School of Engineering – Mechatronics

UVBP 464 Select Rotating Electrical Machines

Select and Recommend a Motor Installation

 This assignment will carry 40% of the final mark.

 A descriptive report is expected to submit and the end of this module.

 The assignment should consist of not less than 1500 words.

 Date of submission – 17th September 2007 before 12.00 noon

James Bruce
5567599
“AL Fab” is a company which fabricates Aluminium structures and is located in the state of Victoria.
Recently the management has taken a decision to put up an elevator for workers to reach different
floors for their convenience. It is estimated that the elevator should be able to carry 200 kg at a time.
The manager has consulted you to install an elevator for this workshop.

The factory comprises of ac power as well as converted dc power which are already in use for different
purposes. Also a motor shaft of 40 cm diameter is already available with them. It is accepted that when
carrying 100 kg (80 kg + 20 kg; one person + container) a shaft speed of 1200 rpm is enough. (this
motor should be connected to the shaft via a set of gear wheels).

Since this is a steel producing factory the average ambient temperature is 45 0C, the air is very dusty
and the floor area is quite grime.

Hint:
The chosen motor has following properties;
Field resistance = 1.2 Ω
Armature resistance = 0.6Ω
Machine constant (K) = 0.86
Field winding constant (c) = 0.26

James Bruce
5567599
 1.1 What are the factors to consider when selecting a motor to the elevator ‘AL Fab’?

Factors to consider when selecting a motor for the elevator are:

 The suitable coupling to be used in the motor, which will reduce wear, friction and slip
to provide better efficiency.
 The load which the motor is going to have to carry, which in this case is a minimum of
80 kilograms, and a maximum of 200 kilograms.
 The environment the motor is going to be exposed to, e.g. dust, temperature, moisture
etc.
 Safe and comfortable travelling speeds to transport workers from one floor to the next
as smooth and as efficient as possible.

2.1 Giving reasons, identify the type of motor which should be used for this application from the
following list;
a. DC series motor
b. DC shunt motor
c. DC compound motor
d. Brushless DC motor

The DC series motor is mostly used for applications where the load is always connected but varies
over a wide limit. Adjusting the Terminal Voltage can alter the speed of the series motor. It has a high
starting torque, a speed that varies with different loads and runs away if there is no load. However
running away won’t be an issue, as a load will always be attached (the weight of the elevator itself).
DC shunt motors are more suited to industrial applications, where reasonably constant speeds are
important, e.g. lathe, mill. Compound DC motors are for high starting torque applications where
runaway characteristics are not desired. Brushless DC motors have come to dominate many
applications: Consumer devices such as computer hard drives, CD/DVD players, and PC cooling fans
use BLDC motors almost exclusively. Low speed, low power brushless DC motors are used in direct-
drive turntables. High power Brushless DC motors are found in electric vehicles and some industrial
machinery. These motors are essentially AC synchronous motors with permanent magnet [Link]
that the elevator will require a high and almost instantaneous application of torque, the best-suited
motor for this is the DC series motor.

2.2 Calculate the required power output of the motor when it carries one person.

= 1200rpm * (π/30)
= 125.6637 rad/s
=F*r - F = ?, r = 0.2 meters
F = 80 kg * 9.81 m/s²
F = 784.8 N

Therefore: = 784.8 * 0.2

= 156.96 N.m
Thus: Power Output = 125.6637 * 156.96
= 19,724.18 W 19.725 kW

James Bruce
5567599
 2.3 Calculate new speed and power output of the motor when it carries maximum weight.

