Handbook of Small Electric Motors MAZ Part 1 pptx

He holds a BS degree in electrical engineering technology and has over 20 years experience, with the past 8 focused on the electric motor industry.. Since February of 1994, he has been a

HANDBOOK

OF SMALL

ELECTRIC MOTORS

William H Yeadon, P.E Editor in Chief

Yeadon Energy Systems, Inc Yeadon Engineering Services, P.C.

McGraw-Hill

New York Chicago San Francisco Lisbon London

Madrid Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto

Library of Congress Cataloging-in-Publication Data

Handbook of small electric motors / William H Yeadon,

editor in chief, Alan W Yeadon, associate editor

p cm

ISBN 0-07-072332-X

1 Electric motors, Fractional horsepower I Yeadon,

William H II Yeadon, Alan W

TK2537 H34 2001

Copyright © 2001 by The McGraw-Hill Companies, Inc All rights reserved Printed in the United States of America Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a data base or retrieval system, without the prior written permission of the pub-lisher

1 2 3 4 5 6 7 8 9 0 DOC/DOC 0 7 6 5 4 3 2 1

ISBN 0-07-072332-X

The sponsoring editor for this book was Scott Grillo and the production super-visor was Sherri Souffrance It was set in Times Roman by North Market Street Graphics.

Printed and bound by R R Donnelley & Sons Company

McGraw-Hill books are available at special quantity discounts to use as pre-miums and sales promotions, or for use in corporate training programs For more information, please write to the Director of Special Sales, Professional Publishing, McGraw-Hill, Two Penn Plaza, New York, NY 10121-2298 Or contact your local bookstore

This handbook is intended to be used as a reference for information regard-ing the design and manufacture of electric motors It is not intended to encourage or discourage any motor type, design, or process Some of the con-figurations or processes described herein may be patented It is the responsi-bility of the user of this information to determine if any infringement may occur as a result thereof

Information contained in this work has been obtained by The McGraw-Hill Companies, Inc (“McGraw-Hill”) from sources believed to be reliable However, neither McGraw-Hill nor its authors guarantee the accuracy or completeness of any informa-tion published herein, and neither McGraw-Hill nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information This work is published with the understanding that McGraw-Hill and its authors are supplying information but are not attempting to render engineering or other professional services If such services are required, the assistance

of an appropriate professional should be sought

This handbook is dedicated to my wife, Luci Yeadon, who took most of the photographs for it.

William H Yeadon Editor in Chief

Larry C Anderson American Hoffman Corporation (Sec 3.14)

John S Bank Phoenix Electric Manufacturing Company (Sec 3.15)

Warren C Brown Link Engineering Company (Sec 3.10.6)

Joseph H Bularzik Magnetics International, Inc (Sec 2.5)

Peter Caine Oven Systems, Inc (Sec 3.16)

David Carpenter Vector Fields, Ltd (contributed the finite-element plots in Chap 4)

John Cocco Loctite Corporation (Sec 3.17)

Philip Dolan Oberg Industries (Sec 3.10.5)

Birch L DeVault Cutler-Hammer (Sec 10.6)

Brad Frustaglio Yeadon Energy Systems, Inc (Sec 6.4)

Francis Hanejko Hoeganaes Corporation (Sec 2.6)

Duane C Hanselman University of Maine (Secs 5.1.4 and 10.11)

Daniel P Heckenkamp Cutler-Hammer (Sec 10.6)

Leon Jackson LDJ Electronics (Sec 3.19)

Dan Jones Incremotion Associates (Secs 5.1.3, 10.12, and 10.13)

Douglas W Jones University of Iowa (Secs 5.2.10 and 10.8 to 10.10)

Mark A Juds Eaton Corporation (Secs 1.1 to 1.12)

Robert R Judd Judd Consulting Associates (Secs 2.2 and 2.3)

Ramani Kalpathi Dana Corporation (Sec 10.7)

John Kauffman Phelps Dodge Magnet Wire Company (Sec 2.10)

Todd L King Eaton Corporation (Sec 10.6)

H R Kokal Magnetics International, Inc (Sec 2.5)

Robert F Krause Magnetics International, Inc (Sec 2.5)

Barry Landers Electro-Craft Motion Control (Chap 9)

Roger O LaValley Magnetic Instrumentation, Inc (Sec 3.18)

