Handbook of Small Electric Motors MAZ Part 2 docx

thermal analysis and, 8.10–8.32velocity profiles, determining, 8.4–8.9 and steel grade designations, 2.4 Arnold Engineering Company, typical ASTM.. See Capacitive-discharge magnetizers C

and linear encoders, 10.25

Absolute count stacking, 3.38–3.39

Absolute encoders, 10.19–10.22

AC See AC induction motors; AC series

motors; Alternating current;

applications for, 3.117–3.123chemistries of, 3.115–3.117dispensing equipment, 3.123joint design, 3.114–3.115for magnets, 2.87, 3.122–3.123overview, 3.109–3.114safety factors, 3.124testing of, 9.42–9.43Advanced Research Project Adminis-tration (ARPA), 10.48–10.49AEG, and PROFIBUS, 10.50Aging (carbon-induced), defined, 2.44Air flux, defined, 1.44

Air gap:

in BLDC motors, 5.40controlling, 3.21–3.22geometry, 4.75–4.84linear equations, 1.33–1.43magnetic coenergy in, 1.18–1.20and mmf in dc series motors,4.5–4.10, 4.117–4.119, 4.122–4.126and mmf in PMDC motors, 4.27–4.32and mmf in universal ac motors,4.122–4.126

in permanent-magnet versus tion motors, 3.25

induc-permeance, 1.21–1.32predicting, 4.97–4.106

Air gap (Cont.):

on magnetic test methods, 2.71n

representative magnetic curves,

and eddy current effect, 3.143

in hybrid step motors, 5.76

leakage flux paths and, 1.30–1.31

and PMDC motors, 4.36–4.37

properties of, 1.49, 2.84, 2.87–2.89

typical magnetizing forces for, 3.125,

3.142

Alpha pattern winding, 4.162, 4.169

Alternating current See also AC

induc-tion motors; AC series motors;

Syn-chronous motors

coil design, 1.72–1.73, 1.76–1.77

dynamic analysis, 1.80–1.81, 1.85–1.88

magnetic properties, 2.53–2.56

magnetic test methods, 2.74–2.80

motor manufacturing process flow,

coefficient of thermal expansion, 3.20

in end frame construction, 3.4

load ratings for bearings, 3.66–3.67reliability ratings for bearings,3.65–3.66

American Hoffman Corporation,3.87n

American Society for Testing and rials (ASTM):

Mate-ac test methods, 2.74–2.76

dc test methods, 2.72, 2.73magnetic test methods, 2.71–2.78P/M-related standards, 2.61

sample B-H magnetization loops,

2.6–2.7steel grade specs, 2.4American Wire Gauge (AWG):

and coil design, 1.69–1.77and lamination design, 3.28

in stator winding design, 5.33–5.35and wire properties, 2.179–2.183and wire sizes, 2.176–2.177Ampere’s law:

in determining armature mmf, 4.5,4.28

and PMDC motors, 4.38Amplitude modulation (AM), defined,10.10

Anaerobic adhesives, defined,3.115–3.116

Analog Devices, 10.40, 10.45–10.46Anchored lead loops, 4.157Ancorsteel:

magnetic characteristics of, 2.66–2.67permeability of, 2.63–2.64

saturation induction for, 2.62Anderson, Larry C., 3.87nAngle of misalignment, defined, 3.58Angular measurement device, 10.9Anisotropic material, defined, 2.87Annealing, lamination, 2.6–2.46Antiferromagnetism, defined, 1.63Antilock brake wheel sensors, materialsused for, 2.62

thermal analysis and, 8.10–8.32

velocity profiles, determining, 8.4–8.9

and steel grade designations, 2.4

Arnold Engineering Company, typical

ASTM See American Society for

Test-ing and Materials (ASTM)

Automated testing, 9.43–9.47

Avogadro’s number, 1.63

AWG See American Wire Gauge

(AWG)Axial air gap motor, 5.9–5.11Axial field, 1.65–1.66Axial play, defined, 3.56–3.57Axis SPA, 3.79n

