TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES

Ayala Blvd., Ermita, Manila

COLLEGE OF ENGINEERING
Department of Mechanical Engineering

ACTIVITY NO. 2
Motor and Electric Drives

Barachina, Aldrian

Soriano, Ramon Mathew

Ramirez, Dennis Karl E.

Cariño, Mark Lorenz

Ariola, Jose Luis

Lim, Marc Gean

Domingo, Marc Lester

Zabala, Nico Dale

Crucillo, Raymund Mark

OCHEDA, ROECCA B.

BSME-NS4A

TEAM 6

ENGR. RODELIO PADRIQUE

PROFESSOR
I. Motor And Electric Drives

A motor is a mechanical or electrical device that produces rotational or linear force to

drive a machine. The electronic device that harnesses and manages the electrical
energy provided to the motor is referred to as a drive. The drive provides variable
amounts and frequencies of energy into the motor, altering the machine's speed and
torque indirectly. Together the motor and the drive form a “drive system”.

A device that transforms electrical energy to mechanical energy is known as an electric

motor. It can also be thought of as a mechanism that converts electrical energy into
mechanical energy. The drive, also known as the electric drive or motor drive, is the
device that houses the motor and causes it to spin.

An electrical drive is an electronic device that controls particular motor characteristics to

convert electrical energy into mechanical power in a precise and controllable manner.

"Electrical Drives" are electrical power systems used for motion control. For motion
control, it comprises of a complex electronic system or a mix of multiple systems. Prime
movers are used to provide movement. Petrol engines, Diesel engines, gas or steam
turbines, steam engines, hydraulic motors, and electric motors are examples of prime
movers. Electric drives are power systems that make use of electric motors.

As indicated in the block diagram below, a modern electrical drive capable of

changeable regulated speed is made up of several key components.
II. How do motor and drives work?

Electrical energy is converted into mechanical energy, or motion. The motor's speed is
fixed when they're directly connected to the electrical supply, regardless of whether the
task requires that amount of consistent power or not.

Drives ensure that motors effectively use electricity. Power is fed into the drive by
placing it between the electrical supply and the motor, and the drive then controls and
regulates the power that is fed into the motor. This enables control of the motor shaft's
speed, direction, acceleration, deceleration, torque, and, in some cases, location.

A constant frequency, constant voltage supply is converted into a variable frequency,

variable voltage supply by the drive. The motor receives only the power it requires by
constantly calculating and altering the frequency and voltage.

We make several different types of drives since one product can never fit all
applications. We have a drive that will work for any application, regardless of the
industry, function, scale, or nation. They are the unsung heroes who make the world go
round!

III. Types of Motors and Electric Drives

A. Types of Electric Motors

i. AC Brushless Motors

Brushless AC motors are among the most widely used in motion control.
They use the induction of a spinning magnetic field generated in the stator
 to synchronize the rotation of the stator and rotor. They are powered by
permanent electromagnets.

ii. DC Brushed Motors

The brush orientation on the stator controls current flow in a DC brushed

motor. In other models, the orientation of the brush relative to the rotor bar
segments is more important. In every DC brushed motor design, the
commutator is quite crucial.

iii. DC Brushless Motors

Brushless DC motors were created to deliver higher performance in a

smaller space than brushed DC motors, and they are smaller than
equivalent AC counterparts. In the absence of a slip ring or commutator,
an embedded controller is utilized to facilitate operation.

iv. Direct Drive

Direct drive technology substitutes conventional servo motors and

transmissions with a high-efficiency, low-wear application. These motors
accelerate more swiftly and are significantly easier to maintain over a
longer period of time.

v. Linear Motors

These electric motors have an unrolled stator and motor that generate
linear force over the length of the device. They have a flat active section
with two ends, as opposed to cylindrical variants. They are usually more
accurate and faster than rotatory motors.

vi. Servo Motors

Servo motors are the backbone of robotics since they are any motor
connected with a feedback sensor to allow placement. The actuators
employed are both rotary and linear. Brushed DC motors are widespread,
but brushless AC motors are replacing them in high-performance
applications.

vii. Stepper Motors

Stepper motors have an internal rotor that is controlled electronically by

external magnets. Permanent magnets or a soft metal might be used to
make the rotor. The rotor teeth align with the magnetic field as the
 windings are activated. This permits them to travel in set amounts from
point to point.

