TERM PAPER

(COURSE :ELECTRICAL SCIENCE-II) (COURSE CODE : ELE-102 )

TOPIC : FACTORS EFFECTING MOTOR SELECTION AND EFFICIENCY

SU BMITTED TO :Mr.Princejit singh (DEPTT. OF ELECTRICAL ENGINEERING.)

SUBMITTED BY:DIPAK KUMAR ROLL :RC4911A26 Reg no :10906448 B.TECH (ME)152

CONTENTS:I. II. III. IV. V. VI. VII. VIII. IX. X. XI. XII. XIII. INTRODUCTION OF MOTOR TYPES OF ELECTRIC MOTOR MOTOR CHARECTERISTICS SELECTION PROCEDURE OF MOTOR MOTOR SELECTION EXAMPLE OF MOTOR SELECTION EFFICIENCY POWER FLOW DIAGRAM OF MOTOR MOTOR LOSSES FACTORS EFFECTING THE EFFICIENCY FACTORS MINIMISING MOTOR LOSSES CONCLUSION REFERENCES

Abstract:-This document having information about mainly motor selection process and factors effecting motor selection and factor which effect the efficiency of electric motor but after reading this document we will be also able to know about motor and purpose of using electric motor also types of electric motor,motor characteristics as motor speed ,synchronous speed ,sleep and power factor also we will be able to know about different types of electric motor. INTRODUCTION OF MOTOR Motors convert electrical energy into mechanical energy by the interaction between the magnetic fields set up in the stator and rotor windings. Industrial electric motors can be broadly classified as induction motors, direct current motors or synchronous motors. All motor types have the same four operating components: stator (stationary windings), rotor (rotating windings), bearings, and frame (enclosure).If we want to know about motor than this is very necessary that we are familiar with motor characteristics as motor speed ,synchronous speed of motor ,slip of the motor and power factor of the motor. Since there are many types of motor available in the market so we have to familiar that some factor which effect the motor selection for different purposes as speed variation, load variation and other thing also efficiency of motor is a major factor which we have to considered. So we have to also familiar different factor which effect motor efficiency. Since efficiency is defined as output power divided by input power and output power depends upon motor loses.
I.

(b) Induction:(1)Single-phase (2)Three-phase (2) DC motor:(a)Separately (b)Self Excited (1)Series (2)Compound (3)Shunt MOTOR CHARACTERISTICS Motor speed:-The speed of a motor is the number of revolutions in a given time , typically revolutions per minute (RPM). The speed of an AC motor depends on the frequency of the input power and the number of poles for which the motor is wound. The synchronous speed in RPM is given by the following equation, where the frequency is in hertz or cycles per second: Synchronous Speed (RPM) = Indian motors have synchronous speeds like 3000 / 1500 / 1000 / 750 / 600 / 500 / 375 RPM corresponding to no. of poles being 2, 4, 6, 8, 10, 12, 16 (always even) and given the mains frequency of 50 cycles / sec. The actual speed, with which the motor operates, will be less than the synchronous speed. The difference between synchronous and full load speed is called slip and is measured in percent. It is calculated using this equation: Slip(%) = *100 III.

TYPES OF ELECTRIC MOTOR Motors are divided into two categories.They are :(1) Alternating current(AC) motor (2) Direct current (DC) motor Again both AC and DC motor divided into these categories :(1) AC motor:(a) Synchronous

II.