Babbit, as bearing material, 3.72Back electromotive force (emf):constant, 4.115

defined, 1.80–1.81, 1.86

in three-phase motors, 10.112–10.113trapezoidal versus sinusoidal drives,10.122–10.124

in two-phase motors, 10.98–10.99,10.101–10.102

Back iron, 5.13, 5.40Back-iron thickness, defined, 3.16Balancing:

PSC motor, 6.69–6.72rotor assembly, 3.19, 3.87–3.98Ball bearing analysis, 9.17–9.23

Ball bearings See Bearings

Band, Robert, 9.43nBank, John S., 3.99nBarium ferrite, as magnet material, 2.90Bearings:

assembly and fitting of, 3.69–3.72ball-type, 3.47–3.48, 3.51–3.55components, 3.51–3.55geometry of, 3.55–3.58grease tests, 9.41lubricants for, 3.51, 3.61–3.66,3.73–3.79

materials used for, 3.58–3.61overview, 3.46–3.48

preloading of, 3.67–3.69selection of, 3.49–3.51sleeve-type, 3.72–3.79static capacity of, 3.66–3.67Bell, F W (Hall device manufacturer),10.93

B-H curve, 1.8–1.9, 2.81–2.84

and Hall devices, 10.32–10.34and PMDC motors, 4.38, 4.42,4.110–4.112

B-H curve (Cont.):

and series dc and ac motors, 4.122

and shaded-pole motor, 6.81–6.82

Boron, properties of, 1.49

Bosch (as developer of CAN), 10.50

Boundary element analysis, 5.65

Boyes, Geoffrey S., 10.46

Bozorth, R M., 1.56

Brackets See End frames

Breakdown torque, defined, 10.52

Brinell hardness values, 1.43

sizing and shaping, 5.11–5.22stator winding design, 5.22–5.36Bularzik, Joseph H., 2.51nBureau of Standards, and dc test meth-ods, 2.74

Cages, bearing, 3.49, 3.51, 3.59–3.61Caine, Peter, 3.103n

Campbell, Peter, 10.28Canadian Standards Association, andinsulation requirements, 2.167

Capacitance See also

Capacitive-discharge magnetizersduring magnetization, 2.95, 3.144thermal, 8.13–8.16, 8.31–8.32Capacitive-discharge magnetizers,2.93–2.97, 3.131–3.133CDM systems, 3.138–3.142,3.145–3.146

fixture design for, 3.133–3.137process of magnetizing, 3.142–3.147Capacitor-start motors:

performance calculations, 6.45–6.59,6.60–6.61

typical applications, 8.34Carbon contamination:

annealing as antidote to, 2.44from brush dust, 4.87Carbonitriding, defined, 3.14Carburizing process, 3.14Carpenter, soft magnetic material prop-erties, 1.46

Carriage, defined, 10.23Carter’s coefficient:

calculating, 4.75and magnetic air gap length,4.99–4.100, 6.78

Cartridge-style brush holders, 3.100Case hardening, explained, 3.14–3.15Cast iron:

coefficient of thermal expansion,3.20

in end frame construction, 3.4

Cast iron (Cont.):

in housing construction, 3.10–3.11

in stator assembly processing, 3.21

CDM systems See Capacitive-discharge

magnetizers

CDX, defined, 10.37

CE mark, European Community, 10.6

CEN, and EMI regulation, 8.32–8.35

Centimeter, gram, second See CGS

thermal conductivity value, 8.16

typical magnetizing forces for, 3.125

C-frame shaded-pole motors, 6.73, 6.74,

Circular-mil slot-fill percentages, 3.32

Clean-sheet methodology, and BLDC

Cobalt See also Samarium-cobalt

intrinsic saturation flux density,1.63–1.64

properties of, 1.49Cocco, John, 3.109nCode wheel, defined, 10.10Coefficient of thermal expansion,

