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Custom MotorsThe OEM Advantage

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How this webcast will work

Perhaps you’re in the early stages of a project that requires a motor.

Or, you purchase motors and you’d like to better understand what’s important in the specifications.

Maybe you have a product that uses a motor, and you want to make sure it’s the right one for the job.

Our primary objective is to help you feel more comfortable in selecting motors.

Today, we’ll give you a methodand some tools to get you up to speed.

A background and understandingof motor selection.

Take advantage of being an OEM.

• Motor Basics

• Application Considerations

• Motor Types

• Case Studies� Medical� Automotive� Construction

• Engineering Tools

Our Discussion Today

Motor Basics• Motors convert electrical power into mechanical power.• Motors provide rotational speed and torque in a wide

variety of applications.• Input power available, application and environmental

constraints, and load requirements all help determinethe optimal motor.

• Input Power Source� Voltage� Frequency� Current (Efficiency)� Control

• Environment� Ingress Protection (IP) rating� Temperature (indoor / outdoor)

• Motor Specs� Size and Weight� Motor Life Expectancy / Maintenance� Noise

• Motor Performance� Speed & Torque� Starting / Stall Torque� Duty Cycle

Application Considerations: Checklist

• Input Power Source�Voltage�Frequency�Current (Efficiency)�Control

Application Considerations

• Environment� Ingress Protection (IP) rating�Temperature (indoor / outdoor)

Application Considerations

Application Considerations: Environment� Ingress Protection (IP)

Protected against long periods of immersion under pressure8

Protected against the effects of temporary immersion between 15cm and 1m. Duration of test 30 minutes 7

Protected against strong jets of water e.g. for use on ship decks - limited ingress permitted 6Totally protected against dust 6

Protected against low pressure jets if water from all directions - limited ingress permitted 5

Protected against dust - limited ingress(no harmful deposit) 5

Protected against sprays from all directions -limited ingress permitted 4

Protected against solids objects over 1mm(e.g. tools, wires and small wires 4

Protected against direct sprays up to 60o from the vertical 3

Protected against solids objects over 2.5mm(e.g. tools and wires) 3


Protected against solids objects over 12mm(e.g. fingers) 2

Protected against vertically falling drops of water 1

Protected against solids objects over 50mm(e.g. accidental touch by hands)1

No protection 0No protection 0

Second number (Protection against liquids)First number (Protection against solid objects)

Application Considerations: Environment� Ingress Protection (IP)

Protected against long periods of immersion under pressure8

Protected against the effects of temporary immersion between 15cm and 1m. Duration of test 30 minutes 7

Protected against strong jets of water e.g. for use on ship decks - limited ingress permitted 6Totally protected against dust 6

Protected against low pressure jets if water from all directions - limited ingress permitted 5

Protected against dust - limited ingress(no harmful deposit) 5

Protected against sprays from all directions -limited ingress permitted 4

Protected against solids objects over 1mm(e.g. tools, wires and small wires 4


Protected against solids objects over 2.5mm(e.g. tools and wires) 3


Protected against solids objects over 12mm(e.g. fingers) 2

Protected against vertically falling drops of water 1

Protected against solids objects over 50mm(e.g. accidental touch by hands)1

No protection 0No protection 0

Second number (Protection against liquids)First number (Protection against solid objects)

IP65

Maximum Temperature at hottest spot

UL 1446 Temperature

Classes

over 240 °C (over 464 ° F)>240 °C

240 °C (464 ° F)S

220 °C (428 ° F)R

200 °C (392 ° F)N

180 °C (356 ° F)H

155 °C ( 311 ° F)F

130 °C (266 ° F)B

Application Considerations: Environment� Temperature Classes

• Motor Specs�Size and Weight�Motor Life Expectancy / Maintenance�Noise

Application Considerations (continued)

• Motor Performance�Speed & Torque�Starting / Stall Torque�Duty Cycle

Application Considerations (continued)





Application Considerations: Checklist

• Price• Quality• Delivery

Application Considerations:

• Universal (AC/DC)

• Permanent Magnet DC

• AC Induction

• DC Brushless

Motor Types

Motor Types: Universal (AC/DC)

Armature

Field

Commutator

Brushes

Characteristics� Operates on AC and DC� Efficiency between 55% to 70% small to large� High speed 8,000 – 20,000+ rpm

