II \ II IIIIII IIII II IIII IIIIII IIII IIII II IIIII IIIIII II 1111 IIIIII II I II

3 1176 00166 4631

DOE/NASA/0123-2
NASA CR-165382
ERC TR-80169
NASA-CR-165382
19810020808
Straight and Chopped DC Performance Data
for a Prestolite MTC4001 Motor and a
General Electric EV1 Controller
Paul C. Edie
Eaton Corporation
Engineering & Research Center
April 1981
Prepared for
National Aeronautics and Space Administration
Lewis Research Center
Under Contract DEN 3-123
for
U.S. DEPARTMENT OF ENERGY
Conservation and Renewable Energy
Office of Transportation Programs
SEP 3 198"'
Lii3R .. ,\R';,

NOTICE
This report was prepared to document work sponsored by the United States
Government. Neither the United States nor its agent, the United States Department of
Energy, nor any Federal employees, nor any of their contractors. subcontractors or their
employees, makes any warranty. express or implied. or assumes any legal liability or
responsibility for the accuracy. completeness, or usefulness of any information.
apparatus. product or process disclosed. or represents that its use would not infringe
privately owned rights.
DOE/NASAl0123-2
NASA CR-165382
ERC TR-80169
Straight and Chopped DC Performance Data for a Prestolite
MTC4001 Motor and a General Electric EV1 Controller
Paul C. Edie
Eaton Corporation
Engineering & Research Center
Southfield, Michigan 48037
April 1981
Prepared for
National Aeronautics and Space Administration
Lewis Research Center
Cleveland, Ohio 44135
Under Contract DEN 3-124
for
U.S. DEPARTMENT OF ENERGY
Conservation and Renewable Energy
Office of Transportation Programs
Washington, D.C. 20585
Under Interagency Agreement DE-AI01-77CS51 044
Alii, zCf 3 V { P ~
TABLE OF CONTENTS
PAGE
SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION. 3
EQUIPMENT TESTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEST
l.
2.
3.
4.
FACILITy ............................ .
Dynamometer . . . . ........... .
Power Source . . . . . . . . . . ........ .
Motor & Controller Installation

. ....
Instrumentation . ........ .
TEST PROCEDURES

. .............. .
1.
2.
TEST
l.
2.
3.
...
Test
Data
Sequence
Acquisition ................................. .
RESULTS ............
Data Reduction
Straight DC Results.
. . . . . . . . . . . . . . . . .
. ..................... .
. ...
..
Chopped DC Results
CONCLUSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GRAPHICAL RESULTS. .........................................
5
9
9
9
9
13
15
15
15
17
18
20
20
23
25
TABULAR DATA............................................... 35
iii
LIST OF TABLES
PAGE
Table 1 - STRAIGHT DC TESTS
(Low Temperature).............................. 36
Table 2 - STRAIGHT DC TESTS
(High . Tempera ture) 38
Table 3
-
CHOPPED DC TESTS
(Low Temperature, l44V I npu t) ........ 40
Table 4
-
CHOPPED DC TESTS
(Low Temperature, l20V Input) .................. 42
Table 5
-
CHOPPED DC TESTS
(High Temperature, l44V Input) ............... 44
Table 6 - CHOPPED DC TESTS
(High Temperature, l20V Input) ................ 46
iv
SUMMARY
This report is intended to supply the electric vehicle manufac-
turer with performance data on the Prestolite MTC-4001 series
wound DC motor and General Electric EV-I Chopper Controller. Data
is provided for both straight and chopped DC input to the motor,
at 2 motor temperature levels. Testing was done at 6 voltage
increments to the motor, and 2 voltage increments to the
controller. Data results are presented in both tabular and
graphical forms. Tabular information includes motor voltage and
current input data, motor speed and torque output data, power data
and temperature data. Graphical information includes
torque-speed, motor power output-speed, torque-current, and
efficiency-speed plots under the various operating conditions.
The data resulting from this testing shows the speed-torque plots
to have the most variance with operating temperature. The maximum
motor efficiency is between 76% and 82%, regardless of temperature
or mode of operation. When the chopper is utilized, maximum motor
efficiency occurs when the chopper duty cycle approaches 100%. At
low duty cycles the motor efficiency may be considerably less than
the efficiency for straight DC. Chopper efficiency may be
assummed to be 95% under all operating conditions. For equal
speeds at a given voltage level, the motor operated in the chopped
mode develops slightly more torque than it does in the straight DC
mode. System block diagrams are included, along with test setup
and procedure information.
Page Missing in
Original Document
INTRODUCTION
Today about one-half of the petroleum consumed in the United
States is used for transportation. The introduction of electric
vehicles could significantly shift the transportation energy base
to other sources such as coal, nuclear, and solar.
In 1976 the Electric and Hybrid Vehicle Program was initiated
within the Energy Research and Development Administration (ERDA),
now the Department of Energy (DOE). In September of that same
year, the Congress passed the Electric and Hybrid Vehicle
Research, Development, and Demonstration Act of 1976 (Public Law
94-413). This Act is intended to accelerate the integration of
electric and hybrid vehicles into our transportation system and to
stimulate growth in the electric vehicle industry.
Part of the Electric and Hybrid Vehicle Program is focused upon
assisting electric vehicle, manufacturers with general technical
problems relating to the design of near-term vehicles. For the
most part, these manufacturers are small companies which often
lack resources for testing, research, or development.
This report is intended to provide these manufacturers with
performance data on an electric motor and chopper controller which
may be used on this type of vehicle.
Due to the limited power and energy capability of batteries, high
efficiency is a very desirable attribute of motors and controllers
used in electric vehicles.
Although there is a great deal of electric motor and controller
developmental work ongoing in both private industry and government
research centers, the data supplied by the manufacturers of motors
usually consists of limited information for straight DC operation
only, and does not cover the motor's performance when used in
conjunction with a chopper/controller.
The testing done under this contract and the resulting data
formats were specified by the NASA Lewis Research Center. This
report summarizes data on a Prestolite MTC-400l series wound motor
and a General Electric model EV-I controller. Other
motor/controller combinations have also been tested, and appear as
separate reports under the same contract number. To assure consis-
tent test results under severe load, the batteries used for these
tests had much higher capacity than those typically available in
an electric vehicle. If smaller, more portable power sources are
used, the resulting motor torque and speed would be limited by the
output capacity of the source.
All tests were made at two motor operating temperatures, as
outlined in the "Test Procedure" section. The data from these
tests should characterize the motor performance under typical
"hot" and "cold" conditions. It should be noted that these are
only representative temperature levels.
3
The data contained in these results is all of a steady-state
nature, and does not show motor or controller efficiency during
acceleration, deceleration or regenerative operation. To provide
a complete range of data, motor nameplate ratings were exceeded in
some instances for short periods of time. At no time were the
motors exposed to severe abuse, physical shock or contaminated
environments.
