Electrical Drives of Machine

Tools

1
Introduction
 The arrangement of the motor nearby the
operative member and also the use of
variable-speed electric motors make it
possible to simplify mechanical
transmissions as well as the construction
of the machine.
 This helps to improve machine-tool
design and considerably reduce the
physical force required to handle the
machine.

2
Introduction
 One or more electric motors driving the
operative members of the machine tool
make up the machine's essential
components.
 The great majority of machine tools are
driven by alternating-current (AC)
three-phase induction motors.
 These motors are simple, reliable and
inexpensive.
 Direct-current (DC) motors are not so
common and are used mainly to drive
heavy machine tools.

3
Induction Motors
 There are electric motors with speed-torque
characteristics known as drooping, rigid
and absolutely rigid.
 With drooping speed motors, change of
torque (i.e., load) results in substantial
motorspeed change.
 If change of torque does not markedly
affect the motor speed, such a motor is
said to, have a rigid characteristic.
 A motor possesses an absolutely rigid
characteristic if its speed does not depend
on load changes.

4
Induction Motors
 The slippage of a motor is denoted by s,
which represents the ratio between the fall
in motor speed under load as compared
with the speed of idling (when M = 0), and
given by the following equation:
s = (n0 – n)/n0
where
 n0 = speed of rotating magnetic field
(synchronous speed of electric motor), rpm
 n= rotor speed (asynchronous), rpm
 Slippage s is expressed as a percentage or
decimal fraction.

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Induction Motors
 The torque developed by the induction
motor can be roughly estimated by means
of the following formula:
M = 2Mc /[(s/sc)+(sc /s)]
where
 Mc =critical torque (maximum load) of
motor
 Sc= critical slippage corresponding to Mc

6
Induction Motors
 Figure 53 depicts the induction motor
speed-torque characteristics.
 With n being equal to n0, M = 0, which
corresponds to the idling of the motor.
 When the motor is started and the rotor is
still immovable (s = 1), the motor develops
starting torque MS, which is higher than the
rated (or nominal) torque Mr.
 The values of Mc and sc determines the
critical point (or the maximum) of the
characteristic.

7
Fig. 53 Speed-torque characteristic of
a.c. motors

8
Induction Motors
 The interval between the idling point and
the critical point of the characteristic is
called the working interval.
 It is this interval that is suitable for stable
operation with the motor speed not
substantially depending on the torque
change.
 The rated value of slippage depends on
the type of motor and its rated power,
and is within the limits of 0.02-0.12.
 The higher the motor power, the lower
the slippage.
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Induction Motors
 In addition to plain induction motors, there
are motors with higher starting torque and
slippage (0.07-0.16).
 While motors with normal slippage have a
rigid speed-torque characteristic and are
used in most machine tools, motors with
higher slippage have a drooping
characteristic and are used in machine-tool
drives with frequent motor starts and
considerable starting loads.

10
Induction Motors
 Curve 1 shown in Fig. 53 is for a rigid
characteristic motor, and curve 2 -for a
drooping characteristic motor.
 It is evident from the Figure that, all other
things being equal, the drooping
characteristic motor has lower rated speed
and higher starting torque Ms.
 Point A represents the rated value of load.

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Induction Motors
 The following induction motor specifications
are usually given in catalogues:
 Rated power Nr, kW;
 rated speed n, rpm;
 synchronous speed n0, rpm,
 ratios Mc /Mr and Ms /Mr (where Mr and Ms
are rated and starting torques,
respectively).

13
Induction Motors
 The value of Mr is determined from the
formula:
Mr = 9550 Nr/n Nm (kgf. m)

 Ratio Mc/Mr defines the value of permissible

mechanical overload of the motor.
Mc /Mr = 1.7-2.5

14
Induction Motors
 The value of Mc depends on mains voltage.
 As the voltage value may change, the
maximum permissible value of overload is
assumed to be 0.85 Mc.
 With general-purpose induction motors
having cage rotors, ratio Ms /Mr = 0.8-2.
 Principal movement drive motors are
started up under no load, so the starting
torque Ms< Mr /2 is sufficient.
 Motors started up under load should
develop higher starting torques.