As per relation stated above, the speed of an AC motor is determined by the number of motor poles and by the input frequency. It can also be seen that theoretically speed of an AC motor can be varied infinitely by changing the frequency. Power factor:-The power factor of the motor is given as:

Power factor= Cos As the load on the motor comes down, the magnitude of the active current reduces. However, there is no corresponding reduction in the magnetizing current, which is proportional to supply voltage with the result that the motor power factor reduces, with a reduction in applied load. Induction motors, especially those operating below their rated capacity, are the main reason for low power factor in electric systems. IV. SELECTION PROCEDURE 1. Required Specifications First, determine the basic required specifications such as operating speed, load torque, power supply voltage and frequency. 2. Calculate the Operating Speed Induction and reversible motor speeds cannot be adjusted. Motor speed must be reduced with gearheads to match the required machine speed. It is therefore necessary to determine the correct gear ratio. 3. Calculate the Required Torque Calculate the required torque for motor by the load torque. 4. Select a Motor and Gearhead Use the required torque and speed to select a motor and gearhead. 5. Confirm the speed In a single-phase induction motor, starting torque is always lower than the rated torque. Therefore, to drive a frictional load, select the speed on the basis of starting torque. This will cause the actual speed to exceed the rated speed. Also, the motors are designed so that increases in motor temperatureare at their lowest when operating close to the rated speed of rotation.

Generally two terms are considered for motorr selection electrical suitability and mechanical suitability ,speed variation and load variation. Electrical suitability:Rated output Acceleration Continuous running Speed variations Load variation Winding resistance How much power is needed How much electrical power is available Capacity in service entrance panel (breaker box) Power supply Motor duty Starting load Mechanical suitability:Motor sizing Fixing dimension Shaft stressing Bearing life Magnet properties Brushless versus brush-type

V.

MOTOR SELECTION

The primary technical consideration defining the motor choice for any particular application is the torque required by the load, especially the relationship between the maximum torque generated by the motor (break-down torque) and the torque requirements for start-up (locked rotor torque) and during acceleration periods. The duty / load cycle determines the thermal loading on the motor. One consideration with totally enclosed fan cooled (TEFC) motors is that the cooling may be insufficient when the motor is operated at speeds below its rated value. Ambient operating conditions affect motor choice; special motor designs are available for corrosive or dusty atmospheres, high temperatures, restricted physical space, etc. An estimate of the switching frequency (usually dictated

by the process), whether automatic or manually controlled, can help in selecting the appropriate motor for the duty cycle. The demand a motor will place on the balance of the plant electrical system is another consideration - if the load variations are large, for example as a result of frequent starts and stops of large components like compressors, the resulting large voltage drops could be detrimental to other equipment. Reliability is of prime importance - in many cases, however, designers and process engineers seeking reliability will grossly oversize equipment, leading to sub-optimal energy performance. Good knowledge of process parameters and a better understanding of the plant power system can aid in reducing over sizing with no loss of reliability. Inventory is another consideration - Many large industries use standard equipment, which can be easily serviced or replaced, thereby reducing the stock of spare parts that must be maintained and minimizing shut-down time. This practice affects the choice of motors that might provide better energy performance in specific applications. Shorter lead times for securing individual motors from suppliers would help reduce the need for this practice. Price is another issue - Many users are first-cost sensitive, leading to the purchase of less expensive motors that may be more costly on a lifecycle basis because of lower efficiency. For example, energy efficient motors or other specially designed motors typically save within a few years an amount of money equal to several times the incremental cost for an energy efficient motor, over a standard-efficiency motor. Few of salient selection issues are given below: In the selection process, the power drawn at 75 % of loading can be a meaningful indicator of energy efficiency. Reactive power drawn (kVAR) by the motor. Indian Standard 325 for standard motors allows 15 % tolerance on efficiency for motors upto 50 kW rating and 10 % for motors over 50 kW rating. The Indian Standard IS 8789 addresses technical performance of Standard Motors while IS 12615