3.19–3.20 See also Thermal

analy-sis

Coenergy See also Energy-coenergy;

Magnetic coenergyequations, 1.12, 1.14

as force and torque determinant,1.17–1.20, 1.91–1.96

Coercivity, magnetic, 2.80, 3.142

C of F, 2.184Cogging:

and BLDC motors, 5.16and step motors, 5.89Coil:

in ac induction motors, 6.1–6.3actuator, permeance value, 1.31during commutation, 4.90–4.93design, 1.67–1.77

magnetizing, 2.92–2.93,3.141–3.142–3.147

Cold-rolled motor lamination steel See

CRML steel

Cold-rolled steel See CRS

Collin, R E., 1.66–1.67Commutation:

and brush selection, 4.84–4.87

in dc series motors, 4.10–4.14defined, 1.91, 4.145, 10.98flashover and ring fire, 4.95–4.96patterns, 10.119–10.122

in PMDC motors, 4.32–4.37system design, 4.87–4.95torque ripple, 10.109Commutator fusing, 3.79–3.87Compaction process, slot fill, 3.34Component slot milling, 3.93–3.94

Compound-wound dc motor

calcula-tions, 4.134–4.137

Comprehensive Energy Policy Act,

10.52

Compressive stress, defined, 3.115

Computer-aided design (CAD), in

friction and windage, 4.128–4.129

for PMDC motor calculations,

Convection See Thermal analysis

Conversions, measuring unit, 1.3–1.6,2.5

Cooling, during magnetizing process,2.98–2.99

Copper:

alloys, 2.87

in armature, 4.60and coil design, 1.67–1.69, 1.73–1.77

in the commutation process, 4.14losses, and Design E motors, 10.53losses, and thermal analysis,8.12–8.13, 8.14, 8.30losses, in dc series motors, 4.16–4.17losses, in PMDC motors, 4.44–4.46,4.114–4.115

losses, in single-phase inductionmotors, 6.27, 6.32, 6.71losses, in switched-reluctance motors,5.103

and powder metallurgy processing,2.60

properties of, 1.46

in stator, 4.74thermal conductivity value, 8.16thermal properties of, 8.19Core losses, 2.46–2.50, 2.53–2.59, 10.53

See also Eddy current loss;

Hys-teresis loss; Magnetic cores

in dc series motors, 4.16–4.17defined, 2.4

and iron powder composites,2.67–2.70

measuring at ultrasonic frequencies,2.79–2.80

in PMDC motors, 4.45–4.46role of coating in reducing, 2.44–2.45,3.37–3.38

in silicon-iron steels, 2.38–2.43and thermal analysis, 8.12, 8.14and variable-speed motors,2.51–2.52

Cores, magnetic See Core losses;

Mag-netic coresCoulomb friction, defined, 3.76

Coulomb’s law, and units of measure,

Critical speed, defined, 3.92

CRML steel, versus pressed material,

magnetic field for, 1.65–1.67

magnetic moment for, 1.59–1.60

Current-torque performance curve,

equations, 2.96–2.97Dana Corporation, 10.65nDarlington transistors, 10.75

DC See DC motors; Direct current

DC motors:

automatic armature winding,4.140–4.181

commutation, 4.84–4.96compared to ac series motors,4.17–4.23

compound-wound dc motor tions, 4.134–4.137

calcula-lamination, field, and housing try, 4.46–4.84

geome-permanent-magnet, 4.23–4.46PMDC motor performance,4.96–4.116

series dc motor performance,4.116–4.130

shunt-connected dc motor mance, 4.130–4.134

perfor-testing of, 9.9–9.15theory, 4.1–4.17typical applications, 8.33winding patterns, 4.138–4.140

DC tachometers See Tachometers

Dead zone, in stepping-motor physics,5.90–5.91

Deceleration, determining, 8.4–8.9Degrees of springback, 2.178Delta connections, 5.23–5.24,10.110–10.112