� Speed is independent of frequency� High starting torque, 4 –6 times rated torque� Life 500 – 2000 Hours


Advantages� High power density� Excellent choice for

portable applications� No control required� Low cost

Disadvantages� High maintenance due to brushes� Poor speed regulation� Requires air through� Noisy� Cogging at low speeds� Inefficient at low voltages (less

than 100V)� High speed limits gearbox usage� Burns out quickly in stall

condition


Motor Types: Universal (AC/DC)Speed, Efficiency vs. Torque

Motor Types: Permanent Magnet DC

Armature

Commutator

Brushes

Permanent Magnet Field

Characteristics� Straight line speed torque curve� Medium speed operation 1,000 – 5,000 rpm� Efficiency 60% to 75% small to large� High starting torque, 8 – 10 times rated torque� Operates on DC voltage� Life 2,000+ Hours� Totally enclosed construction typical


Advantages� Works well with

gearboxes� Operates on DC

without control� Speed control

attainable withinexpensive controls

� Low cost


Disadvantages� High maintenance due

to brushes� Medium noise due to

brushes� Cogging at low speeds

(less than 300 rpm)� Loss of significant

power on full waverectified voltage

� High starting torquecan damage gearboxes

Motor Types: Permanent Magnet DCSpeed, Efficiency vs. Torque

Motor Types: AC Induction

Rotor

Stator

Shaft

Characteristics� Relatively fix speed operation, limited to 3400 RPM� Efficiency 40% to 70% small to large� Low (single phase) to medium (three phase) starting

torque� Operates on AC voltage� Life 20,000+ Hours� Totally Enclosed Construction is typical


Advantages� Long life� No control required� Maintains speed over

wide range of torque� Works well with

gearboxes� Low starting current� Suitable for speed

control� Quiet

Disadvantages� Requires capacitor

(single phase only)� Can have difficulty

starting (single phase)� Not suitable for portable

applications� Low power levels for size� High cost per

horsepower


Motor Types: AC InductionSpeed, Efficiency vs. Torque

Motor Types: DC Brushless

Rare Earth Rotor

MagnetsStator

Hall Effect Magnet

Hall Effect Sensors

Characteristics� Variable speed operation� High efficiency between 65% - 80% small to large� High starting torque� Requires a control to operate� Life 20,000+ Hours� Similar speed torque characteristics to PMDC


Advantages� Totally Enclosed typical� Long life� Low maintenance� High power levels for size� Works well with

gearboxes� Can be used in variable

speed applications

Disadvantages� High cost due to rare

earth magnets� Controls are expensive� Cogging at low speeds

< 300 rpm


Motor Types: DC BrushlessSpeed, Efficiency vs. Torque

Motor Types: Speed vs. Torque Comparison

Motor Types: Quick Reference Chart

*Note: Comparisons are valid for motors of similar physical size

Voltage

Speed

Horsepower

Efficiency

Life

Maintenance

Noise

Speed Regulation

Starting Torque

UMAC, DC

8,000-20,000+

Very High

55%-70%

Low

High

Noisy

Poor

High

PMDC

1,000-5,000

Medium

60%-70%

Medium

Medium

Medium

Fair

Very High

ACAC

1,600-3,400

Low - Medium

40%-80%

Very High

Very Low

Quiet

Good

Low - Medium

BLAC, DC (Control)

1,000-5,000

High

65%-80%

Very High

Very Low

Very Quiet

Excellent

Very High

Customizing a Standard Motor:� Output Shaft� End Brackets / Mounting Face� Housing� Foot Mount� Custom Winding /

Performance� Accessories (brake, encoder,

power cord, etc.)