The test data presented here is not intended to represent the
absolute maximum power available from any motor or controller.
Under certain conditions, the motor or controller may be capable
of exceeding the input and output power levels shown in the data
and still remain However, since this represents the
extreme conditions of motor/controller operation and is useful
only in limited circumstances, such data is not presented here.
Data is presented in graphical and tabular forms. Tests were run
as detailed in the section titled "Test Procedure." Tabular data
represents the arithmetic average of all test runs, and is
intended to reduce data scatter as well as the volume of total
data recorded. Tabular data will supply the user with performance
information at a specific desired test point.
Graphical data presents the averaged results plotted and extra-
polated, such that information for any given point within the
testing range may be found.
4
EQUIPMENT TESTED
Description of M o t o ~
The motor tested in this report is a Prestolite model MTC-400l
series wound DC motor. This motor is shown in Figure 1, with a
print detailing critical dimensions in Figure 2. Weight of this
motor is 45.5 Kg (100.6 Ibs.) with all mounting hardware attached.
The following nameplate data appears on the motor:
Part No ..
Volts DC
Class
Ser.
MTC-4001 0170
96
H
Lll
During inspection, prior to testing, no signs of abuse or wear
were noted.
5
6 2
15.804
to center
of vent
Description of Controller
The chopper/controller testing in conjunction with the Prestolite
motor was a General Electric model EV-I. This unit is a
conventional SCR controller. The controller is shown in Figure 3,
with a print detailing critical mounting dimensions in Figure 4.
Weight of the controller is 24.3 Kg (53.7 Ibs.). The only
nameplate data on the controller is a 144 volt DC rating. During
inspection, prior to testing, it was found that the plastic mounts
holding the oscillator card to the base were cracked, probably
caused by mishandling when the unit was shipped. Several wires
had been pulled off the card, apparently due to the shipping
abuse. Once these were repaired, the unit functioned properly.
7
figure 3 General Electric Model Controller
13.013
12.511
Note: Bottom View
11.014
location of 10-32 Holes
9.010
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13 12
11 t
l
8.509
1
10.613
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t f-- 2.6364
19 8
,
f
00 ;.:3-
11
.662
-f::-.
5OO
T- 9.007
"1
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9.485
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i
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7.485
8.508
~ ' f 4
I
11.00 4
r
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-
32 13 Places Ref.
5.986
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,,+
1Jr
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" "ron
-11
1t--.500
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V.<Juv
8.506
12.500
16.014
8
figure 4 Drawing of General Electric EV-1 Controller Base Plate
rrES'l' FACILITY
l. Dynamometer
'rhe motor controller combination was mounted as shown in
Figures 5-6. A conventional T-slot bedplate served as the
mounting base., 'l'o absorb the motor output power, a General
Electric DC dynamometer rated at 100 hp @ 6000 rpm was used.
The dynamometer used a motor generator set as its source of DC
power, and was controlled by a console locabed outside the
test cell (Figure 7). The control console consisted of
necessary dynamometer power and speed controls, along with a
safety annunciator system to shut down the entire test cell
should an overspeed, overcurrent or overtemperature condition
occur. An automatic halogen fire extinguishing system was
used to protect the entire testing area.
2. Power Source
To power the motor and controller, I E ~ a d acid type batteries
were used (Figure 8). Four 36 volt, 1100 amp hour batteries
were wired in series using 4/0 copper stranded wire. Taps
were wired at 6 volts increments from 0 to 144 volts. The
batteries were charged using a Barrett current regulated
industrial charger, rated at a capacity of 300 amps. Room air
and hydrogen from the batteries were exhaust.ed directly to the
outside 'via overhead blowers.
3. Motor & Controller Installation
Figure 9 shows the motor mounting and transducer configu-
ration. The motor was mounted directly on a small I-beam,
which was in turn mounted on the bedplate. The motor was
coupled to the telemetry transmitter (which is discussed in
the Instrumentation section) by special machined slip fit
couplings, held by a keyway. The transmitter assembly was
coupled to the torque speed transducer (also discussed in the
Instrumentation section) wi th Waldron Flex-l\lign couplings,
which compensate for small alignment or balance errors. The
opposite end of the torque/speed transducer was coupled to the
dynamometer using another Waldron coupling.
All alignments between shafts were held to ,,,i thin 0.20 mm
(0.008 in.) during setup.
The controller was mounted on a bench located directly over
the motor to keep wire lengths as short as possibleo All
power wi.ring was accomplished using rubber insulated 4/0
stranded copper welding cable. Connections were made to the
motor and controller via copper crimp type lugs.
The motor was cooled, when necessary to maintain temperature
within the specified limits, by a squirrel cage blower motor
fot"cinq air through the motor's coolin
c
] duct. Room air was
9
10
11
also forced over the motor housing using a conventional fan.
Motor and controller operator controls were located on the
dynamometer console. These included motor power and control-
ler power switches and controller acceleration potentiometer.
Safety systems for the dynamometer also served to shut off the
motor/controller in event of an unsafe condition. A 300 amp
DC contactor, controlled at the console, switched battery
power to the motor. When data was taken for chopped DC
operation, power was routed through a resistive load in series
with the battery to simulate a more realistic source impe-
dance, as would be found in a typical electric vehicle. This
resistance had a value of 0.059 OHM, and was capable of
dissipating approximately 5200 watts.
4. Instrumentation
Connection between the motor and dynamometer was made via a
Lebow type 1604-2K torque-speed transducer. The torque
transducer was of the rotary transformer type; the speed
transducer was of the magnetic pickup type. Full-scale ranges
were 225 N-m (2000 in-lbs) for the torque and 15,000 rpm for
the speed pickup.
Also coupled directly to the motor was an Inmet Model 20lA
temperature telemeter. Two type T thermocouples were mounted
on the motor armature laminations, 180 degrees apart.
Thermocouple wire was run underneath the motor bearings,
through the shaft keyway (which was extended for this purpose)
and directly to the telemeter module. The module and its 9
volt power source were mounted in an aluminum disc 19.0 cm
(7.5 inches) in diameter and rotationilly balanced to 6000
rpm. A loop antenna was mounted on the small support I-beam
to receive the FM transmission. A receiver was located on the
control console and calibrated to readout directly in degrees
centigrade.
Other temperature measurements were made directly on the field
windings, with type K thermocouples. Thermocouple wire was
run directly to the control console for readout.
Torque, speed and temperature readout were accomplished using
a Daytronics 9000 series modular signal conditioning rack.
Readout was directly in 81 units. A readout was also provided
to calculate motor output horsepower from the speed and torque
signals.
Current measurements were made using T&M Research Type F
coaxial shunts located on the bench, directly over the motor.