15
Changing a.c. motor speed
 The rotor speed of a cage-rotor induction
motor is found from the formula
n = (2 x 60f/p)(1- s) rpm
where
 f = alternating current frequency, Hz
 p = number of pole pairs
 s = slippage of rotor
 It is evident from the formula that motor
speed can be changed by:
⚫ changing current frequency,
⚫ slippage or
⚫ the number of pole pairs.

16
Changing a.c. motor speed
 With the frequency of alternating current in the
mains being constant, the first method can be
applied only if there is a separate a.c. generator
to feed the electric motor.
 The second method of speed changing - by
change of slippage - is accomplished by
introducing effective resistance into the rotor
circuit, which can be done only with wound-rotor
induction motors.
 The third method of speed changing - by
changing the number of pole pairs - is the most
widely used in machine tools. It involves the use
of multi-speed pole-change motors.

17
The synchronous speed is given as
Ns = (120 f/P) rpm
where f is supply frequency and P is number
of pole pairs.
 Thus if it is possible to change the value of
P, the synchronous speed can be varied.
 For a slip s, the rotor speed of induction
motor = Ns (1-s)

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 Therefore speed of induction motor can be
varied by pole changing.
 Since the number of pole pairs can only be
changed in steps like from 2 to 4, this
scheme provides stepped speed control.
 Generally, speed control using pole
changing method is restricted to two steps.

19
Basic Principle of Pole Changing
Method:
 To better understand the basic concept of
pole changing; let us consider a magnetic
circuit as shown in the next slide.

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21
 There are four pole faces A, B, C and D.
 Two coils are wound on pole face A and C
in the direction as shown in above figure.
 Now, the two coils on A and C can be
connected in series in two different ways:
 Connection-1: Connect coil terminal
A2 and C1 together.
 In this connection, when supply is
connected across coil terminals A1 and C2,
the current will flow in the direction as
shown in figure.

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• Thus, this type of connection results into a
two pole induction motor.
• The speed of this induction motor will be
Nr = (120f/P)(1-s)
= (120f/2)(1-s)
= 60f(1-s)
Assuming supply frequency of 50 Hz and slip
s = 0.1,
Nr = 3000 (1-0.1)
= 2700 rpm

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 Connection-2: Connect coil terminal
A2 and C2 together.
 This connection is known as constant-
torque connection.
 In this connection, the direction of current
in pole A coil is clockwise while that in pole
C coil is anti-clockwise.
 This is shown in figure below.

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• Therefore, the magnetic field due to both the
coils will emanate from the respective coil.
These magnetic flux lines will complete its
circuit through the adjacent pole B and D as
shown by green colored lines in the figure.

• Thus, this connection of stator coils results

into a four pole induction motor whose speed
of rotation is given as,
Nr = (120f / P)(1-s)
= (120f /4)(1-s)
= 30f(1-s)
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 Assuming supply frequency of 50 Hz and
slip s = 0.1,
 Nr = 1500 (1-0.1)
 = 1350 rpm
 It is thus clear from the above discussion
that speed control of induction motor using
pole changing method is achieved in steps.
 We cannot have a continuous or smooth
speed control using this method.

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Direct Current Motors
 Direct current motors with shunted
excitation (shunt-wound motors) are
extensively used in heavy machine-tool
drives.
 They are connected according to the circuit
diagram shown in Fig. 54.
 The armature winding A is connected to
the mains through starting rheostat 1,
exciting (shunt) winding SW, and
rheostat 2 used for speed variation.

