Types of Motors

By Deependra kumar

What is Mechatronics?
Interdisciplinary field comprising the design and development of smart electromechanical devices. This includes electronics, sensors, mechanics, microcontrollers, materials and human computer interaction. Mechatronics is key to a wide range of products including camcorders, appliances, smart weapons and electric vehicles.

Electric Motors
Types of electric motors presently used are:

1. DC motors Shunt Series Compound Separately excited Switched reluctance motors Stepper Motors

Electric Motors (Contd)

2. AC motors Induction Wound rotor synchronous Permanent magnet synchronous Reluctance motors

Examples of everyday motors

Your car is loaded with electric motors: Power windows (a motor in each window) Power seats (up to seven motors per seat) Fans for the heater and the radiator Windshield wipers The starter motor Electric radio antennas Motors in all sorts of places: Your iPod Several in the VCR Several in a CD player or tape deck Many in a computer Most toys that move Electric clocks The garage door opener Aquarium pumps At home: The fan over the stove and in the microwave oven The dispose-all under the sink The blender The can opener The refrigerator - Two or three in fact: one for the compressor, one for the fan inside the refrigerator, as well as one in the icemaker The mixer The tape player in the answering machine Probably even the clock on the oven The washer The dryer The electric screwdriver The vacuum cleaner and the Dustbuster minivac The electric saw The electric drill The furnace blower Even in the bathroom, there's a motor in: The fan The electric toothbrush The hair dryer The electric razor

EVERYTHING!!!!!

Motor Selection
1. Cost 2. Thermal capacity 3. Efficiency power consumption and loss 4. Torque-speed profile (RPM) and capability 5. Acceleration 6. Power density, volume of the motor 7. DC or AC and controller 8. Suitability for hazardous environment 9. Availability of spare parts 10. Mechanical Transmission reversible?

DC Motors
Dc motors may be further classified for intermittent or continuous duty. Continuousduty dc motors can run without an off period Intermittent-duty: Ex. Paper shredders, wiper motors DC Motor types: Wound-field dc motors are usually classified by shunt-wound, serieswound, and compound-wound. In addition to these, permanent-magnet, brushed and brushless dc motors are also available, normally as fractional-horsepower dc motors.

A typical permanent magnet DC electric motor, disassembled.

Geared DC Motors continued

Schematic of a simple permanent magnet DC motor

Permanent Magnet Brushed DC (PMDC) motors

Permanent Magnet Brushed DC (PMDC) motors are the most common BDC motors found in the world. These motors use permanent magnets to produce the stator field. PMDC motors are generally used in applications involving fractional horsepower because it is more cost effective to use permanent magnets than wound stators. The drawback of PMDC motors is that the magnets lose their magnetic properties over time. Some PMDC motors have windings built into them to prevent this from happening. The performance curve (voltage vs. speed), is very linear for PMDC motors. Current draw also varies linearly with torque. These motors respond to changes in voltage very quickly because the stator field is always constant.

Series-Wound Series-wound Brushed DC (SWDC) motors have the field coil in series with the armature. These motors are ideally suited for high-torque applications because the current in both the stator and armature increases under load. A drawback to SWDC motors is that they do not have precise speed control like PMDC motors have.

 Stepper motors: The inputs of a stepper motor are signal pulses and the shaft of a stepper motor moves between discrete positions proportional to pulses. If the load of the motor is not too great, open-loop control is usually used to control the motor. Stepper motors are used in disk drive head positioning, plotters, and numerous other applications.