These shunts were rated for a 100 mV drop at 200 amps and
frequency response of over 0.5 MHz at rated current. Voltage
measurements were taken directly from the motor and controller
terminals via coaxial cable.
13
14
For the straight DC tests, current and voltage measurements
were made directly on Fluke Model 8350A digital voltmeters.
For the chopped tests, both the current and voltage signals
were fed into Phillips type PM-8940 optical isolators. These
units have a frequency response of DC to 1.5 MHz % 3 dB, with
a phase shift of less than 2 degrees at 15 kHz. The isolators
serve to amplify (for current measurements) or attenuate (for
voltage measurements) the input signal as well as to "float"
the inputs, allowing the output signal "commons" to be tied
together. The isolator
1
s "front end" is battery powered,
completely eliminating any chance for ground loops to be
created on the signal lines.
Since it was necessary to measure average and RMS voltages and
currents, as well as average wideband power for the chopped DC
tests, a Hewlett-Packard 545lB Signature Analysis System was
utilized.
Output signals from the isolators were fed directly into the
Hewlett Packard system. Analog-to-digital converters sampled
the data at 20,000 points/sec., and digitally performed the
calculations for average, RMS and power measurements.
The analyzer was programmed to print out all data required for
each test point automatically. To assure waveform integrity,
data from each channel was constantly monitored on an
oscilloscope while being input to the analyzer.
TEST PROCEDURES
1. Test Sequence
A typical test run consisted of initially assuring the motor
to be at the correct test Two temperature ranges
were tested, 25-45C and l30o-l50oC. For the high tempera-
ture runs, this was accomplished by wrapping the frame with
layers of fiberglass insulation. Once the desired temperature
range had been reached, the motor was driven to its maximum
rated speed by the dynamometer. When speed had stabilized,
the motor was powered at a specific input voltage and data was
recorded. Once completed, the dynamometer speed was reduced
600 RPM for a second data point. This procedure continued
until the torque transducer limit was reached. When the motor
heated above its testing temperature range, forced air blowers
were turned on, allowing it to cool. Once the maximum torque
point had been taken, the motor was brought back to maximum
speed at 500 RPM increments to record motor hysteresis. When
completed, the next voltage tap was selected, and tested as
before. Six motor input voltage levels were selected: 16,
24, 36, 64, 80, and 96 volts. When all required input
voltages were tested, the entire procedure was repeated a
total of 3 times. The procedure was followed for both
ripple-free and chopped testing, the only difference being
that for the chopped data, motor input voltage was controlled
by adjusting the chopper acceleration potentiometer to achieve
the proper level. Chopped data was taken at 80 and 96 volt
input levels to the chopper, and the above test sequences were
followed for both chopper input voltages. Battery condition
was constantly monitored to assure that excessive "droop" was
not occurring due to lack of charge level. For the resulting
data, "droop" in input voltage level is primarily due to
interconnecting cable IR drop, inter-battery connection IR
drop, and for chopped data only, the IR drop due to the series
0.059 OHM added resistance.
2. Data Acquisition
Data which was directly read from instruments and the Hewlett
Packard analyzer printout was typed into a portable CRT screen
located on the control console. The CRT was tied into the
Eaton VAX 11/780 computer, pre-programmed with a "form"
format, so that ali data was typed under correct headings.
This allowed an orderly method of data acquisition, and made
it possible to "call up" data from previous runs to compare
data points for hysteresis and to assure that there was no
substantial data shift from identical earlier tests.
Once in the VAX system, all data from the tests was averaged
for each unique test point. This included all three test runs
as well as hysteresis points. Averaging was done arithmeti-
cally, and was available on hard copy as final test results.
15
The following parameters have been measured for the motor at each
test point:
1. Motor speed - measured at the motor shaft in units of revs./
min. (Accuracy, :1% of 6000 RPM full scale.)
2. Motor torque - measured at the motor shaft in units of
Newton-meters. (Accuracy, :1% of 225 Nm full scale.)
3. Motor temperatures - measured at various points internal to
the motor (see section titled "Instrumentation" for details)
in units 'of degrees centigrade. (Accuracy, :0.4C for field
measurements, :2C for armature measurements.)
4. Motor input voltage - measured at the input terminals of the
motor in units of volts. (Accuracy, :0.01% of 199 volt full
scale. )
5. Motor input current - measured at the input terminals of the
motor in units of amperes. (Accuracy, :0.50% of 400 ampere
full scale.)
6. Controller input voltage - measured at the input terminals to
the controller in units of volts. (Accuracy, :1% of 200 volt
full scale.)
7. Controller input current - measured at the input terminals to
the controller in units of amperes. (Accuracy, :1% of 400
ampere full scale.)
8. Controller input power - measured at the input terminals to
the controller in units of watts. (Accuracy, :2% of 80,000
watt full scale.)
9. Controller output voltage - measured at the output terminals
of the controller in units of volts. (Accuracy, :1% of 200
volt full scale.)
10. Controller output current - measured at the output terminals
of the controller in units of amperes. (Accuracy, :1% of 400
ampere full scale.)
11. Controller output power - measured at the output terminals of
the controller in units of watts. (Accuracy, :2% of 80,000
watt full scale.)
(Measurements '1-'3 were made for all tests, measurements 14 and
15 for straight DC tests, and measurements 16-111 for chopped DC
tests. )
16
TEST RESULTS
The test results are tabulated in Tables 1 through 6 and depicted
graphically in Figures 10 through 19. As indicated in the "Test
Procedures" Section of this report, three separate test runs were
made at each test condition. Each run started at maximum speed.
The motor was gradually loaded, and data was taken at the speeds
indicated in the tables until maximum load was achieved. The load
was then gradually removed, and data was again taken at the same
speeds. Consequently, the original test data consists of six data
points at each speed and each test condition. This data was
averaged and reduced to decrease the data scatter and the volume
of test data to be reported.
17
1. Data Reduction
18
The original intent of running three test points with speed
decreasing and three test points with speed increasing was to
show the effect of hysteresis on the motor performance.
However, the hysteresis effects were found to be negligible,
so all six data points were averaged together.
For tests of a motor that will be used with a specified power
source, the input voltage is usually varied in accordance with
the power supply characteristics. Where the power source is
not specified, the input voltage is usually held constant.
For the straight DC tests, constant voltage data was desired.
Since the input voltage varied somewhat, a correction factor
was applied to the speed data. This compensation factor con-
sidered the internal copper IA RA drop of the motor but did
not include an allowance for brush drop. The following compen-
sation equation was used:
compensated speed = test speed
VIDEAL - RAIA
VTEST - RAIA
0.00624 ohms was used for the value of RA. The new compen-
sated speed was used in all subsequent calculations such as
motor output, power, and efficiency. The curves were also
plotted using the compensated speed or the compensated power
output as a parameter.