=x/ ²
x = √ (156.96 * 125.6637²)
= 2,478,612.729
New Torque = (200kg * 9.81m/s²) * 0.2 m
= 392.4 N.m
Therefore New Speed = √ (x / )
= √ (2,478,612.729 / 392.4)
= 79.4767 rad/s or 759 rpm
Thus New Power Output =
= 79.4767 * 392.4
= 31,186.66 W 31.2 kW

2.4 Estimate the rated power of the motor (as given in the name plate).

Power on the nameplate is normally given in Horse Power rather than Watts, thus a conversion is
needed:

To convert Watts (W) to a horsepower rating (HP) simply multiply the Watts by 0.00134

W x 0.00134 = HP

So Power = 31,186.66 * 0.00134

= 41.79 HP

2.5 Calculate the terminal voltage required for maximum weight.

= √ (Tc / K)
= √ [392.4 * (0.26 / 0.86)]
= 10.892 Wb

= (0.86 * 10.892 * 79.4767) + {√ [392.4 / (0.86 * 0.26)] * 0.6}

= 769.6 V

2.6 Calculate the current required for maximum weight.

Therefore Current =√( / Kc)

= √ [392.4 / (0.86 * 0.26)]
= 41.892 A

3.1 Identify the importance of using a motor starter and explain the most suitable motor start for
this application.
James Bruce
5567599
It is important to use a motor starter with DC motors to protect it from damage. DC starter motors
prevent due to short circuits in the equipment, damage from long term overloads and damage from
excessive starting currents caused by very low internal resistance before start up.
The most suitable starter for this DC motor would be the Automatic starter, as it requires no attention,
and once the motor is running, there will be no resistance, thus eliminating power loss.

3.2 Using proper graphs and circuit diagrams, explain the speed controlling methods of the
motor used for this application.

The primary method of changing the speed in a DC series motor is to change the terminal voltage.
Reducing VT will reduces the speed:

Inserting resistors could also be used to change the speed, however this will cause high power loss.

After receiving the shipment of the motor for the hoist, discuss 3 important points under
4.1 Choosing a location to install

The location that is chosen for installation should have as little as possible of dust, dirt, grime, liquids
and other contaminants. Given that the factory does have a larger than average consistency of dust and
grime in the air, the motor should be stored in a separate room from the rest of the factory. The motor
must have enough space around it for the free flow of air to maintain an ambient temperature of 40 0C
or lower. Given that the ambient temperature of the factory is 45 0C, the room should have a air
conditioning system in it to regulate the temperature of the air. The motor should also have enough
space around it to allow easy access for maintenance etc.

4.2 Mounting the motor

 Most motors come with a mounting base. The mounting dimensions are usually based on
standards. The majority of motors are the horizontal types that are floor mounted. The motor may
have to be mounted on a ceiling or on a wall. Unless the purchase order specifies how the motor is
going to be mounted, the motor will arrive with standard horizontal mounting.
 The mount should be made of a material that is effective at absorbing vibration.
 Mount the motor on a firm level foundation. The foundation must have sufficient strength to carry
the load. Medium to heavy loads cannot sagely be fastened to soft masonry materials such as
plaster of plasterboard.

James Bruce
5567599
 4.3 Methods of coupling the rotor shaft to the load (elevator)

 Direct coupling is used when the speed requirement of the machine is the same as that of the
motor. Some common examples are fan blades, pumps and motor-generator units.
 Belts and pulleys are the simplest and least costly method of coupling the motor to the load when
the rpm of the motor does not meet the requirements of the load. Speed changes are accomplished
through the ratio of the diameter of the pulley of the motor and that of the load. The maximum
speed ratio obtainable is dependent of several factors. These include the standard size of pulleys
available, distance between pulleys and arc of contact on the small pulley.
 Chains and drives are used when belt slippage cannot be tolerated under varying loads. Chain
drives are noisier than belt drives.
 **(Preferred option)** Gear drives are the most expensive of any system used to couple a load to
the motor. They are used to reduce the slip to zero. Gear drives also provide greater speed ratios
than either belts or chains. Gear drives are noisier than belt or chain drives. These are usually
enclosed and submerged in an oil bath. This keeps the gears lubricated and reduces friction.