DC Motors
Permanent Magnet DC Motors Rare-earth magnets make for small, lightweight motors with up to 50% more torque than ordinary ones having comparable dimensions. This allows a smaller rare-earth motor to do the job of a more expensive and larger conventional unit. The typical range of torque for both brush-type and brushless dc motors is from 7.0 oz-in. to 4,500 lb-ft.
Stepper Motors Stepper motors offer many advantages. Although feedback is not usually required, stepper motors are compatible with feedback signals, either analog or digital. Error is noncumulative as long as pulse-to-step integrity is maintained by the stepper motor. A stream of pulses can be counted into stepper motors, and the stepper motor's final position will be known within a small percentage of one step. -No need for encoders -Requires a special stepper motor controller

The series motor has the field coil wired in series with the armature. It is also called a universal motor because it can be used in DC or AC applications. It has a high starting torque and a variable speed characteristic. The motor can start heavy loads, but the speed will increase as the load is decreased.

The shunt motor has the armature and field circuits wired in parallel , giving essentially constant field strength and motor speed.

The compound motor combines the characteristics of both the series and the shunt motors. A compound motor has high starting torque and fairly good speed torque characteristics at rated load. Because complicated circuits are needed to control the compound motors, this wiring arrangement is usually only used on large bi-directional motors.

Servo Motors

The advantages by this integrated servo motor solution are: De-central intelligence. Simple installation. No cables between servo motor and driver. EMC safe. Switching noise remains within servo motor. Single or dual supply. Compact. Does not take space in cabinet. Typically a 3/5 core cable is used from PLC or similar to MAC motor. 24 or 48VDC power for MAC50-141, 115/230V for MAC800 Low price. Interface possibilities with the MAC servo motor: From PC/PLC with drive commands via RS232/RS485/RS422 Pulse/direction or quadrature inputs. 10 bit (MAC50-141), 12bit (MAC800) 10V input for speed or torque control. A+B encoder output. Register mode via 4 inputs or serial commands Option for nano PLC built-in with grafical programming tools. Option for Fieldbus. ProfibusDP, Canbus, CANopen, Devicenet, Ethernet, Wireless. Multiaxis operation with up to 255 units on the same 460Kbit RS485 bus.

DC Motors
Dynamic braking (dc motor-generated energy is fed to a resistor grid) or regenerative braking (dc motor-generated energy is fed back into the dc motor supply) can be obtained with dc motors on applications requiring quick stops, thus eliminating the need for, or reducing the size of, a mechanical brake.

Dynamic Braking
Dc motors are normally braked by disconnecting the armature from the power source. The armature is then short circuited or a current-limiting resistor placed across the armature terminals while the field coils remain energized. In either case, armature current reverses, armature torque reverses, and the motor tries to reverse. The speed in the forward direction rapidly decreases as does the voltage generated in the armature. At the point of reversal or zero speed, generated voltage is zero. The motor stops at this point since current cannot flow and no more reversing torque is generated. A small resistance allows a large current flow. Since braking torque is proportional to armature current, the motor and load stop in a short time. Some resistance is recommended to limit the severity of braking, especially with gearmotors.

Regenerative braking
Regenerative braking is used on hybrid gas/electric automobiles to recoup some of the energy lost during stopping. This energy is saved in a storage battery and used later to power the motor whenever the car is in electric mode. In hybrid vehicles when you slow down or brake the electric motor begins to reverse direction, it becomes an electric generator or dynamo. This generated electricity is fed into a chemical storage battery and used later to power the car at city speeds. Naturally this works best in stop and go situations. **With the number of charge cycles increasing thanks to these specific control functions, BMW combines Intelligent Alternator Control with AGM (absorbant glass mat) batteries able to handle a higher load than conventional lead/acid batteries.

MOTOR EFFICIENCIES
High efficiency motors are built with larger-diameter wire, longer rotors, silicon steel laminations and other features.