B. Types of Electric Drives

i. Based on Supply
a. AC Motor Drives

An AC drive is a device that changes the frequency of the

electrical supply to an electric motor, such as a three-phase
induction motor, to adjust its speed. Variable Frequency Drive
(VFD) or Variable Speed Drive (VSD) is another name for an AC
drive (VSD).

b. DC Motor Drives

It is a DC electrical motor's speed control system that gives power

to the motor so that it can run at the appropriate speed. Analog
and digital DC drives are the two types of DC drives. Precision
control is possible with a digital DC drive.

ii. Based on Number of Motors

a. Individual

Each component of a machine will have its own drive

motor. Consider the lathe machine.

b. Multi Motor

Different motors are used to control different elements of a

machine. Cranes, for example.

c. Group Drive

One motor is used to drive two or more machines in a group

drive. A single shaft connects the motor to the other machines,
which are connected to the shaft through belts and pulleys. The
most cost-effective mode of transportation is as a group.

iii. Based on Speed

a. Constant Speed Drive

More or less constant speed drives, squirrel cage induction

motors, and manual controls are employed in machine tools.
 b. Variable Speed Drive

Variable speed drives are used to manage machine speed,

acceleration, deceleration, torque, and finally machine direction.
They're utilized to cut down on energy use.

iv. Based on Control Parameters

a. Vector Control Drive

Vector control is the most precise type of variable frequency drive

(VFD). In this control mode, an inverter uses pulse width
modulation (PWM) techniques to manage torque and speed. For
AC synchronous and induction motors, these are employed.

b. Constant Power Drive

Constant power drive in that range of speed control occurs when

a motor, while carrying rated current in its armature, generates
constant power at all speeds in that range of speed control.

c. Constant Torque Drive

When dealing with fixed volumes, a constant torque load type

drive stands out. Screw compressors, feeders, and conveyors are
examples.

IV. Energy Utilization of Motor and Electrical Drives

A motor that is directly connected to an electrical power source accelerates to a set

speed. The motor draws a large amount of current when it accelerates, which is known
as the 'motor starting current,' and it generates a lot of heat. This excessive heat
significantly increases motor wear and shortens its lifespan. As a result, most
automobile manufacturers specify a maximum number of 'starts' per hour. The starting
current of a motor can be reduced by using a 'soft starter' or a variable-speed drive
(VSD). This allows for a smoother start and reduces motor wear.

The weight being moved uses only around 75 to 80 percent of the energy put into an
electric motor. This comprises:

 In the motor's drive unit, there is a 5% heat loss.

 Approximately 8% internal losses in the motor
 additional friction losses if the motor is connected to a transmission system such
as a gearbox or pulley
A motor's 'loading' is the amount of work it does in comparison to its maximum rated
power output.

The following are examples of electrical drive applications:

 Electric traction, or the transfer of items from one area to another, is the primary
application of this drive. Electric trains, buses, trolleys, trams, and solar-powered
vehicles with batteries are among the several types of electric tractions.
 Electrical drives are widely utilized in a wide range of residential and industrial
applications, including motors, transportation systems, factories, textile mills,
pumps, fans, and robotics, among others.
 These are employed as major movers in petrol or diesel engines, gas or steam
turbines, and hydraulic and electric motors.

Finally, we may deduce from the preceding information that a drive is a type of electrical
device that controls the energy provided to an electrical motor. The drive provides
energy to the motor in unpredictable amounts and at unpredictable frequencies,
eventually controlling the motor's speed and torque.