For the chopped DC tests, it appeared to be more appropriate
to try to simulate the voltage "droop" characteristics of
presently available electric vehicle batteries. At each test
point, the controller was adjusted to maintain a nearly
constant value of average motor voltage; thus, speed conpen-
sation is not necessary.
Once the data was averaged, a best fit plotting routine was
utilized on the VAX to produce the following plots:
1. Torque - speed (for each voltage level)
2. Power - speed (for each voltage level)
3. Torque - current (for all voltage levels)
At this time, plots of efficiency-speed were derived by the
following process: (for straight DC)
1. Lines of constant power were drawn on the power-speed
curves.
2. From these lines, values of speed at each power level
for every voltage were extrapolated.
3. Knowing speed and power, torque was calculated for
every point.
4. Current was extrapolated for every torque value using
the torque current curves.
5. Efficiency for each point was calculated as
n = power out
VxI
6. For each line of constant power, the efficiency was
plotted against speed using a best fit program.
For the chopped DC data a similar method was used with the
following exceptions:
1. Once torque was known for each intersection point,
input power to the motor was extrapolated using a
torque vs. input power plot (derived for each voltage
level from the averaged data).
2. Once derived, efficiency was calculated as
n = power ?ut and plotted against speed for each
power In
power level using a best fit program.
The final plot of chopper efficiency versus volts was derived
us ing the following routine.
1. Equations were calculated for controller efficiency
power out versus controller output power for each
power in
motor input voltage level using each averaged data
point.
2. For fixed levels of controller output power, the value
of controller efficiency and voltage were stored.
3. Plots were made of controller efficiency-controller
output voltage for each power level.
4. Since these plots were overlapping within a very small
range of efficiency (approximately 95%), plots were
replaced with a band showing the maximum and minimUM
extremes of controller efficiency within the power
levels indicated.
19
2. Straight DC Results
The straight DC data for two ranges of temperatures are pre-
sented in Tables 1 and 2. The voltage, current, torque, and
speed variables are tabulated in the conventional manner. The
compensated speed and the compensated power output were calcu-
lated as discussed in the Data Reduction Section of this
report. The calculated efficiency is the ratio of the compen-
sated power output to the product of the nominal voltage and
current.
The temperature tabulations illustrate one of the difficulties
in performing this type of testing. Not only does the temp-
erature vary from one point to another in the machine, but the
temperature difference also varies.
The tabulated data is depicted graphically in Figures 10
through 17. These curves all have the expected shape.
The data was recorded for two temperature ranges in order to
allow an evaluation of temperature effects. The most discern-
able temperature effects appear in the torque-speed curves.
The high temperature curves (Figure 11) are shifted downward
or to the right of the corresponding low temperature curves
(Figure 10). .
The shift in the torque-speed curves is primarily due to the
increase of armature resistance with increased temperature.
Since the torque-current curves are in close agreement, a
given torque will produce a greater lARA voltage drop at the
higher temperature. Consequently, the counter electromotive
force and the speed will decrease.
Temperature appears to have very little effect on motor effi-
ciency. For both temperature ranges, the peak efficiencies
are between 76% and 82%. These peak efficiencies all appear
at moderate loads, reasonably high speeds and near maximum
voltage. The efficiency drops below 75% only at light loads
or low voltage.
3. Chopped DC Results
The chopped DC data are tabulated in four categories as
follows: '
Table 3 25-45C 96 Volt Input
Table 4 25-45C 80 Volt Input
Table 5 l30-l50
o
C 96 Volt Input
Table 6 l30-l50
o
C 80 Volt Input
This data is also depicted graphically in Figures 10 through
19.
20
The voltages refer to the nominal input voltages to the
chopper. Two voltage ranges were used to allow an evaluation
of the effects of the batteries' state of charge. The 96 volt
tests were intended to represent a fully charged battery. The
80 volt tests were intended to represent a partially
discharged battery.
Both the average and the root mean square (RMS) values of all
the voltages and currents were recorded. Only the average
values of the variables were used to generate the curves
depicted in Figures 10 through 19. The RMS v a l u e ~ were
recorded to give an indication of the form factor of each
variable and to aid in future modeling work. The duty cycle
of the controller may roughly be " considered to be the ratio of
the average value of the chopper output voltage to the average
value of the chopper input voltage.
A comparison of the chopper input power wattmeter reading with
the product of the average input voltage and current value
will indicate that sizeable errors may result by using the
volt-amp product as a measure of power. For the low voltage
tests, the product of the average values of voltage and
current is greater than the wattmeter reading. However, at
high values of test voltage the volt-amp product is less than
the wattmeter reading. (The deviation at high test voltage is
approximately 3%, and may be attributed to instrumentation
error.) The same results are found when the product of the
RMS values are compared to the wattmeter readings.
On the output side of the chopper a similar comparison may be
made. Here the product of the average values of voltage and
current are less than the wattmeter reading for low values of
motor voltage and are higher than the wattmeter reading for
high values of motor voltage. (Again, a 3% deviation is
typical at high voltage, and may be attributed to instrumenta-
tion error.) These results are the opposite of those found on
the input side of the chopper. The product of the RMS values
of voltage and current are always greater than the wattmeter
reading.
The maximum values of motor efficiency for the chopped DC case
are approximately the same as the maximum values for the
straight DC case. These maximum efficiency values all occur
at or near maximum vol tage and correspond to du'ty cycles near
100%. Consequently, they should be expected to approach the
straight DC values. At low duty cycles the efficiency may be
considerably less than the efficiency for straight DC.
The measured chopper efficiency is about 95% throughout the
test range. Small errors in either chopper input or output
power measurement result in variations in the calculated
chopper efficiency. Consequently, the variations observed at
individual test points are not significant.
21
22
A comparison of the chopped DC torque versus speed curves with
the corresponding straight DC curves shows that the chopped DC
curves are shifted slightly upward and to the right. For
equal speeds, the additional torque produced in the chopped
mode is due to the AC component in both the current and flux
waves.
The torque-speed curves for the chopped mode of operation
(Figures 12, 14, 16 and lS) show that the curve for maximum
voltage coincides with the next lower voltage curve for high
values of torque. This phenomenon is caused by the impedance
of the power source. The corresponding tabulated data shows
that for the highest voltage curve in each category, the
chopper duty cycle is nearly 100% and that a constant voltage
cannot be maintained at the chopper output terminals as torque
is increased. In the region of coincidence, the chopper duty
cycle is also 100% for the second highest voltage curve.
CONCLUSIONS
A fairly elaborate setup is required to perform the tests
described in this report.
1. Power Supply Requirements
Ideally the motor should be tested with the specific power
supply with which it will be used. In the case of battery
powered vehicles, the variations of battery characteristics
and its limited energy capacity make actual vehicle batteries
impractical. Some compromises must be made. In the straight
DC mode of operation, a constant voltage source appears to be
most desirable. In the chopped mode, the internal impedance
of the source substantially affects wave shapes.