A D.C. Motor Example

MOTOR EFFICIENCIES
High-efficiency motors are built to reduce motor energy loss. Improvements in several areas, including increase motor service life: Larger-diameter wire, increasing the volume of copper by 34 to 40%. This change reduces copper losses that result naturally from current passing through the copper-wire windings. Larger wire slots to accommodate larger wire. This reduces the amount of active steel in each steel lamination. Longer rotor and stator core to compensate for the loss of steel and the resultant need to add more laminations. High-grade silicon steel laminations approximately 0.018 in. thick, having an electrical loss of 1.5 W/lb. The chemical makeup and thinner gage of the laminations, plus a coating of inorganic insulation on each piece, reduce eddy current losses. Special annealing and plating of rotor and stator components and use of high-purity cast aluminum rotor bars reduce hysteresis losses. (If you push on something, it will yield: when you release, does it spring back completely? If it doesn't, it is exhibiting hysteresis, in some broad sense) Higher-grade bearings reduces friction loss. Tighter tolerances and more stringent manufacturing-process control reduce losses from unplanned conducting paths and stray load phenomena. Motors rated 1-250 HP must be efficient to be used in the USA

DC Motors
Encoders Direct Drive or Geared BMWs electric water pump Inefficient motor

Motor-load connection through a gear

Increasing torque by using gears -

Sample

Motor
Specs
The Robot Power CM80 is a powerful low-cost 24VDC brushed gearmotor with an integrated planetary gearbox. You may purchase the CM80 in our Web store. Features

The CM80 sports the following features: Motor Size: 78mm dia. x 163mm long (3.07" x 6.42") Gearbox Size: 56mm dia. x 50(15:1) or 37.5mm(4.25:1) long - 2.20" x 1.97"/1.45" Gearbox Ratios: 15:1 (pictured) and 4.25:1 Output Shaft: 0.625" dia. x 4.0" long with standard 3/16" keyway Output Bearings: Motor - roller bearings, gearbox - ball bearings Weight: 8.0lb with motor and gearbox Rated voltage: 24VDC Terminals: 2 with M6 bolts and nuts Brushes: 4 Timing: Neutral - slightly adjustable

Performance Motor Speed: 7000 RPM no load at 24V Output Speed: 15:1 425 RPM, 4.25:1 1300 RPM no load at 24V No Load Current: 7A at 24V Stall Current: a lot! Peak Output Power: 1500W (2.0HP) at 24V motor spec Peak Efficiency: 65% motor spec not including gearbox May be overvolted to 36V Application Information The CM80 is not a precision servo type motor and as such it has only moderate efficiency. When generating a full 1500W of output power the CM80 will consume approximately 2300W of input power. This is about 100A at 24V. Motor controls, batteries, and wiring must be sized accordingly. Batteries: - Since the CM80 is capable of drawing very high current it is recommended that high output, low internal resistance batteries be used: some of these include Nicad, Nimh and Lead-Acid. Motor Controls: - The motor control chosen for the CM80 should be capable of sourcing 100A of current for significant time periods and be capable of withstanding peak current surges of 200A or more. The Robot Power OSMC is an ideal match for the CM80. Smaller current-limiting controllers may be used with caution. Capacitors: - The CM80 does not come with pre-installed capacitors. During testing we found it to be very electrically quiet due to its sealed case and axial brush design. Capacitors may easily be installed within the brush cap for a clean installation. If capacitors are desired we recommend heavy interference suppressor type capacitors such as the Panasonic ECQU3A series. A capacitor value of .1F to .22F usually works well. Wiring: - 10GA (2.6mm) or larger copper wire should be used when connecting the CM80. Heavy gauge ring terminals may be used or the power cables may be directly soldered to the motor terminals.

 The CM80 includes an integrated planetary gearbox with either a 15:1 or 4.25:1 ratio. A massive 9mm thick steel ring gear supports the steel planet gears riding on hardened 5mm steel pins. This isn't your father's cordless drill gearbox! The gearbox held together with three rather small M3 bolts. When mounting the CM80 it is recommended that both the gearbox and the motor can be supported. The M3 face mounting holes on the gearbox are NOT sufficient to support the motor and gearbox.

 The planetary first stage carrier and the output shaft carrier are both machined from a single piece of high-quality steel into which the hardened planet gear pins are pressed. A 17mm ball bearing supports the output shaft. The 4" shaft length allows easy direct mounting of wheels and pulleys or sprockets with enough shaft left for an outboard bearing. The armature of the CM80 is of a axial design which minimizes sparking and armature wear. Little or no break-in is required to seat the brushes on the armature.