Demagnetization:

Curie temperature and, 2.85effect of armature reaction, 4.9,4.31

percentage, 3.127

in PMDC motors, 4.36–4.42representative curves, 2.102–2.163testing, 9.11–9.12

Dielectric breakdown test, 2.184–2.185

Dies See Stamping dies

Diesters, as bearing lubricants, 3.61, 3.62

Differential compound motor,

4.135–4.137

Differential scanning calorimetry, 2.187

Diffusion metal-oxide semiconductor

Direction sensing, defined, 10.2

Disk See Code wheel

Dissipated power equation, 10.139

redundant sensors, 10.48–10.49sensor databus systems, 10.49–10.51smart sensors, 10.48

stepping-motor control circuits,10.70–10.79

stepping-motor current limiting,10.80–10.93

for switched-reluctance motors,10.65–10.70

terminology, 10.1–10.4units of measure, 10.1D-type bearing seals, 3.50, 3.60Dual-current-mode PWM, 10.116,10.117

DuPont, insulating materials chart,2.174

Dust core technology, defined,2.65–2.66

Dynamic analysis:

moving-coil actuator, 1.85–1.88stepping motor, 5.92

Dynamic braking mode, 10.76–10.77Dynamic coefficent of friction test,2.184–2.185

Dynamic friction, versus static friction,5.90

Dynamic radial load rating, defined,3.63

Dynamic unbalance, 3.89Dynamic viscosity, 3.77Dynamometer, 5.80Eaton Corporation, 1.1n, 10.51nEccentricity errors, encoder,10.15–10.16

Eccentric load tests, 9.41E-coat, defined, 2.86Eddy current loss, 1.52–1.57,2.46–2.50

in bonded cores, 3.26

in cleated cores, 3.27

Eddy current loss (Cont.):

Electrical energy See Energy

Electrical Steels (AISI), products

linear, 10.22–10.25magnetic, 10.25–10.28

End bells See End frames

End frames, manufacturing, 3.4–3.10End leakage reactance, 4.83End play, defined, 3.56–3.57

End shield See End frames

End-turn factor, 5.32Energy, electromechanical:

conservation of, 1.10, 1.12–1.15,1.91–1.96

equations for, 1.10–1.15unit conversions, 1.4Energy-coenergy applications,1.15–1.21, 1.91–1.96Energy-efficient motors, defined,10.52

Energy product curve, defined,10.33

Environmental standards:

application-related, 10.4–10.6safety-related, 10.6–10.7Epoxy:

for insulation coating, 2.163–2.164,2.175, 2.176

as motor adhesive, 3.116, 3.122for suppressing oxidization, 2.86Epstein tests:

ac-related data, 2.74–2.76, 2.79core losses and, 2.47, 2.53–2.54dc-related data, 2.72

and properties of magnetic motorsteels, 2.8–2.18

spectral analysis, 9.15–9.27speed-torque curve, 9.1–9.5thermal analysis, 9.8

European Community CE mark, 10.6

European pole design, 3.32

in ac series motor analysis, 4.19–4.20

in dc series motor analysis, 4.15

and eddy currents, 1.53–1.54

and energy-coenergy approach, 1.91

equations for, 1.8, 1.11, 1.20, 2.100

and magnetic flux changes, 2.84, 2.100

in PMCD motor analysis, 4.43

Far field, magnetic, 1.64–1.65

Farrand Industries, Inc., 10.35, 10.37

Federal Communications Commission

(FCC), and EMI regulation, 8.32

Ferrite:

density of, 5.21, 5.69

and eddy current effect, 3.143

hard versus soft, 2.90

Field intensity, magnetic:

defined, 1.8–1.9, 1.20

as magnetic property, 2.1–2.2unit conversions, 1.4Field resistance, defined, 4.73–4.74Finite element analysis (FEA):and computerized testing, 9.43and step motors, 5.65