2. Temperature Control
The temperature of the motor windings can change very rapidly.
To expedite testing, the winding temperatures should be
monitored and some method of heating and cooling the motor is
desirable.
3. Instrumentation
For the chopped mode of operation, the instrumentation must be
carefully considered. Significant errors can result from
using the product of voltage and current as an indicator of
power. Suitable wattmeters must be used. Many readings will
be a small fraction of full scale and accuracy may be less
than expected.
4. Test Results
a. The controller efficiency may be assumed to be about 95%
throughout the test range.
b. The maximum efficiency of the motor was between 76% and
82% regardless of the motor temperature or the mode of
operation. However, at low chopper duty cycles the motor
efficiency may be considerably less than it is on straight
DC.
c. Most of the variations caused by changing test conditions
are discernable on conventional torque-speed curves. For
equal torque, a motor at high temperature will run
somewhat slower than the same motor at a lower
temperature. For equal speeds, a motor operated in the
chopped mode develops slightly more torque than it does in
the straight DC mode.
d. The hysteresis effects of the motor alone, as well as the
motor-controller combination, are negligible and can be
ignored.
23
Page Missing in
Original Document
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D. Efflclency-Speed-Power Relationsh
FIOllrg 10 low TomporAturo-Stralght DC
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2- 21V
3- 36V
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B. Output Power-Speed Characteristic
1- 3HINRTTS
2- 8N1VflTIS
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D. Efflclency-Speed-Power Relationsh
Figure 11 High Temperature-Straight DC
Z6

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A. Speed-Torque Characteristics B. Output Power-Speed Characteristics

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Figure 12 Low Temperature-Chopped DC-120 Volt Input
27
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3- 36V
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5- BIY
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... i IIPK" 1 III
A. Torque-Power-Voltage Relationships B. Motor Efficlency-Speed-Po",
Relationships
28
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I.
1 - 5111111IVftTTS
2- 91111111VftTTS
3-1ueewmS
----------------------------
VOlTS
C. Controller Efficiency
Figure 13 Low Temperature-Chopped DC-120 Volt Input

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1- 16V
2- 2&V
3- 36V
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A. Speed-Torque Characteristics B. Output Power-Speed Characterist:cs
::
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C. Torque-Current Characteristics
Figure 14 Low Temperature-Chopped DC-144 Volt Input
29
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Torque-Power-Voltage Relationships B. Motor Efflclency-Speed-Pow.
I
Relationships
1- 50G1MTTS
2- 9001WATTS
3-1&00MTTS
----------------------------
,.. -----------------------

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VOLTS
C. Controller Efficiency
Figure 15 Low Temperature-Chopped DC-144 Volt Input
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A. Speed-Torque Characteristics
B. Output Power-Speed Characteristics
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C. Torque-Current Characteristics
Figure 16 High Temperature-Chopped DC-120 Volt Input
31
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A. Torque-Power-Voltage Relationships B. Motor Efflclency-Speed-Powe
Relatlonsh Ips
32

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C. Controller Efficiency

2- 911111VATTS
3-1 UlBlVRTTS
Figure 17 High Temperature-Chopped DC-120 Volt Input
.1
1- 36V
1- :V
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2- 81V 2- 'V
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A. Speed-Torque Characteristics B. Output Power-Speed Characteristics
AI1f'S
c. Torque-Current Characteristics
Figure 18 High Temperature-Chopped DC-144 Volt Input
33
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A. Torque-Power-Voltage Relationships B. Motor Efflclency-Speed-Pow(
Relationships
34
1- 5n1Vf1TTS
2- 9IfIIMlTTS
3-1 UllNffiTS

va..TS
C. Controller Efficiency
Figure 19 High Temperature-Chopped DC-144 Volt'lnput
TAB U L A R D A T A
35
Table 1
:.,..)
:n
PRESTOLITE MODEL MTC-4001 DC MOTOR
DEN3-123
GENERAL ELECTRIC EV-1 CONTROLLER
PRESTOLITE STRAIGHT DC TESTS, 25-45
0
C TEMPERATURE RANGE
MOTOR
COMPENSATED COMPENSATED
BATTERY FIELD MOTOR INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT
TAP TEMP (OC) ARMATURE VOLTAGE CURRENT TORQUE SPEED SPEED POWER EFFICIENCY
(VOLTS) #1 #2 TEMP (OC) (VOLTS) (AMPS) (Nm) (RPM) (RPM) (WATTS) (%)
16 39 39 54 16.6 22.8 0.1 2500 2413.7 25.3 6.9
39 39 53 16.6 28.7 0.7 2000 1932.8 141.7 30.9
38 38 53 16.4 39.4 2.3 1500 1462.9 352.5 55.9
38 37 55 16.2 65.0 6.9 1000 988.4 714.5 68.7
37 37 55 15.2 191.3 34.1 500 527.9 1885.9 61.6
38 38 54 14.3 354.2 72 .3 250 285.9 2165.5 38.2
24 35 35 57 25.0 25.4 0.1 3500 3354.6 35.1 5.8
35 35 58 25.0 29.9 0.6 3000 2884.9 181.3 25.3
35 35 59 24.8 36.2 1.5 2500 2417.0 379.8 43.7
36 36 59 24.7 47.2 3.3 2000 1941.3 671.1 59.2
36 36 60 24.4 70.8 7.7 1500 1472.9 1188.2 70.0
35 35 62 23.6 159.6 26.0 1000 1016.9 2769.9 72.3
33 33 59 21.7 400.4 85.1 500 559.9 4991. 7 52.0
36 39 39 63 37.7 26.6 0.0 5000 4771.4 0.0 0.0
40 40 62 37.6 30.7 0.5 4500 4311.4 225.8 20.4
40 40 59 37.5 35.0 1.2 4000 3842.5 483.1 38.3
40 40 _60 37.3 41.0 2.0 3500 3377.2 707.6 47.9
40 40 60 37.4 49.4 3.5 3000 2886.8 1058.5 59.5
40 40 60 37.1 63.5 6.1 2500 2422.9 1548.4 67.7
39 39 61 36.6 98.2 12.7 2000 1967.6 2617.9 74.1
39 38 64 35.4 195.1 33.0 1500 1524.8 5271.5 75.1
44 44 80 33.3 402.6 82.1 1000 1086.5 9345.1 64.5
Table 1 Cont'd.