Bill Lawrence Oven Systems, Inc (Sec 3.16)

Andrew E Miller Software and motor designer (Secs 4.5, 6.4.3, and 6.4.4)

Stanley D Payne Windamatics Systems, Inc (Sec 3.10.4)

Derrick Peterman LDJ Electronics (Sec 3.19)

xi

Curtis Rebizant Integrated Engineering Software (contributed the boundary

ele-ment plots in Figs 5.58 to 5.61)

Earl F Richards University of Missouri (Secs 1.14, 4.1, 6.2, 6.3, and 8.4 to 8.8)

Robert M Setbacken Renco Encoders, Inc (Secs 10.1 to 10.5)

Karl H Schultz Schultz Associates (Secs 3.1 to 3.9)

Joseph J Stupak Jr. Oersted Technology Corporation (Sec 2.8)

Chris A Swenski Yeadon Energy Systems, Inc (Secs 3.6.5, 6.4, and 7.4)

Harry J Walters Oberg Industries (Sec 3.10.5)

Alan W Yeadon Yeadon Engineering Services, PC (Secs 3.10, 3.11, and 4.2 to 4.5)

Luci Yeadon Luci’s Photography (contributed most of the photographs in this

handbook)

William H Yeadon Yeadon Engineering Services, PC (Secs 1.13, 2.1, 2.9, 2.11, 3.10

to 3.12, 4.3, 4.6 to 4.8, 5.1 to 5.3, 6.1, 6.4, 7.1 to 7.4, and 8.1 to 8.3)

Over the course of my career I have had the privilege to meet many of the giants of this industry Many I have met through my association with the Small Motors and Motion Association (SMMA) and others through business relationships Included among them are Dr Cyril G Veinott, Professor Philip H Trickey, Dr Ben Kuo, Dr Duane Hanselman, and those authors who have contributed to this handbook There is, however, one person of whom I must make special mention He is Dr Earl Richards, Professor Emeritus of the University of Missouri at Rolla This man never ceases to amaze me He is always willing to help out selflessly with projects of this type I have taught many motor design courses with him When a student asks questions of him, he can start at the lowest level of understanding necessary and develop in a very understandable way a logical and reasonable answer to the ques-tion His ability to communicate and teach is truly amazing He has been very help-ful in the preparation of this book

I also need to acknowledge the dedication of my secretary, Kristina Wodzinski Without her tireless effort this work would not have been completed

xv

ABOUT THE CONTRIBUTORS

LARRYC ANDERSON(Sec 3.14) is an applications consultant with American Hofmann Corpo-ration, one of the world’s leading manufacturers of precision balancing machines He has been with the company since 1990 and performs unbalance analysis on rotating assemblies for man-ufacturers worldwide He holds a BS degree in electrical engineering technology and has over

20 years experience, with the past 8 focused on the electric motor industry

JOHNS BANK(Sec 3.15) is the executive vice president of Phoenix Electric Manufacturing Company and is responsible for coordinating new product development and developing advanced strategies He received his bachelor’s degree in business administration (magna cum laude) from the University of Michigan in 1981 and his JD from UCLA in 1984 He is also a Certified Public Accountant in the state of Illinois (1981) and a licensed real estate broker in the state of Illinois (1981) Mr Bank currently serves on the board of directors of SMMA (1995–present) and EMERF (1997–present) He is the Company Representative and Voting Member of NEMA (1992–present), EMCWA (1992–present) and NAM (1992–present)

WARRENC BROWN(Sec 3.10.6) graduated with a BSME from Michigan State University in

1966 and with an MBA from Michigan State University in 1968 He was the Manager/Director MIS of Burroughs Corporation in Detroit, Michigan, from 1968 to 1982 He directed sales and marketing at Link Engineering Company from 1982 to 1990 Since 1990, he has been vice pres-ident for motor products of Link Engineering Company He has been a member of SAE, ESD, and SMMA