V. Performance Parameters of Motor and Drive

1. Efficiency

One of the most significant characteristics for modern electric motor drives is
efficiency. The mechanical power given to the mechanical load is simply divided
by the total electrical power consumed by the motor drive to calculate efficiency.
Efficiency is measured in percentages. If an electric motor drive has a 75 percent
efficiency rating, for example, it converts exactly three-quarters of the electricity
used into useful mechanical energy. The remaining quarter of the energy is lost
as heat in the electronics and motor. Because there are so many motor drives
around the world, efficiency is clearly very important.

2. Power Factor

Technically, the power factor is defined as the sine of the angle formed by the
voltage and current provided to the motor drive. The power factor quantifies how
close the two sine waves are to matching up when the AC voltage and current
provided to a motor drive are seen as sine waves. The power factor is unity when
the sine waves of the voltage and current perfectly line up. The power factor is
zero when the sine waves are entirely opposite each other. Higher power factors
(as close to unity as possible) are preferable because they reduce electrical
power system losses. If the power factor of an industrial load falls below a certain
 threshold, electric utility companies charge an additional price. Low power factors
result in power system losses and power quality issues.

3. Harmonic Distortion

When a power electronic converter in a motor drive takes a non-sinusoidal

current from the power system, harmonic distortion can arise. High-intensity
discharge lighting, power electronic power supply, and other forms of harmonic
distortion are among them. Harmonic distortion has the potential to harm other
equipment connected to the same electrical system. Harmonic distortion is a
power quality issue that impacts the electrical system as well as other equipment
that uses electricity.

4. Size and Cost

The size/weight of a motor drive is ultimately what defines its suitability for a
given application. In most cases, the cost of a motor drive is certainly a major
consideration; yet, in most cases, the impact of cost may be overstated. In most
cases, the cost of the motor/motor drive represents a very tiny portion of the total
cost of the motor. The cost of energy to run the motor throughout its life accounts
for the great bulk of the cost in most applications.

A huge industrial motor, for example, would cost P4000 to buy and install, but
P60,000 in electricity expenditures to keep it operating during its 10-year life
lifetime. This is one of the primary reasons for the importance of efficiency.
Although an energy-efficient motor drive may be more expensive than a standard
motor drive, the capital cost is usually insignificant when compared to the energy
expenditures. Most of the time, a more expensive energy-efficient motor drive
more than pays for itself. This is a crucial notion that is frequently missed.

5. Power Density Ratio

The power/density ratio is the proportion of a motor drive's power output to its
weight or size. The power/density ratio is especially important in vehicular
applications, such as automotive and aerospace, where space and weight are
limited.
VI. Baseline efficiency level of the device

Most electric motors are designed to run at 50% to 100% of rated load. Maximum
efficiency is usually near 75% of rated load. Thus, a 10-horsepower (hp) motor has an
acceptable load range of 5 to 10 hp; peak efficiency is at 7.5 hp. A motor's efficiency
tends to decrease dramatically below about 50% load.

VII. Factors that contribute to energy losses and inefficiencies.

The efficiency of an electric motor depends on the choice of materials used for the core
and windings, their physical arrangement and the care and precision with which they
are handled and assembled.

Motor performance depends on three elements such as voltage across terminals,

resistance across terminals, and magnetic force. Various factors that affect these
elements and change motor performance will be discussed here by way of giving some
specific examples.

The factors that affect motor performance;

1. Voltage of Power Supply

If only the voltage of power supply changes, the change in motor is in direct
proportion to that change in voltage.

2. Type of Power Supply

Unlike the constant-voltage power supply, the power supply with resistance will
have a voltage drop due to its internal resistance, causing the stall current and,
therefore, the stall torque to drop with the speed line bottomed to the left.

3. Windings Specification

It's the Winding Specifications that affect motor performances greatly, changing
the number of turns per slot or the diameter of magnet wire produces results
different from each other.

4. Environmental Temperature

Environmental temperature affects the magnetic forces of magnets and the

winding resistance, so indicates changes in motor performance.
 5. Type of Magnet

Magnets are available in a wide variety of types, but discussed here taking them
as changes in magnetic force. Changing the anisotropic magnets from wet to dry
results in decreasing stall torque (Ts) and increasing no-load speed (N0) due to
magnetic force weakened.