PRESTOLITE MODEL MTC-400 1 DC HOT OR
DEN3-123
GENERAL ELECTRIC EV-1 CONTROLLER
PRESTOLITE STRAIGHT DC TESTS, 25-45
0
C TEMPERATURE RANGE
MOTOR
COMPENSATED COMPENSATED
BATTERY FIELD MOTOR INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT
TAP
TEMP (OC) ARMATURE VOLTAGE CURRENT TORQUE SPEED SPEED POWER EFFICIENCY
(VOLTS) #1 112
TEMP (OC) (VOLTS) (AMPS) (Nm) (RPM) (RPM) (WATTS) (%)
64 42 42 58 66.5 55.8 4.2 5000 4814.7 2118.5 59.3
43 43 56 66.1 66.2 6.1 4500 5356.1 2783.8 65.7
43 43 59 65.7 83.0 9.4 4000 3897.7 3838.4 72.3
44 44 58 65.0 111.3 15.1 3500 3443.8 5447.9 76.5
43 43 60 64.0 167.3 26.7 3000 3000.8 8393.8 78.4
42 42 60 62.3 270.0 49.5 2500 2570.8 13331.7 77 .2
44 44 70 59.5 434.2 88.3 2000 2158.5 19967.5 71.9
80 39 39 45 82.4 82.5 9.1 5000 4852.5 4626.1 70.1
41 41 43 81.6 105.3 13.6 4500 4411.0 6284.7 74.6
41 41 45 80.5 144.0 21.9 4000 3973.2 9115.8 79.1
41 41 47 79.1 209.7 36.3 3500 3539.7 13461. 2 80.2
39 38 44 77 .1 315.5 61.0 3000 3117.9 19925.2 78.9
45 45 55 73.9 459.8 95.8 2500 2714.7 27245.7 74.1
96 45 45 52 97.4 127.3 18.2 5000 4927.5 9395.3 76.9
45 45 52 96.7 146.9 22.1 4750 4716.9 10920.9 77.4
44 44 58 95.9 172.1 27.4 4500 4504.7 12930.9 78.3
45 45 59 95.1 203.7 34.5 4250 4290.0 15505.6 79.3
44 44 61 94.1 242.2 43.6 4000 4081.3 18642.2 80.2
44 43 62 93.0 289.2 54.0 3750 3874.1 21916.7 78.9
43 43 67 91.6 347.0 68.0 3500 3672.2 26160.5 78.5
44 43 69 90.2 403.7 82.6 3250 3463.7 29973.1 77 .3
44 44 80 89.1 468.7 99.0 3000 3239.0 33593.7 74.7
w
......
Table 2
w
CX)
PRESTOLITE MODEL MTC-4001 DC MOTOR
DEN3-123
GENERAL ELECTRIC EV-l CONTROLLER
PRESTOLITE STRAIGHT DC TESTS, 130-150
o
C TEMPERATURE RANGE
MOTOR
COMPENSATED COMPENSATED
BATTERY FIELD MOTOR INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT
TAP TEMP (OC) ARMATURE VOLTAGE CURRENT TORQUE SPEED SPEED POWER EFFICIENCY
(VOLTS) #1 12 TEMP (OC) (VOLTS) (AMPS) (Nm) (RPM) (RPM) (WATTS) (X)
16 143 143 174 16.5 23.6 0.2 2500 2421.1 50.7 13.4
143 143 174 16.4 30.3 0.9 2000 1948.6 183.7 37.9
143 143 176 16.4 41.8 2.6 1500 1461.3 398.0 59.5
143 143 177 16.1 69.0 7.6 1000 992.6 790.3 71.6 .
142 142 179 15.4 182.0 32.0 500 522.3 1751.0 60.1
142 142 176 14.6 305.1 61.5 250 277 .6 1788.6 36.6
24 145 145 169 24.9 25.4 0.6 3500 3379.5 212.4 34.8
145 145 168 24.8 31.2 1.1 3000 2902.5 334.5 44.7
146 145 170 24.7 38.1 2.0 2500 2428.5 508.8 55.6
146 145 172 24.6 50.3 3.9 2000 1953.3 798.1 66.1
145 145 174 24.3 75.1 8.7 1500 1479.0 1348.0 74.8
145 144 174 23.6 155.9 25.9 1000 1017.7 2761.4 73.8
144 143 173 22.0 359.7 75.1 500 550.6 4331.9 50.2
36 144 144 160 37.3 25.9 0.6 5000 4822.8 303.2 32.5
144 144 161 37.2 30.0 1.0 4500 4350.2 455.7 42.2
145 145 162 37.2 35.5 1.7 4000 3873.7 689.9 54.0
145 145 162 37.0 41.9 2.7 3500 3401.6 962.2 63.8
146 146 165 36.9 51.0 4.2 3000 2924.9 1286.9 70.1
146 146 166 36.7 66.2 7.0 2500 2451.8 1798.0 75.4
146 146 167 36.3 98.4 13.6 2000 1981. 3 2822.9
79.7
145 144 167 35.5 185.8 32.4 1500 1524.1 5173.3 77 .3
145 145 165 33.5 367.3 75.4 1000 1080.1 8531. 9 64.5
Table 2 Cont'd.
PRESTOLITE MODEL MTC-4001 DC MOTOR
DEN3-123
GENERAL ELECTRIC EV-1 CONTROLLER
PRESTOLITE ELECTRIC STRAIGHT DC TESTS, 130-150
o
C TEMPERATURE RANGE
MOTOR
COMPENSATED COHPENSATED
BA:'TERY FIELD MOTOR INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT
rAP TEMP (OC) ARMATURE VOLTAGE CURRENT TORQUE SPEED SPEED POWER EFFICIENCY
(VJLTS) ffl #2
TEMP (OC) (VOLTS) (A..''''PS) (Nm) (RPM) (RPM) (WATTS) (%)
64 139 139 136 65.8 53.0 4.5 5000 4863.8 2292.9 67.6
140 140 134 65.5 63.8 6.6 4500 4394.1 3038.3 74.4