JOSEPHH BULARZIK(Sec 2.5) is a staff engineer He received a BS in chemistry from Arizona State University, Tempe, in 1982 He received a PhD in chemistry from the University of Cali-fornia, Berkeley, in 1987 He conducted postdoctoral research in the field of superconducting oxides at Princeton University, Princeton, New Jersey, in 1989 He was an assistant professor of chemistry at Lycoming College, Williamsport, Pennsylvania, from 1987 to 1989 He has seven years of experience in magnetic materials research He is a member of ASM He has worked in research for Magnets International, Inc., East Chicago, Indiana, since 1994, and he worked in research at Inland Steel Company, East Chicago, Indiana, from 1990 to 1994

PETERCAINE(Sec 3.16) graduated from the University of Wisconsin in Platteville with a BS in industrial engineering His career at Oven Systems, Inc., has included applications engineering, custom product sales, and management For the past three years, he has managed the electric motor equipment division

DAVIDCARPENTER(Chap 4 finite-element plots) received a first-class honors BSc in electri-cal engineering from the University of Southampton, England, in 1979 and joined GEC Ltd

as an induction motor design engineer In 1986 to 1987 he was appointed as visiting professor

at Lakehead University, Canada, and in the following year he received an MSc from Coven-try University, England After joining Vector Fields Ltd as an application engineer in 1991, he received a PhD from the University of Bath, England, in 1993 He was appointed to the posi-tion of vice president of Vector Fields, Inc., United States, in 1995 He is a Charter Engineer and a member of the IEEE

JOHNCOCCO(Sec 3.17) is the director of Loctite Corporation’s North American Application Engineering Center For the past 10 years, he has been working with Loctite Corporation’s

cus-C.1

tomer base, developing adhesive and sealant applications for use in small motors In the past two years, he has conducted several design seminars at original equipment manufacturers focusing on this topic He holds a bachelor’s degree in chemical engineering and is a licensed Professional Engineer

PHILIPDOLAN(Sec 3.10.5) graduated from Marquette University with a BA He was vice pres-ident of Marketing for Oberg Industries and had previous experience in plant management and strategic planning

BIRCHL DEVAULT(Sec 10.6) was born in Pittsburgh, Pennsylvania, in 1946 He received a BS

in electrical engineering from the University of Pittsburgh in 1967 He joined the Westing-house Electrical Graduate Student Course in 1967 In 1968, he joined the WestingWesting-house Stan-dard Control Division, Beaver, Pennsylvania, as an associate design engineer In 1981, he joined the Control Division in Asheville, North Carolina Since February of 1994, he has been

a senior development engineer with Cutler-Hammer, Milwaukee, Wisconsin, responsible for the design and application of magnetic motor control He is a Registered Professional Engi-neer in the state of Pennsylvania He has eight patents in the area of motor control He is a member of IEEE He has published papers related to motor control in TAPPI and IEEE pub-lications

BRADFRUSTAGLIO(Sec 6.4) has a BSME from Michigan Technological University and is a design engineer for Yeadon Energy Systems, Inc

FRANCISHANEJKO(Sec 2.6) is a metallurgical engineer and received his BS and MS degrees from Drexel University He has been employed by the Hoeganaes Corporation for 22 of the last 25 years During that time, he has held numerous positions in the sales and marketing and research and development departments His current position is manager of electromagnetics and customer applications in the research and development department, with responsibilities for customer service and product development He is a past chairman of the Philadelphia Sec-tion of the APMI

DUANEC HANSELMAN(Secs 5.1.4 and 10.11) is an associate professor in electrical engineering

at the University of Maine He holds PhD and MS degrees from the University of Illinois He

is a senior member of IEEE and an associate editor of the IEEE Transactions of Industrial

Electronics He is the author of numerous articles on motors and motion control He has

pub-lished several textbooks, including Brushless Permanent-Magnet Motor Design and MATLAB

Tools for Control System Analysis and Design (McGraw-Hill, 1994).

DANIELP HECKENKAMP(Sec 10.6) received his BS in mechanical engineering from the Uni-versity of Wisconsin, Milwaukee, in 1983 In 1981, he joined the Square D Company in Mil-waukee, where he was responsible for the design of industrial lifting magnets and their applications In 1983, he transferred to the Square D Controls Division, where he was respon-sible for contactor development He joined Cutler-Hammer’s controls division in 1988 as a product development engineer, where he has been responsible for the design and maintenance

of contactors and overload relays His current position is principal engineer

LEONJACKSON(Sec 3.19) received an AS from Port Huron Junior College in 1957 He also received a BS in electrical engineering from Wayne State University in 1960 He also attended the University of Loyola for business administration He received honors from the Tau Betta