and universal motors, 4.55–4.57FIP gaskets, 3.120

First law of thermodynamics, 1.10Fixed-source unbalance, defined,3.87

Fixtures, magnetizing, 2.97–2.99,3.133–3.137

Flange sealing, 3.120–3.121

Flashover, 4.95–4.96 See also Arcing

Flemming’s law, 6.45Flux:

and B-H curve geometry, 4.77–4.80,

4.110–4.112calculations, polyphase motors,6.98–6.99

calculations, single-phase motors,6.54–6.56

defined, 1.7–1.21permeance, 1.21–1.32predicting air gap, 4.97–4.106Flux density:

armature-related, 4.5–4.10and BLCD motors, 5.13–5.14, 5.17,5.40–5.41

and core loss, 2.46–2.50defined, 1.8, 1.20equations, 1.2, 1.3

as magnetic property, 2.2–2.4, 2.80unit conversions, 1.3–1.4

Fluxmeters, 2.100–2.101, 3.130, 3.142Flux path permeance equations,1.21–1.32

and motor efficiency, 2.58

and spectral analysis, 9.15

Four-pole armature See Armature

Fractional-pitch winding, 5.24–5.32

Frayman, L., 2.63

Free angle, ball-bearing, 3.58

Free space, permeability of:

and the B-H curve, 2.80–2.83

Freon, role in cooling, 2.98

Frequency response functions (FRFs),

9.30–9.36

FRFs, 9.30–9.36

Friction, in bearing systems, 3.76–3.79

Friction and windage losses:

and Design E motors

Full-load heat run test, 9.5–9.6, 9.46

Full-load torque, defined, 10.52

Full-voltage idle test, 9.47Full-wave wye, defined, 5.23–5.24Furnaces, annealing, 2.45–2.46Fusing, 3.79–3.87

Gasketing, 3.120–3.121

Gauss, defined, 10.25 See also CGS

sys-tem of unitsGaussian system of units, 1.2–1.3Gaussmeters, 2.100, 3.130, 3.142Gear dynamic load tests, 9.38General Electric Electro-press process

of slot fill, 3.34Globe Products, 4.140n, 4.162, 4.163Gradient pole design, 3.32

Grain boundaries, defined, 1.43–1.44Grain growth, annealing process and,2.44, 2.46

Graphite:

and brush contact loss, 4.16

in the commutation process, 4.14and powder metallurgy processing,2.60

Grating, defined, 10.11Gray, Alexander, 4.96Gray coding, 10.21

Grease, bearing See Lubricants

Green paper, explained, 2.101–2.102Gross slot area (GSA), calculating, 4.53,4.67–4.68, 5.62–5.63

GSA, defined, 5.62Gun-wound salient pole motors,3.35–3.36

H A Holden Co., lead wire applicationchart, 2.188

Half-cycle magnetizers:

advantages of, 3.130–3.131fixture design for, 3.133–3.137power surges and, 2.93selection of, 3.132–3.133

Half-cylinder flux paths See Flux path

permeance equationsHalf-H bridge, 10.78–10.79Half-pitch winding, 5.24–5.32Half-stepping, defined, 5.89–5.90Half-wave wye, defined, 5.23–5.24

Hall, Edwin Herbert, 2.100, 10.29

Hardening process, shaft, 3.14–3.15

Hard magnetic materials, 1.43–1.52

in rotor assembly process, 3.17–3.18

in wound stator assembly process,

Hot-rolled steel See HRS

Hot-staking method, 4.159Hot strength tests, bond strength, 3.114

Housing manufacture, 3.10–3.12 See also Lamination, field, and housing

geometry

H paper, 3.34–3.35HRS, in shaft manufacture, 3.12H-type bearing shields, 3.59, 3.60Hunt, Robert P., 10.27