141 141 135 65.2 79.8 9.6 4000 3925.8 3948.3 77 .3
140 139 136 64.7 109.3 15.4 3500 3464.4 5589.3 79.9
141 140 138 63.6 163.7 27.0 3000 3020.8" 8544.7 81.6
142 141 138 62.2 257.7 48.5 2500 2576.4 13090.8 79.4
141 141 142 59.7 391.5 81.0 2000 2148.9 18235.3 72.8
80 138 138 136 81.8 79.1 9.2 5000 4890.3 4713.4 74.5
139 139 136 81.1 101.6 13.6 4500 4436.6 6321. 2 77.8
141 141 138 80.3 138.1 21.1 4000 3985.7 8810.5 79.7
142 142 140 78.9 201.0 34.9 3500 3549.6 12978.3 80.7
145 145 145 76.9 294.6 57.4 3000 3123.2 18781.2 79.7
146 146 146 74.1 430.1 90.5 2500 2706.5 25660.7 74.6
96 139 138 119 96.7 123.4 17.9 5000 4962.7 9306.4 78.6
139 139 117 96.3 144.4 22.2 4750 4736.7 11016.4 79.5
141 141 117 95.6 166.6 27.0 4500 4520.6 12787.1 80.0
141 141 118 94.8 196.5 33.7 4250 4305.3 15200.0 80.6
144 144 122 94.0 233.0 41.7 4000 4085.0 17845.9 79.8
143 143 115 93.0 273.2 51.5 3750 3873.2 20897.2 79.7
145 144 117 91.9 322.5 62.9 3500 3660.3 24120.1 77 .9
146 146 126 90.3 379.6 78.0 3250 3462.6 28294.9 77 .6
146 147 133 89.2 448.1 93.9 3000 3236.1 31834.6 74.0
w
~
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o
MOTOR
INPUT TEMPERATURE OC
Table 3
PRESTOLITE MODEL MTC-4001 DC MOTOR
GENERAL ELECTRIC EV-l CONTROLLER
PRESTOLITE CHOPPED DC TESTS, 25-45
0
C TEMPERATURE RANGE, 96 VOLTS CONTROLLER INPUT TAP
CHOPPER
INPUT
CHOPPER CHOPPER
INPUT OUTPUT
DEN3-123
MOTOR OUTPUT
VOLTAGE FIELD FIELD VOLTAGE
CHOPPER
INPUT
CURRENT
(AMPS)
AVG. . RMS
POWER VOLTAGE
CHOPPER
OUTPUT
CURRENT
(AMPS)
AVG. RMS
CHOPPER
OUTPUT
POWER
(WATTS)
SPEED TORQUE POWER EFFICIENCY
NOMINAL 11 12 ARMATURE AVG. RMS (WATTS) AVG. RMS (RPM) (Nm) (WATTS) (%)
16
24
36
38
38
39
40
40
43
41
42
42
43
44
44
45
40
41
42
43
41
42
43
42
45
38
38
39
39
40
42
41
42
42
43
44
44
45
40
40
42
43
41
42
43
41
45
57
57
57
57
59
64
60
60
61
61
62
63
68
60
61
59
62
62
63
65
66
73
100.5 102.1 14.8 40.2 1392.3
100.1101.7 16.6 43.4 1528.8
99.9 101.5 19.0 48.4 1571.1
99.4 101.1 25.5 62.9 2343.9
95.3 9 8 ~ 2 71.1 151.9 5186.8
87.9 92.9 147.8 268.5 8748.5
15.8 36.9 27.2 49.7
16.0 38.5 34.3 55.2
59.9 39.2 44.6 63.8
16.0 39.1 73.1 90.5
15.8 35.1 220.3 240.6
15.6 33.6 409.0 423.2
1334.9 2500
1495.0 2000
1706.7 1500
2258.0 1000
4715.3 500
7731.5 250
100.0 101.6 18.3 43.0 1753.7 23.7
99.7 101.2 20.4 46.1 1930.2 23.8
99.4 100.9 24.0 51.8 2277.4 24.3
99.0 100.5 28.2 58.6 2657.6 24.2
98.2 99.9 36.9 74.1 3350.4 24.2
94.9 97.2 76.0 141.9 6107.7 24.0
74.9 82.4 298.3 409.7 16149.8 25.1
100.0 101.5 23.7 45.5 2320.4 35.4
99.7 101.1 25.8 48.5 2453.0 35.5
99.2 100.8 28.9 52.7 2799.6 35.7
98.7 100.3 32.1 56.2 3121.6 35.7
98.3 99.9 37.0 63.6 3493.8 35.5
97.4 98.9 44.3 75.0 4122.9 35.9
96.0 97.8 61.6 101.4 5509.6 35.9
90.7 93.2 122.8 185.5 9667.8 35.8
69.6 75.9 362.9 436.1 20531.6 35.8
44.5 27.7 49.9 1726.3
45.4 133.3 54.6 1881.3
47.8 40.8 62.3 2222.5
48.4 52.9 72.2 2589.9
47.7 78.4 96.2 3228.9
45.1 174.4 197.2 5796.3
40.3 518.6 525.4 14702.3
53.9 28.6 48.2 2179.9
54.8 32.4 52.2 2380.8
56.0 37.2 56.8 2642.2
56.9 43.2 62.3 2939.6
57.6 52.3 71.0 3347.2
58.2 67.6 85.4 3955.5
57.5 102.6 120.4 5291.1
53.8 204.3 224.5 9024.9
45.6 485.9 494.4 18813.4
3500
3000
2500
2000
1500
1000
500
5000
4500
4000
3500
3000
2500
2000
1500
1000
0.6
1.4
3.0
8.1
40.8
89.4
0.6
1.3
2.3
4.3
9.0
30.1
118.0
0.6
1 .1
1.7
2.7
4.2
7.0
13.8
36.1
106.8
157.1
293.3
471.4
848.6
2137.2
2341.5
220.0
408.6
602.4
901.0
1414.3
3153.4
6181.1
314.3
518.6
712.4
990.0
1320.0
1833.4
2891.5
5672.9
11188.8
11.7
19.6
27.6
37.6
45.3
30.3
12.7
21.7
27.1
34.8
43.8
54.4
42.0
14.4
21.8
27.0
33.7
39.4
46.4
54.6
62.9
59.5
~
~
Table 3 Cont1d.