Pi educational honor society and the Etta Kappa Nu engineering honor society for academic achievement He has worked for General Magnetic Corporation and LDJ Electronics, Inc., where he is currently president He is a member of the IEEE Magnetics Society

DANJONES(Secs 5.1.3, 10.12, and 10.13) has a BSEE from Hofstra University and a MS in mathematics from Adelphi University He is a member of ASME, IEEE, ISA, and AIME He has 38 years experience in the motor business He founded Incremotion Associates in 1982 and has previously worked for such companies as Vernitron, Printed Motors, Inc., Singer-Kearfott, Electro-Craft Corporation, Data Products Corporation and IMC Magnets Corporation

C.2 ABOUT THE CONTRIBUTORS

DOUGLASW JONES(Secs 5.2.10 and 10.8 to 10.10) is an associate professor of computer sci-ence at the University of Iowa He received his PhD in computer scisci-ence from the University

of Illinois, Urbana, in 1980 He completed his BS in physics at Carnegie-Mellon University in

1973 His research interests are discrete event simulation, resource protection in architecture, operating systems, system Programming Languages, and the history of computing

MARKA JUDS(Secs 1.1 to 1.12) has BS and MS degrees in mechanical engineering from the University of Wisconsin He is currently a senior principal engineer for Eaton Corporation’s Innovations Center, where he designs electromagnetic devices He also has expertise in heat transfer and mechanical dynamics

ROBERTR JUDD(Secs 2.2 and 2.3) is currently president of Judd Consulting Associates, Inc., a general ferrous metallurgy and electrical-sheet consulting firm He acquired his doctorate in materials science from Carnegie-Mellon University and holds a bachelor’s degree in mechani-cal engineering from the University of Rochester He spent 30 years in principal research posi-tions for U.S Steel and Ispat-Inland For three years he served as director of research and development for Johnstown Corporation, a large ferrous foundry and fabrication firm He has also taught general metallurgy at Carnegie-Mellon University His professional activities include ASM, AIME, MPIF and the ASTM A-6 subcommittee on magnetics He is also the treasurer and organizing committee member of the annual Conference on the Properties and Application of Magnetic Materials He holds patents in the powder metallurgy and soft mag-netic material fields

RAMANIKALPATHI(Sec 10.7) was a senior project engineer with Dana Corporation He com-pleted his PhD in electrical engineering at Texas A&M University in 1994 and has been with Dana for the past five years Recently he has returned home to start his own consulting firm in Madras, India His interests are in the areas of power electronics and control of switched-reluctance motors

JOHNKAUFFMAN(Sec 2.10) graduated from Purdue University with a BA in industrial eco-nomics in 1963 He has worked for Phelps Dodge Magnet Wire Company for 35 years He holds four patents for magnet wire and cable products and equipment

TODDL KING(Sec 10.6) received BS and MS degrees in electrical engineering from the Uni-versity of Wisconsin-Madison in 1978 and 1980, respectively He joined Borg Warner Corporate Research Center, Des Plaines, Illinois, in 1980, where he worked in analysis of motors and actu-ators and the design of automotive controls, actuactu-ators, and sensors He joined Eaton Corporate Research and Development Center, Milwaukee, Wisconsin, in 1988 as a senior engineer spe-cialist, where he worked in the design of actuators for appliance, automotive, aerospace, hydraulic, and truck products He also worked in the design and analysis of commercial and industrial motor controls He became the engineering manager for the Design Analysis Tech-nology Group in 1990 and added systems techTech-nology in the Eaton Innovation Center, where he has responsibility for defining the strategic direction of systems technology for the corporation

HAROLDR KOKAL(Sec 2.5) is a senior staff engineer He received his BS and MS degrees in metallurgical engineering from the University of Minnesota, Minneapolis, in 1964 and 1970, respectively He has 30 years experience in process and product research He is a member of APMI and AIME He has worked in research at Magnetics International, Inc., East Chicago, Indiana, since 1992 He worked in research at Inland Steel Company, East Chicago, Indiana, from 1985 to 1992, and at U.S Steel Corporation, Coleraine, Minnesota, and Monroeville, Pennsylvania, from 1968 to 1985 He was an MRRC Research Fellow at the University of Min-nesota, Minneapolis, from 1965 to 1966