Hybrid step motors:

controllers for, 10.72–10.74design, 5.74–5.79

operation, 5.50–5.51Hydrocarbons, as bearing lubricant,3.61

Hysteresis:

and current limiting, 10.89–10.92effect on encoder accuracy, 10.15pulse-width modulation (PWM),10.113–10.114

Hysteresis loss:

defined, 2.2–2.3equations for, 1.52–1.53, 2.46–2.50loop tracer data, 2.77–2.78and noise control, 10.43–10.44

in soft versus hard magnetic als, 1.44–1.45

materi-Hysteresis synchronous motors, 7.5–7.9

IBRAs See Internal brush ring

assem-blies (IBRAs)Idle heat run tests, 9.7, 9.46

ID machining, rotor assembly,3.15–3.16

IEC:

and brush holder design, 3.102and Design E motors, 10.65and EMI regulation, 8.32and environmental standards,10.4–10.7

and SERCOS, 10.49and thermal testing conditions, 9.8

on brush contact loss, 4.16

and smart transducer interfaces, 10.51

Impregnation resins See Sealants

Impulse magnetizer See

Index See Reference mark

Indramat (SERCOS-compatible

and step motors, 5.80

three-phase motor, calculations,

Input power equation, 10.139

Inside-diameter (ID) rotor machining,3.15–3.16

Institute for Applied Microelectronics,10.6

Institute of Electrical and Electronics

Engineers (IEEE) See IEEE

Insulated-gate bipolar transistors

(IGBTs) See IGBTs

Insulation material, 2.163–2.176Integrated circuit (IC) technology, andenvironmental concerns, 10.6Intel (as developer of CAN), 10.50,10.51

INTERBUS-S, 10.50Internal brush ring assemblies(IBRAs), 3.100–3.101International Electrotechnical Commis-

sion (IEC) See IEC

International Protection (IP) codes,10.6–10.8

International Rectifier, 10.79Interpolar leakage reactance, 4.83Interpolation:

defined, 10.3optical encoder, 10.16–10.17Intrinsic curve, defined, 2.82Intrinsic saturation flux density,1.63–1.64

Intrinsic value, defined, 1.44Ireland, James R., 4.99Iron:

and armature force, 1.15–1.20intrinsic saturation flux density, 1.63losses, polyphase motors, 6.100losses, single-phase motors, 6.56, 6.57and powder metallurgy applications,2.51, 2.59–2.71

ISO Standards, for acceptable armaturebalance, 4.61

Isotropic material, defined, 2.87Jackson, Leon, 3.138n

Jitter, effect on encoder accuracy,10.16

John C Dolph Company, resins,2.171–2.173

Joint design, 3.114–3.115

Kit encoders, defined, 10.9

Knee of the curve, defined, 2.82

stator, 4.61–4.69universal motor construction,4.46–4.54

Laplace operator, thermal analysis and,8.15

Lap winding:

in dc motors, 4.138–4.140.4.143–4.156versus wave winding, 4.165–4.168,4.181

LaValley, Roger O., 3.124nLawrence, Bill, 3.103nLDJ Electronics, 3.138nLead wire, 2.88–2.189Leakage factor calculations:

for polyphase motors, 6.97for series dc and ac motors,4.119–4.128

for single-phase motors, 6.52–6.53,6.64–6.67

for synchronous motors, 7.19–7.21Leakage flux paths:

defined, 1.15permeance of, 1.29–1.32Least significant bit (LSB), 10.21Left flier top coming (LFTC), defined,4.145

Left-hand rule, 1.6Leine & Linde, 10.51LEM Instruments (Hall device manu-facturer), 10.93

Length unit conversions, 1.5Lenz’s law:

explained, 3.142–3.143reactance voltage and, 4.10Leonhard, W., 10.98

Level wind area, explained, 3.31Linear commutation, defined,4.10–4.12, 4.33–4.35, 4.84Linear current limiters, 10.81–10.83Linear encoders, 10.9–10.19,10.22–10.25