5.1 In consultation with ABC, what are the risks you identified in this work environment? How
can you overcome them?

Risks identified were:

Overheating – This can be avoided by a cooling system being installed in the room which holds
the motor. By doing this cool air will be circulating throughout the room and into the motors
cooling fans rather than hot.
Wear of parts due to dust/dirt etc – The amount of dust and other substances in the air can be
reduced by installing an exhaust fan in the ceiling of the room, which will suck out most of the
harmful dust from the room. Also regular cleaning of the floors will help to reduce grime
content, dirt etc.
Stable foundation – The position of the motor must by on a solid foundation, capable taking on
the weight of not only the motor, but the load the motor must carry (the elevator and it’s
passengers. This can be made sure of by going over the blue prints of the building and making
an assessment of the safest position on the required level of the building.

5.2 Identify OHS requirements you follow when installing and doing maintenance for the hoist
motor at ‘AL Fab’.

- Observation of changes in the motor’s operating conditions.

- Keeping the motor and the area around the motor clean.
- Providing for adequate ventilation.
- Lubricating machinery on schedule.
- Making small repairs before major problems occur.
- Measuring electrical characteristics of the motor and comparing them over a period of time to
detect any changes that may be detrimental to the motor.
- Keeping records of the maintenance checks and any repairs made to the motor.
- Only operate machinery, or use tools if properly trained to do so.
- Wear correct clothing required for the job.

5.3 Describe the electrical protection, which should be provided for this motor.
James Bruce
5567599
 (Hint – find external resources when answering this question. Eg: Electrical Wiring Practice
Volume 1 by Keith Pethebridge & Ian Neeson, internet)

- Protection against indirect

contact
- Earthing
- Protection against overloads and short circuit current
- Devices for automatic disconnection of supply
- Protection against over voltage and under voltage

6.1 Explain causes that could result in failure of the hoist motor at ‘AL Fab’.

The most common possible causes for failure of the hoist motor are high temperatures, dirt and
grime. Foreign materials that collect on a motor reduce the effectiveness of the motor ventilation
system. This in turn causes the operating temperature to rise. The higher the temperature at which
the motor must operate, the shorter it’s useful life. These undesirable conditions can result in either
mechanical or electrical failure of the machine. Dirt that collects in the moving parts of a motor
will cause premature wear on those parts. Metallic and abrasive particles can cause electrical
failures as well.

Explain important points to be considered when doing maintenance for the hoist motor in each
of the following sessions.

6.2 Weekly

 Start each motor to determine if it comes up to speed with the normal time frame.
 Check the line voltage to see if it is within tolerance and is balanced on a three phase system.
 Listen to each motor for any unusual noises.
 Inspect switches, fuses, starter and any electrical controls.
 Observe any excessive sparking of brushes.
 Check lubricant levels of bearing and look for any leaks.
 Look for corrosion on slip rings and commutators.
 Use a thermometer to measure the temperature of frames and bearings.

6.3 Quarterly

 Clean motor thoroughly to remove dirt from the ventilation ducts and insulation.
 Measure and record the insulation resistance
 Operate motor at its normal load and measure the temperature.
 Inspect for mechanical tightness of the mounting
 Check capacitors for leakage or swelling.

6.4 Semi-annually

 Drain and flush oil reservoirs on motors having bearings. Replace oil with recommended type.
James Bruce
5567599
 Replace grease in the reservoirs and flush old grease.
 Check bearings.
 Check electrical connection for good contact and any corrosion. Clean and tighten.
 Measure insulation resistance.
 Inspect the ends of squirrel cage rotors for overheating and loose or broken bars.
 Remove brushes and inspect them for cracks or breaks. Check tension on the brushes.
 Check coupling system for alignment and mechanical tightness.
 Tighten other hardware on the motors such as mounts.
 Inspect fans for loose or broken blades.
 Take temperature measurements after motor has run under load for an adequate period.
 Measure line current and voltage. Compare to previous reading and the nameplate ratings.

James Bruce
5567599