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Fig. 54. Circuit diagram of shunt-wound
motor connection

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Direct Current Motors
 The torque and speed values for the d.c.
motor are determined by means of the
following formulas:
M= kIaΦ, Nm (kgf.cm);
n= [(V – Iara)/cΦ] rpm
where M = torque developed by motor, Nm
 n = motor speed, rpm
 V = mains voltage, V

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Direct Current Motors
 Ia = current intensity in armature winding,
A
 ra = armature circuit resistance, ohm
 c = constant of given motor
 k = 0.05-0.12 - proportionality factor
 Φ = magnetic flux of motor, Wb.s
 The speed-torque characteristics of the
motor are shown in Fig. 55.

32
Fig. 55 Speed-torque characteristics of
shunt-wound dc motor.

33
Changing the speed of d.c. motors

 Change of d.c. motor speed can be

effected:
➢ by changing the armature circuit
resistance,
➢ by changing the magnetic flux, and
➢ by changing the input voltage.
 The first method is explained in the
next sheet though it is rarely used
because it involves energy losses.

34
Direct Current Motors
 Number 1 denotes the line corresponding to the
rated speed torque characteristics.
 The relatively small value of armature winding
resistance determines a sufficiently rigid rated
characteristic of the shunt-wound motor, as shown
graphically by the modest slope of line 1.
 With the motor in operation, the resistance of
rheostat 1’ can be increased; this will result in an
increase of, the total armature circuit resistance
leading to slopes 2, 3 and 4 of the characteristic
line.
 The second method-by changing the magnetic
flux- is the most commonly used. The magnetic
flux value is changed by rheostat 2’ (Fig. 55).

35
 Fig. 55 Speed-torque characteristics of
shunt-wound dc motor.

n= [(V – Iara)/cΦ] rpm

36
Changing the speed of d.c. motors
 The rheostat resistance being increased,
the exciting current and magnetic flux are
reduced, which results in an increase in
idling motor speed and slope of motor
speed-torque characteristics, represented
by a number of straight lines (5, 6, 7, 8).
n= [(V – Iara)/cΦ] rpm
 The number of these characteristics
depends on the number of steps on
rheostat 2’.
 Where the number of rheostat steps is
large, motor speed changing becomes
practically stepless.

37
Changing the speed of d.c. motors

 Line 9 in Fig. 55 represents the

speed-torque characteristic of motor
with reversed armature polarity, in
which the direction of motor rotation
is reversed.
 The third method of speed changing
- by changing the input voltage -
involves the use of special circuitry
and is employed in generator-motor
systems.

38
The Generator-Motor System
 This system, known also as the Ward-
Leonard system, is used in heavy and
high-power machine tools with frequent
motor reversal or where infinitely variable
speed or feed are required.
 This system also facilitates the starting of
the machine tool.
 The system (Fig. 56) consists of induction
a.c. motor 2; d.c. generator 3 driven by
motor 2; self-excited direct-current
generator 1 for the excitation of
generator 3 and motor 4.
39
The Generator-Motor System

40
The Generator-Motor System
 d.c. motor 4 is used as the drive motor of
the machine tool.
 Motor 4 is started up by means of shunt-
circuit rheostat 6 connected to the
exciting winding of generator 3.
 Rheostat 6 reduces the magnetic flux of
generator 3.

41
The Generator-Motor System
 This gives a very small value of voltage on
the generator brushes, which is then
gradually increased.
 As motor 4 is sped up, it develops a back
electromotive force (emf) and the shunt-
circuit rheostat is gradually switched off,
increasing the generator voltage.

42
The Generator-Motor System
 The generator-motor system allows the
speed of motor 4 to be varied in two ways:
(a) by changing the input voltage fed into
motor 4 with the aid of rheostat 6 (by
changing the magnetic flux of generator
3); {n= [(V – Iara)/cΦ] rpm}; and
(b) by changing the excitation magnetic
flux of motor 4 by means of rheostat 5.
{n= [(V – Iara)/cΦ] rpm};
 The reversal of motor 4 is accomplished by
changing over the direction of current in
the exciting winding of generator 3 with
the aid of switch 7.

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