ROBERTF KRAUSE(Sec 2.5) is a technical director He received his BS and PhD degrees in material science from Notre Dame University, South Bend, Indiana, in 1962 and 1966, respec-tively He has 31 years experience in metallurgy and magnetic materials He is a member of the ASM and IEEE He has worked in research at Magnetics International, Inc., Burns Harbor, Indiana, since 1991 He worked in research at Inland Steel Company, East Chicago, Indiana,

ABOUT THE CONTRIBUTORS C.3

from 1987 to 1991; at Crucible Steel Company, Pittsburgh, Pennsylvania, from 1986 to 1987; at Westinghouse Electric Corporation, Churchill, Pennsylvania, from 1972 to 1986; and at U.S Steel Corporation, Monroeville, Pennsylvania, from 1966 to 1972

BARRYLANDERS(Chap 9) has 24 years of experience in the design and testing of ac and dc motors, including writing electrical and mechanical design and testing software for fractional-horsepower ac, brush DC, and brushless dc motors, as well as for fine-pitch custom gearing In addition, he has 17 years of experience in spectral analysis of sound, vibration, and current on these motor types and on ball bearings as received, as well as in failure analysis of field prob-lems As a senior project engineer and registered Professional Engineer, he currently has responsibility for an engineering development, analysis, and test group for ac and dc products

at Electro-Craft Motion Control, Gallipolis, Ohio (a Rockwell Automation business)

ROGERO LAVALLEY(Sec 3.18) is a senior application engineer with Magnetic Instrumenta-tion, Inc He has 25 years experience in the area of magnetic applications In his present posi-tion he is responsible for reviewing customer requirements for the magnetizing, demagnetizing, and measuring of permanent magnets and magnet assemblies and for propos-ing the appropriate equipment and complete systems

BILLLAWRENCE(Sec 3.16) has a BSME and an MBA from Marquette University He has worked in sales of servo electric motors at Moog, Inc., and in sales of specialty motors at Doerr Electric He is currently the vice president of Oven Systems, Inc

ANDREWE MILLER(Secs 4.5, 6.4.3, and 6.4.4) has a BS in chemical engineering from Michi-gan Technological University He has several years of experience in software design and three years of experience in the motor design industry

STANELYD PAYNE(Sec 3.10.4) is the vice president engineer at Windamatics Systems, Inc., Fort Wayne, Indiana

DERRICKPETERMAN(Sec 3.19) has over eight years experience with magnetics research and instrumentation He completed a BA in physics at Washington University, St Louis, Missouri,

in 1989 and a PhD in physics at Ohio State University in 1996 He currently holds the position

of magnetic measurement specialist at LDJ Electronics

CURTISREBIZANT(Figs 5.58 to 5.61 boundary element plots) is an engineer at Integrated Engi-neering Software, which produces and markets software for electromagnetic, thermal, and structural system simulation He has a BS in electrical engineering from the University of Man-itoba and has extensive experience with electromagnetic CAE software

EARLF RICHARDS(Secs 1.14, 4.1, 6.2, 6.3, and 8.4 to 8.8) is Professor Emeritus of Electrical Engineering in the School of Engineering, University of Missouri, Rolla He received his PhD from the University of Missouri He has 16 years of field experience in motor design and over

36 years of experience in the instruction of motor technology His professional emphasis is on electromechanical, power, and control systems He currently instructs graduate-level engineer-ing courses and is frequently sought as an industrial and legal consultant

ROBERTM SETBACKEN(Secs 10.1 to 10.5) is vice president of engineering at Renco Encoders, Inc He received his MSME degree in 1979 He has developed and tested analog and digital electromechanical and hydraulic servosystems for the military and commercial interests Since joining Renco in 1990, he has been involved with the design and manufacture of incremental rotary optical encoders for the industrial and office automation industries

KARLH SCHULTZ(Secs 3.1 to 3.9) holds a BSME from Western Michigan University He is a senior member of SME and a member of SMMA He has 25 years experience in manufactur-ing and management with such companies as General Signal, General Electric, Emerson Elec-tric, Clark Equipment, Chrysler, and Cincinnati Milacron, and his own consulting firm

C.4 ABOUT THE CONTRIBUTORS