 The brushholder is cast Aluminum for efficient heat dissipation. There are 4 brushes to share the current to this high-power motor. Roller bearings support the back end of the armature. Copper M6 bolts on the motor terminals allow easy connection to the power cables. The motor terminals may be rotated 90 degrees and relocated through the back side of the brush cap to reduce the maximum radial dimension of the CM80 to the diameter of the motor can (requires drilling the brush cap). Motor "timing" is slightly adjustable by rotating the brush cap relative to the magnets.

Suppression Capacitors

Putting a high power motor with sparking brush gear close to a receiver will most certainly cause interference The two capacitors between each terminal and the case should always be the same value. Brushless motors do not require suppression capacitors and they should not be fitted. The interconnecting leads between the motor and controller should be kept short to reduce radiating interference so keep the controller as close to the motor as possible, tucked underneath or to one side but not touching and with plenty of free air space around it. If the motor leads have to be more than a few inches long then twisting them together can reduce interference.

AC Motors

An AC motor has two basic electrical parts: a "stator" and a "rotor" as shown in Figure 8. The stator is in the stationary electrical component. It consists of a group of individual electro-magnets arranged in such a way that they form a hollow cylinder, with one pole of each magnet facing toward the center of the group. The term, "stator" is derived from the word stationary. The stator then is the stationary part of the motor. The rotor is the rotating electrical component. It also consists of a group of electro-magnets arranged around a cylinder, with the poles facing toward the stator poles. The rotor, obviously, is located inside the stator and is mounted on the motor's shaft. The term "rotor" is derived from the word rotating. The rotor then is the rotating part of the motor. The objective of these motor components is to make the rotor rotate which in turn will rotate the motor shaft.

AC Motors

Electric Cars
Simple golf cart
A simple DC controller connected to the batteries and the DC motor. If the driver floors the accelerator pedal, the controller delivers the full 96 volts from the batteries to the motor. If the driver take his/her foot off the accelerator, the controller delivers zero volts to the motor. For any setting in between, the controller "chops" the 96 volts thousands of times per second to create an average voltage somewhere between 0 and 96 volts.

Electric Car
An AC controller hooks to an AC motor. Using six sets of power transistors, the controller takes in 300 volts DC and produces 240 volts AC, 3-phase. The controller additionally provides a charging system for the batteries, and a DC-to-DC converter to recharge the 12-volt accessory battery.

AC Motors
In an AC controller, the job is a little more complicated, but it is the same idea. The controller creates three pseudo-sine waves. It does this by taking the DC voltage from the batteries and pulsing it on and off. In an AC controller, there is the additional need to reverse the polarity of the voltage 60 times a second. Therefore, you actually need six sets of transistors in an AC controller, while you need only one set in a DC controller. In the AC controller, for each phase you need one set of transistors to pulse the voltage and another set to reverse the polarity. You replicate that three times for the three phases -- six total sets of transistors. Most DC controllers used in electric cars come from the electric forklift industry. The Hughes AC controller seen in the photo above is the same sort of AC controller used in the GM/Saturn EV-1 electric vehicle. It can deliver a maximum of 50,000 watts to the motor.

PULLEYS, BELTS AND SPROCKETS

Dc motors are often applied where they momentarily deliver three or more times their rated torque. In emergency situations, dc motors can supply over five times rated torque without stalling (power supply permitting). The gears are used to amplify the torque on load side at lower speed compared to the motor speed

A. Non-slip Panther drive (Standard on H-frame style) Extremely efficient Best for operation in rain and snow Uses synchronous gearbelts and sprockets B. V-belt drive Conventional Frame Only Very smooth and almost silent Economical 4L belts are widely available

DC motor torque vs. speed curve.

Brushed Motors Sample Setup

Brushless Motor Sample Setup