addresses the efficiency criteria of High Efficiency Motors. Both follow IEC 34-2 test methodology wherein, stray losses are assumed as 0.5 % of input power. By the IEC test method, the losses are understated and if one goes by IEEE test methodology, the motor efficiency values would be further lowered. It would be prudent for buyers to procure motors based on test certificates rather than labeled values. The energy savings by motor replacement can be worked out by the simple relation : kW savings = kW output [ 1/old 1/ new ] where old and new are the existing and proposed motor efficiency values. The cost benefits can be worked out on the basis of premium required for high efficiencyvs. worth of annual savings. EXAMPLE OF MOTOR SELECTION Choosing the Correct DC Motor for a Specific Application Design engineers are often faced with having to determine the best DC motor choice for a given functional requirement or design parameter. A typical example might look like this: Functional Requirement: DC Gear head motor capable of accelerating a 6.804kg, two-wheel drive robot with wheel diameters of 3.825 at a rate of 0.9144m/spuare second. Top speed required will be around 1.2192 m/s Design Parameters: Supplied Voltage = 12Volts, Motor size limited to an overall diameter of approximately 2 and an overall length of not more than 4 (Less the output shaft length.) Design engineers are not always in a position to be assured their decision is the best given the universe of possible gear head motor options. Their decisions are often constrained by one of more of these 5 concerns: 1.Time 2.Money 3.Knowledge 4.Power and 5.Weight
VI.

In order to best solve this design problem, an engineer might choose to accomplish the following tasks in this order: 1. Calculate the required wheel torque and RPM described in the functional requirement 2. Research DC motor manufacturers to determine the availability of gear-head motors that meet the Functional Requirements and the Design Parameters. 3. Compare the published specifications of the various gear-head motors to determine which will provide the best value in terms of the constraints listed above. 4. Choose one or several motors for prototyping and testing. Step One: Calculate the Required Wheel Torque and RPM Review the functional requirement: DC Gear head motor capable of accelerating a 6.804kg, two wheel drive robot with wheel diameters of 3.825 at a rate of 0.9144m/square second. Determine the torque (force) that must be generated at each wheel in order to meet the functional requirement. Mass = 6.804 kg Acceleration = 0.9144 meter/square second Torque = Newton/meters Calculate required force F = MA Force = Mass Acceleration Force= 6.804kg 0.99144m/ s2 Force = 5.8N The Total force required to meet the Functional Requirement is 5.8 N. However, the vehicle has 2 motors and wheels. Therefore each motor/wheel combination needs only supply half the required force or 2.9 Newtons. Force(wheel) = 2.9N Calculate the torque requirement for each wheel.

Torque is a twisting or turning force that acts on an axis or pivot. The 2 wheels of this vehicle turn on an axis or shaft. The distance from the center of the turning axis to the outside of the wheel is the radius of the wheel. The torque or turning force of the axle acts through the radial distance as illustrated in the graphic below. Torque = Force Distance Distance = Wheel Radius = Wheel Diameter/2 = 3.825/2 inches =0.0486meter Force = Force required per wheel = 2.9 Newtons

Torque(wheel)= 2.9m* 0.0486 N Torque(wheel)=0.14094Nm or it can be expressed in milli Newton meters by multiplying by 1000. Many manufacturers of fractional horsepower motors express torque in milli Newton meters. Wheel Torque(wheel)=140.9mNm. The required torque at each wheel is 0.14094 Newton meters. Note: Remember that DC motors develop less torque as the armature rotational speed increases. For this reason we will need to find a motor that can produce 0.14094 Newton meters of continuous torque at or near the design rpm of 250 revolutions per minute. Calculate the required wheel RPM to maintain a speed of 4 feet per second Wheel Diameter = 3.825 =