“Blank Sheet” Custom Design:� New lamination� Significant tooling expense� “No compromise” designs� Most cost effective for higher

volume applications

Case Studies in CustomizationTwo Kinds of Customization

Customizing a Standard Motor: “Blank Sheet” Custom Design:

Case Studies in CustomizationTwo Kinds of Customization

Drop-In Replacement PM for Commercial Floor Cleaning Equipment

Custom Motor Assembly for

Hydraulic Pump

Winding Change:� Increase starting torque� Change no-load speed� Alter speed-torque curve

shape

Motor Size Change:� D2L (Diameter2 X Length)� Larger motor required

for more output power

Case Studies in CustomizationCustomizing Performance

Case Studies

• Medical� MRI Cooling Pump

• Construction� Cellulose Insulation Blower

• Automotive� Transmission Gear Shifter

Case Study: Medical EquipmentMRI Cooling Pump

Design Objectives:� Very long life required – 50,000+ hours

• customer had recently had a costlyrecall over multiple failures of their lowcost motor – they felt their reputationwas at stake

� Fluid pump load� 230V single phase AC power available� Fixed machinery – high power density

was not required� Continuous duty� Low maintenance & high reliability

required

Case Study: MedicalMRI Cooling Pump

Solution:� The long life requirement

eliminated brush typemotors

� A PSC single-phase ACinduction motor is anexcellent choice for a pumptype application

Note: Comparisons are valid for motors of similar physical size

Voltage

Speed

Horsepower

Efficiency

Life

Maintenance

Noise

Speed Regulation

Starting Torque

UM

AC, DC

8-20,000+

Very High

55 - 70%

Low

High

Noisy

Poor

High

PM

DC

1 - 5,000

Medium

60 - 70%

Medium

Medium

Medium

Fair

Very High

AC

AC

1,600-3,400

Low-Med

40 - 80%

Very High

Very Low

Quiet

Good

Low-Med

BL

AC, DC (Control)

1 - 5,000

High

65 - 80%

Very High

Very Low

Very Quiet

Excellent

Very High

Indicates Appropriate Choice

Motor Type:

Case Study: MedicalMRI Cooling Pump

Solution:� Motor was customized with a

special capacitor, bearings,and construction to meet thelife requirement

Case Study: ConstructionCellulose Insulation Blower

Characteristics and Objectives:� Machine must be portable� 500 hours minimum life

� existing motor lasted only 25 hours� 15 amp current limit (115V AC supply

voltage)� limited by household circuit breakers

� Continuous duty� 1.5 HP, 12,000 RPM, high vibration fan load� Drop in replacement for the existing motor

� they needed replacements quickly asexisting motor had high failure rate

� Quiet, not excessively noisy


Solution:� The portable requirement

pointed toward a highpower density motor

� Although noisy,a universal motorsatisfied the speed andpower requirement

AC, DC

Motor Type:


Voltage

Speed

Horsepower

Efficiency

Life

Maintenance

Noise

Speed Regulation

Starting Torque

UM

8-20,000+

Very High

55 - 70%

Low

High

Noisy

Poor

High

PM

DC

1 - 5,000

Medium

60 - 70%

Medium

Medium

Medium

Fair

Very High

AC

AC

1,600-3,400

Low-Med

40 - 80%

Very High

Very Low

Quiet

Good

Low-Med

BL

AC, DC (Control)

1 - 5,000

High

65 - 80%

Very High

Very Low

Very Quiet

Excellent

Very High



Solution:� Customized with special

housing and foot mount todrop into existing machine

� Special commutator andconstruction allowed themotor to withstand the highvibration

Case Study: AutomotiveTransmission Gear Shifter

Characteristics and Objectives:� Extremely high reliability required

• motor failure would render vehicle inoperative� 12V DC automotive battery power available� Very high starting torque required� Exposed on underside of vehicle� Minimal actual run time


Solution:� The reliability requirement

would seem to eliminate abrush type motor

� However the short run-time,in addition to the highstarting torque, made aPM DC motor a good fit


Voltage

Speed

Horsepower

Efficiency

Life

Maintenance

Noise

Speed Regulation

Starting Torque

UM

AC, DC

8-20,000+

Very High

55 - 70%

Low

High

Noisy

Poor

High

PM

DC

1 - 5,000

Medium

60 - 70%

Medium

Medium

Medium

Fair

Very High

AC

AC

1,600-3,400

Low-Med

40 - 80%

Very High

Very Low

Quiet

Good

Low-Med

BL

AC, DC (Control)

1 - 5,000

High

65 - 80%

Very High

Very Low

Very Quiet

Excellent

Very High


Motor Type:


Solution:� Customized IP66 construction,

application specific endbracket and automotiveconnector

� Extensive reliability testingdone during design phase,and continues duringproduction

• Speed Torque Power EquationPower = Speed * Torque / ConstantExample: Power (hp) = Torque (lb-ft) * Speed (rpm) / ~5252

• Current CalculationCurrent Single Phase = Power / ( Voltage * Power Factor * Efficiency)Current Three Phase = Power / (√3 * Voltage * Power Factor * Efficiency)Note: DC = Power Factor of 1.0. Three phase power is assumed to be balanced.