6. Flux Yoke

Magnets are held in a housing for their full capability, while using thin-wall
housing will result in magnetic force leaking through the housing wall. That is
where magnet yokes are used to prevent magnetic leakage thus maintaining the
full capacity of the magnets.

7. Phase

Phase refers to positional relations between the centreline of each polar magnet
and the switching position of commutator segments and brushes.

Motors, assembled initially with neutral phase, runs under load lagging
momentarily in the electrical phase due to its phenomenal armature reaction.

VIII. Ways in improving the efficiency of motor devices

1. Cover Motor with Frame

Functionality of frame of a motor is to provide mechanical protection to the

winding. It is also responsible for the interface for installation through feet.

The motor frame plays a critical role in its thermal performance because it is
responsible for transferring the heat generated inside the motor out to the frame
surface where air blown by the fan will promote heat dissipation. This will reduce
heat losses.

2. Keep Motor Surrounding Clean

Another basic tip is to keep the minimum gap between any walls positioned near
the back of the fan cover to allow air intake.

Keep motor surroundings clean and periodically check for any air blockage that
can reduce the cooling system performance. So the more cool motor will be
running, it will be having more life span.
3. Increase Mass of Stator Windings

Stator which is major component of the motor is cause of 60% losses so in

order to reduce these losses; the mass of the stator winding must be kept larger
as this increase in mass will reduce electrical resistance.

4. Reduce Slip of Motor

Rotor losses are also considered as secondary source of losses that are largely
caused by the degree slip displayed by motor. Slip is actually the difference in
(RPM) of speed of the magnetic field and the actual RPM of the rotor and shaft at
a given load.

Where slip is obtained by subtracting the speed of motor under load from the
speed of the motor without load divided by speed by motor under load.

So in order to reduce these losses, slip must be reduced and that can be
done by making higher conductivity of rotor.

5. Improve Quality of Copper Used

Copper must be largely used because copper has high conductivity. But copper
must be die-cast as recently processes have developed for die casting of copper.

Core magnetic losses are originated from hysteresis, 20% of total losses are
caused by the eddy currents and saturation of the magnetic core. By using good
quality of materials and quality control, losses can be minimized to improve
efficiency.

To reduce the effect of hysteresis and saturation steels containing small amount
of silicon to be used in laminations instead of lower-cost carbon steels. In this
way core losses can be removed.

6. Reduce Thickness of lamination

By reducing the thickness of lamination and increasing the length of lamination, it

can minimize the flux density also and core losses.

7. Provide Proper Insulation

Eddy current losses can be largely minimized by ensuring proper insulation

between the sheets or laminations used.
IX. Calculations

From Mabuchi-Motor

1. Voltage of Power Supply

2. Type of Power Supply

 3. Winding Specification

Increased in number of turns per slot results in a drop in speed in direct proportion.

The increased diameter of magnet wire results in increasing stall torque and stall
current in inverse proportion of the wire diameter raised to the second power.
4. Environmental Temperature
5. Type of Magnets

6. Flux Yoke
7. Phase
References:

What’s the Difference Between a Motor and a Drive? | Machine Design

Yup, it's the motor drive that makes systems in motion all around us | EEP (electrical-
engineering-portal.com)

What does a drive do, anyway? Here’s a short introduction - Control Techniques
(driveobsessed.com)

Types of Electric Motors | automate.org

What is an Electrical Drive? Types, Advantages, Disadvantages

(instrumentationtools.com)

Motor energy use, efficiency and loading | nibusinessinfo.co.uk

Electric Drive : Types, Block Diagram, Classification and Its Applications (elprocus.com)

MOTOR DRIVE PARAMETERS (Electric Motor) (what-when-how.com)

https://www.mabuchi-motor.com/product/knowledge/performance/winding.html

https://electrical-engineering-portal.com/5-factors-that-mess-up-motor-efficiency-and-how-to-
improve-it

https://www.aarohies.com/7-ways-to-improve-electric-motor-efficiency/