0.0971 meters Wheel Circumference = x Diameter = 3.142 x 0.0971 meters = 0.305 meters Required Speed = 1.219 meters/second RPS Revolutions Per Second = rpm/60 Speed = RPS Circumference 1.219=RPS* 0.305 m RPS = 3.996 RPM = 239.76 Step Two: Research manufacturers in order to determine the availability of gear-head motors that meet the functional requirements and the design parameters. List the required torque and Wheel velocity from the previous calculations Required torque = 0.1409 Newton meters = 1.247 inch pounds = 19.95 inch ounces Wheel velocity = 239 Revolutions per minute = 3.996 Revolutions per second = 25 Radians sec Note: It is important to calculate the motor specifications using one set of units, but it is also necessary to list the specifications in a variety of units since individual manufacturers use different units. For the purpose of choosing a motor for this lesson activity, we will consult the Pittman Motor Company specifications. Review the functional requirements and the design parameters: Functional Requirement: DC Gear head motor capable of accelerating a 15lb, two-wheel drive robot with wheel diameters of 3.825 at a rate of 3ft/sec2. Top speed required will be around 4 feet/sec Design Parameters: Supplied Voltage = 12Volts, Motor size limited to an overall diameter of approximately 2 and an overall length of not more than 4 (Less the output shaft length.) Note: Motor manufacturers publish their motor specifications online as a convenience to engineers and designers looking to make motor purchases. For the most part these motor manufacturers are expecting to sell caseloads of motors to OEMs (Original

Equipment Manufacturers) and are not expecting to sell individual motors. VII. EFFICIENCY We are interested in delivering the maximum amount of power to the load, and want to minimize power dissipated as heat. We can express the efficiency of a motor as the power delivered divided by the power input. If we are able to measure the torque delivered and operating speed of a motor, we can calculate its output power as simply T * S. The input power is just the applied voltage times the current. There is an easier way of estimating motor efficiency than by actually measuring output torque and speed. This can be done by considering the electrical power that is not lost to friction or winding resistance. Considering the equivalent circuit shown above, we are interested in the portion of the current that corresponds to the delivered torque, and the portion of the voltage that is not dropped across the motor resistance. Measuring the running but unloaded motor will reveal that it draws a current that is relatively independent of speed (the small speed-dependent portion corresponds to the other losses mentioned above, and will be ignored here). This current, If, corresponds to the frictional loss of the motor. We can thus consider that the current that is actually being used to turn the load is simply Efficiency of a motor is the power delivered (its torque times its speed) divided by the power input (voltage times current). The following graph shows efficiency as a function of torque for the Solar Sprint motor, and also for a motor of similar design, but with much lower friction.

The graph indicates that this motor has a maximum efficiency of less than 50 percent. The curve for the low friction case shows a much higher efficiency, indicating that the motor's friction is a significant problem. The horizontal axis of this graph is current. Note that this current is related to torque (delivered plus frictional) by the torque constant, so this is also a graph of efficiency versus torque. Another thing to remember is that, for a particular applied voltage, speed and torque are intimately related. Writing the voltage equation for the motor, we get V = KS + IR Rearranging: S = V/K - IR/K Knowing that torque is KI: S = V/K - RT/K**2 So the speed of the motor is maximum when torque is equal to the frictional torque. This is the "no load speed". Speed declines linearly with increasing torque increase until it reaches the stall condition. In short:Efficiency= Mathematically:Electrical Motor Efficiency when Shaft Output is measured in Watt

If power output is measured in Watt (W), efficiency can be expressed as: = Pout / Pin (1) where = motor efficiency, Pout = shaft power out (Watt, W), Pin = electric power in to the motor (Watt, W) Electrical Motor Efficiency when Shaft Output is measured in Horsepower If power output is measured in horsepower (hp), efficiency can be expressed as: m = Pout 746 / Pin (2) where Pout = shaft power out (horsepower, hp) Pin = electric power in to the motor (Watt, W) POWER FLOW DIAGRAM OF MOTOR Input to motor or stator power(Pi) Stator Cu loss Stator iron and winding loss Air gap power Rotor input(P1) Rotor Cu loss Pmech Friction and winding loss of motor Output power of motor
VIII.

As we seen according to this power flow diagram output power of motor depends upon different motor losses and output power effect the motor efficiency so motor losses effect the efficiency of motor. So this is necessary that we must have knowledge about different motor losses.

IX.