• Total EfficiencyEffTotal = EffMotor * EffGearbox

Engineering ToolsEssential Equations

Engineering ToolsSTP Calculator

Engineering ToolsMotor Efficiency Curves

AC 1-Phase Motor Efficiency

25

35

45

55

65

75

85

95

0 0.2 0.4 0.6 0.8 1 1.2

Motor Horsepower

Effic

iency

Max Efficiency

Min Efficiency

AC 3-Phase Motor Efficiency

30

40

50

60

70

80

90

0 0.2 0.4 0.6 0.8 1 1.2

Motor Horsepower

Eff

icie

ncy

Max Efficiency

Min Efficiency

PM Motor Efficiency

40

4550

5560

65

7075

8085

90

0 0.1 0.2 0.3 0.4 0.5

Motor Horsepower

Eff

icie

ncy

Max Efficiency

Min Efficiency

Universal Motor Efficiency

30

35

40

45

50

55

60

65

70

75

0 0.5 1 1.5 2 2.5 3

Motor Horsepower

Eff

icie

ncy

Engineering ToolsReducer Efficiency Curves

Planetary Gearbox Efficiency

60.0

65.0

70.0

75.0

80.0

85.0

90.0

95.0

100.0

0 100 200 300 400

Gearbox Ratio

Eff

icie

ncy Max Efficiency

Average Efficiency

RA Planetary Gearbox Efficiency

50.0

55.0

60.0

65.0

70.0

75.0

80.0

85.0

90.0

95.0

0 100 200 300 400

Gearbox Ratio

Eff

icie

ncy

Max Efficiency

Average Efficiency

Parallel Shaft Gearbox Efficiency

40.0

45.0

50.0

55.0

60.0

65.0

70.0

75.0

80.0

85.0

90.0

0 50 100 150 200 250 300 350

Gearbox Ratio

Eff

icie

ncy

Max Efficiency

Average Efficiency

Right Angle Gearbox Efficiency

30.0

40.0

50.0

60.0

70.0

80.0

90.0

0 20 40 60 80 100 120

Gearbox Ratio

Eff

icie

ncy

Max Efficiency

Average Efficiency

Engineering ToolsTypical Power Factors

AC Single-Phase AC Three-PhasePMDCUniversal

4 Pole 4 Pole

2 Pole 2 Pole

FWR

DC

AC

DC

0.76 – 0.99 0.49 – 0.58

0.84 – 0.99 0.56 – 0.83

0.88 – 0.95

1.00

0.86 – 0.96

1.00

Factor

Type

Factor

Type





Prioritize Checklist REVIEW

Motor Quick Reference Chart

*Note: Comparisons are valid for motors of similar physical size

Voltage

Speed

Horsepower

Efficiency

Life

Maintenance

Noise

Speed Regulation

Starting Torque

UMAC, DC

8,000-20,000+

Very High

55%-70%

Low

High

Noisy

Poor

High

PMDC

1,000-5,000

Medium

60%-70%

Medium

Medium

Medium

Fair

Very High

ACAC

1,600-3,400

Low - Medium

40%-80%

Very High

Very Low

Quiet

Good

Low - Medium

BLAC, DC (Control)

1,000-5,000

High

65%-80%

Very High

Very Low

Very Quiet

Excellent

Very High

REVIEW

Motor Types: Speed vs. Torque Comparison REVIEW

Two Kinds of CustomizationCustomizing a Standard Motor:

� Output Shaft� End Brackets / Mounting Face� Housing� Foot Mount� Custom Winding /

Performance� Accessories (brake, encoder,

power cord, etc.)

“Blank Sheet” Custom Design:� New lamination� Significant tooling expense� “No compromise” designs� Most cost effective for higher

volume applications

REVIEW

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please stay tuned for today ’s webcast custom motorschasek/me 472/motors/groschopp/motor... ·...

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