
( J Rotor + η ⋅ J External ) ⋅ ∆n
Racks, conveyor belts, winders: Braking torque: M Brake =
v Load side 9.55 ⋅ t Brake
1
n Motor side = M Motor side = ⋅ FLoad side ⋅ r *
J Load = m⋅r2
2π ⋅ r η
M 12 ⋅ t1 + M 22 ⋅ t 2 + M 32 ⋅ t 3 ...
RMS torque: M RMS =
Worm gear spindle:
2
t1 + t 2 + t 3 + ...
v Load side 1 hSp  hsp 
n Motor side = M Motor side = ⋅ ⋅ FLoad side J Load
*
= m ⋅  
hSp η 2π  2π 
Motor selection (for positioning):

1. Speed: nmax < nn 2. RMS torque: M RMS < M n ...M 0 (100 K )

Torque: M = F ⋅r Output: P = 0.105 ⋅ M ⋅ n
3. Max. torque: M max < approx.3.3...4 ⋅ M 0(100 K )
J External
Force due to weight: FG = m⋅ g Frictional force: FR = µ ⋅ FG 4. Ratio of the moments of inertia: = 1 ... 10
g = 9.81 m/s2 J Motor

Page 34