DESCRIPTION OF MOTOR LOSSES

Typically, motor losses are categorized, first, as those which occur while the motor is energized but operating at no-load; and, second, those additional losses due to the output load. Specific losses are: 1. No-load losses a. Windage and friction b. Stator iron losses c. Stator I2R losses 2. Load Losses a. Stator I2R losses (due to increase in current under load) b. Rotor I2R c. Stray load losses The no-load losses and the conductor losses under load can be measured separately, however, the stray load loss requires accurate input-output test equipment for determination. The stray-load loss consists of losses due to harmonic currents and flux in the motor. Factors affecting stray load losses include: Stator and rotor slot geometry Number of slots Air gap length Rotor slot insulation Manufacturing process POWER LOSSES In an ideal motor, all applied power would be delivered to the load. In a real motor, there are several places that power gets lost. One major loss is in the electrical resistance of the motor windings. It can be calculated as I2 *R. Because motor current is proportional to the torque generated by the motor, resistive losses are also proportional to motor torque. The second major loss is friction. As with the loss in the winding resistance, friction converts applied energy into heat. Friction can be considered to be composed of several components. "Standing friction" must be overcome before the motor will start.

"Running friction" is ordinarily less, and is seen as a torque resisting motor turning. It is the same at all motor speeds. We will ignore starting friction, as we ordinarily apply enough voltage to get over it very quickly. Because torque is related to the motor curent by the torque constant, frictional torque will show up as a constant running current for the unloaded motor. There are other possible opportunities for losing power in the motor. In an iron core motor, changing magnetic fields actually induce current flow in the iron core (eddy currents). These currents result in a power loss that increases with motor speed. Another loss stems from the fact that the winding has inductance. When current flows through a winding, energy is stored in the magnetic field. When current is stopped by commutation, this energy must go somewhere, and it doesn't go anywhere that is useable! (this is the source of brush sparking, for example). This energy loss increases with increasing motor speed. There are also frictional forces due to aerodynamic effects. These losses increase with increasing motor speed. The efficiency of a motor is determined by intrinsic losses that can be reduced only by changes in motor design. Intrinsic losses are of two types: fixed losses independent of motor load, and variable losses dependent on load. Fixed losses consist of magnetic core losses and friction and windage losses. Magnetic core losses (sometimes called iron losses) consist of eddy current and hysteresis losses in the stator. They vary with the core material and geometry and with input voltage. Friction and windage losses are caused by friction in the bearings of the motor and aerodynamic losses associated with the ventilation fan and other rotating parts.

Variable losses consist of resistance losses in the stator and in the rotor and miscellaneous stray losses. Resistance to current flow in the stator and rotor result in heat generation that is proportional to the resistance of the material and the square of the current (I2R). Stray losses arise from a variety of sources and are difficult to either measure directly or to calculate, but are generally proportional to the square of the rotor current. Part-load performance characteristics of a motor also depend on its design. Both and PF fall to very low levels at low loads. Primary and Secondary Resistance Losses The electrical power lost in the primary rotor and secondary stator winding resistance are also called copper losses. The copper loss varies with the load in proportion to the current squared - and can be expressed as Pcl = R I2 (3) where Pcl = stator winding - copper loss (W) R = resistance () I = current (Amp)

Mechanical Losses Mechanical losses includes friction in the motor bearings and the fan for air cooling. FACTORS EFFECTING THE EFFICIENCY, POWER AND SIZE OF ELECTRICAL MACHINES. The physical size of an electrical machine has a profound effect upon its efficiency, power output, relative cost and temperature rise. Suppose we increase the size of a machine such that its linear dimensions are scaled in exactly the same proportion, meanwhile using the same materials. Retain the same current densities and flux densities Copper losses and iron losses per unit volume will be the same. Furthermore, assume that no. of slots and conductors remain the same, and that rotating speed (rpm) is unchanged Assume that linear dimensions are increased by K: Volume and mass increases by K3 losses increase by K3 too. Slots are K times wider and deeper therefore conductor cross section increases by K2, current rating increases by K2 too. For generated voltage, length increases by K, peripheral speed increases by K voltage generated increases by K2. Power rating increases by K4, whereas losses increase by K3. Everything seems to favour increasing the machine size. But the big problem with increasing the size is temperature rise! If dimensions increase by K, then losses increase by K3, but heatdissipating surface area only increases by K2. Therefore larger machines need more effective cooling. Ultimately, a point is reached where the increased cost of cooling exceeds the savings from better power density and efficiency this fixes the upper limit to the size.
X.

Iron Losses These losses are the result of magnetic energy dissipated when when the motors magnetic field is applied to the stator core. Stray Losses Stray losses are the losses that remains after primary copper and secondary losses, iron losses and mechanical losses. The largest contribution to the stray losses is harmonic energies generated when the motor operates under load. These energies are dissipated as currents in the copper windings, harmonic flux components in the iron parts, leakage in the laminate core.

This analysis applies to all electrical machines (motors and transformers) FACTORS MINIMISING MOTOR LOSSES IN OPERATION POWER SUPPLY QUALITY Motor performance is affected considerably by the quality of input power, that is the actual volts and frequency available at motor terminals vis--vis rated values as well as voltage and frequency variations and voltage unbalance across the three phases. Motors in India must comply with standards set by the Bureau of Indian Standards (BIS) for tolerance to variations in input power quality. The BIS standards specify that a motor should be capable of delivering its rated output with a voltage variation of +/- 6 % and frequency variation of +/- 3 %. Fluctuations much larger than these are quite common in utility-supplied electricity in India. Voltage fluctuations can have detrimental impacts on motor performance. Voltage unbalance, the condition where the voltages in the three phases are not equal, can be still more detrimental to motor performance and motor life. Unbalance typically occurs as a result of supplying single-phase loads disproportionately from one of the phases. It can also result from the use of different sizes of cables in the distribution system. XII. CONCLUSION In this document we discussed about motor that motor is a mechanical device which converts electrical energy into mechanical energy .Electrical motor are divided into two categories AC motor and DC motor and AC and DC motor are further divided into different categories .But in general we use mainly Dc motor induction motor and synchronous motor.Motor selection depends upon some factor as load variation,starting load,speed variation,power supply and some other factor.Motor efficiency is defined as output power divided by input power and output power depends upon different-different motor losses XI.

so we can say that motor efficiency depends upon motor loss as Cupper loss,Iron loss ,Eddy current loss,friction loss etc. ACKNOWLEDGMENT I take this opportunity to present my votes of thanks to all those guidepost who really acted as lightening pillars to enlighten our way throughout this document that has led to successful and satisfactory completion of this study. We are highly thankful to our subject teacher Mr. Princejit singh sir for his active support, valuable time and advice, whole-hearted guidance, sincere cooperation and pains-taking involvement during the study and in completing the assignment of preparing the said project within the time stipulated. Lastly, We are thankful to all those, particularly the various friends , who have been instrumental in creating proper, healthy and conductive environment and including new and fresh innovative ideas for us during the project, their help, it would have been extremely difficult for us to prepare the project in a time bound framework. REFERENCES http://www.mediafire.com/?gamwuta0wgx#1 http://www.mediafire.com/?zgrolyhjh1g http://www.ehow.com/list_7273989_3_phaseelectric-motor-specifications.html sawdustmaking.com/ELECTRIC %20MOTORS/electricmotors.html http://findarticles.com/p/articles/mi_m0BPR/is _8_20/ai_107123416/ http://www.globalspec.com/Specifications/Mot ion_Controls/Motors/AC_Motors

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http://www.gearseds.com/files/Lesson3_Mathe matical%20Models%20of%20Motors.pdf http://www.engineeringtoolbox.com/electricalmotor-efficiency-d_655.html www.cerici.org/.../Factors%20Affecting %20Speed%20and%20Accuracy%20of %20Response

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