PRESTOLITE MODEL MTC-4001 DC MOTOR
GENERAL ELECTRIC EV-l CONTROLLER
DEN3-123
PRESTOLITE CHOPPED DC TESTS, 25-45
0
C TEMPERATURE RANGE, 96 VOLTS CONTROLLER INPUT TAP
MOTOR
INPUT TEMPERATURE OC
VOLTAGE FIELD FIELD
CHOPPER
INPUT
VOLTAGE
CHOPPER
INPUT
CURRENT
(AMPS)
NOMINAL 11 12 ARMATURE AVG. RMS AVG. RMS
CHOPPER
INPUT
POWER
(WATTS)
64
80
96
42
43
43
42
41
40
45
40
42
44
44
45
45
39
40
41
41
41
41
40
44
42
43
42
42
41
40
45
40
42
44
43
44
45
39
40
41
41
41
40
39
43
55
56
59
60
62
64
65
54
56
57
59
59
61
48
50
56
55
58
59
61
62
97.1
96.1
94.7
93.2
88.2
78.3
64.8
94.7
92.4
89.5
98.5 51.1 66.0
97.5 58.7 75.0
96.3 72.3 91.0
94.8 95.1 117.6
4950.4
5608.5
6796.2
8697.6
90.0 147.1 174.3 12547.5
80.3 266.2 291.3 20191.3
66.4 422.7 435.1 27796.6
96.0 77.6 86.7 7433.6
93.8100.6110.2 9410.8
90.2 140.9 150.3 12680.5
83.6 84.2 209.2 215.3 17672.3
78.7 79.3 269.6 277.3 21411.9
71.6 73.0 345.3 351.7 25081.2
92.9
92.3
90.3
89.3
88.3
85.1
83.9
80.8
94.1104.1107.3 9948.6
92.9114.7117.910824.0
92.0 127.6 131.1 11824.8
90.0 145.5 148.8 13190.0
88.6 164.7 168.0 14628.8
86.5185.4190.216162.7
84.7 211.5 218.2 17989.4
81.9241.8246.019884.3
CHOPPER
OUTPUT
VOLTAGE
CHOPPER
OUTPUT
CURRENT
(AMPS)
CHOPPER
OUTPUT
POWER
(WATTS) AVG. RMS AVG. RMS
63.2 77.1 56.3 68.6 4779.9
62.9 76.8 66.8 78.9 5463.6
63.1 76.8 83.6 96.3 6617.7
63.1 76.0 111.7 125.3 8479.5
63.2 73.4170.1184.312170.8
62.4 68.2 290.7 302.0 19377.2
58.4 61.2 432.2 444.1 26562.6
78.7 85.7 82.3 89.2 7270.2
79.6 85.3 106.1 113.0 9186.4
78.9 83.3 146.9 153.7 12347.3
78.2 80.0 212.9 217.7 17163.4
72.7 74.6 277.1 280.3 20633.9
66.8 68.0 352.6 357.6 23952.2
88.5
87.5
86.5
84.7
82.4
81.2
78.4
76.1
90.5 105.8 109.0 9794.4
89.1 117.3120.010685.3
87.9 130.3 133.3 11640.6
86.4 148.9 152.1 13036.4
84.4 167.7 170.2 14407.3
82.7 190.1 193.8 15930.9
80.4 217.2 222.1 17688.7
77.6 246.3 250.3 19198.6
MOT 0 R 0 U T PUT
SPEED TORQUE POWER EFFICIENCY
(RPM) (Nm) (WATTS) ( ~ )
5000
4500
4000
2500
3000
2500
2000
5000
4500
4000
3500
3000
2500
5000
4750
4500
4250
4000
3750
3500
3250
4.6
6.5
9.6
15.2
27.7
55.4
91.0
9.0
13.8
22.2
36.8
51.8
69.4
13.6
15.9
18.7
22.3
26.5
31.3
37.4
43.9
2409.7
3064.3
4022.9
5573.4
8705.9
14509.8
19067.0
4714.4
6505.8
9303.0
13493.6
16280.3
18176.5
7123.9
7912.3
8815.9
9929.0
11104.9
12296.7
13713.6
14947.2
50.4
56.1
60.8
65.7
71.5
74.9
71.8
64.8
70.8
75.3
78.6
78.9
75.9
72.7
74.0
75.7
76.2
77.1
77.2
77 .5
77.9
~
N
Table 4
PRESTOLITE MODEL MTC-4ool DC MOTOR
GENERAL ELECTRIC EV-I CONTROLLER
DEN3-123
PRESTOLITE CHOPPED DC TESTS, 25-45
0
C TEMPERATURE RANGE, 80 VOLTS CONTROLLER INPUT TAP
MOTOR CHOPPER
CHOPPER
INPUT
CURRENT
(AMPS)
CHOPPER CHOPPER.
CHOPPER
OUTPUT
CURRENT
(AMPS)
CHOPPER
OUTPUT
POWER
( WATTS)
INPUT TEMPERATURE OC INPUT I NPUT OUTPUT
VOLTAGE FIELD FIELD VOLTAGE POWER VOLTAGE
NOMINAL 11 12 ARMATURE AVG. RMS AVG. RMS (WATTS) AVG. RMS AVG. RMS
16
24
36
39
39
43
44
44
45
41
40
41
41
41
42
45
38
39
40
40
40
41
41
40
37
39
39
43
43
44
45
40
40
41
41
41
42
45
38
39
40
40
40
41
40
40
36
63
63
65
66
70
84
70
70
69
71
71
72
76
53
55
55
57
58
62
62
63
65
83.0
82.8
82.4
81.8
76.6
67.9
83.0
82.8
82.4
82.1
81.2
77.2
57.1
82.8
82.5
82.1
81.9
81.3
80.7
78.8
73.4
49.0
84.1 13.9
83.8 16.7
83.4 19.6
83.1 26.8
79.4 86.0
74.2 179.7
34.7
38.8
44.3
58.9
159.4
284.0
1100.7
1313.3
1540.1
2045.0
5012.4
8150.7
15.9
16.3
16.2
16.1
16.0
15.6
84.2 18.8 38.3 1506.6 23.6
83.9 21.3 42.2' 1721.3 24.0
83.6 24.0 45.8 1907.5 24.0
83.4 27.9 52.6 2209.9 23.7
82.8 37.0 68.0 2842.7 23.6
79.5 83.4 139.4 5556.3 23.3
64.5 319.1 402.1 13654.7 23.0
83.8
83.4
83.3
82.9
82.2
81.9
80.5
24.0 40.6
26.1 43.3
28.8 46.5
33.1 51.7
87.8 57.9
46.8 70.5
66.0 97.0
1979.1
2126.1
2338.7
2656.4
3008.3
3690.4
4945.2
76.4. 135.5 183.1 8945.4
53.3 429.5 464.9 19127.0
35.8
35.6
35.4
35.8
35.7
35.9
35.7
35.5
34.7
34.1 24.2 41.7
35.9 32.4 48.6
36.0 43.0 57.1
35.7 70.9 83.3
31 .3 227.3 241 .6
28.9 404.6 414.3
1058.2
1280.5
1471.7
1969.3
4590.3
7077 .1
41.527.143.41461.1
43.1 32.5 48.7 1700.7
43.7 39.2 54.0 1865.1
43.8 50.4 64.2 2161.2
43.0 74.4 87.5 2768.7
40.7 171.5 188.0 5245.2
33.2 482.7 488.8 12053.2
51.2 28.7 43.3 1869.2
51.6 32.0 46.3 2025.3
52.2 36.5 51.0 2236.3
53.1 43.7 56.8 2519.1
53.3 51.9 64.0 2852.2
53.2 68.4 80.4 3513.0
51.9 100.6 113.4 4659.2
49.0 201.1 215.3 8397.9
38.5 477.5 476.9 17309.0
MOT 0 R 0 U T PUT
SPEED TORQUE POWER EFFICIENCY
(RPM) (Nm) (WATTS) (%)
2500
2000
1500
1000
500
250
3500
3000
2500
2000
1500
1000
500
5000
4500
4000
3500
3000
2500
2000
1500
1000
0.5
0.8
2.9
7.9
41.9
87.6
0.5
1.1
2.1
4.0
8.5
28.6
107.5
0.5
1.0
1.6
2.6
4.0
6.9
13.6
35.5
104.5
131.0
167.6
455.7
827.6
2194.8
2294.3
183.3
345.7
550.0
838.1
1335.7
2996.2
5631.1
261.9
471.4
670.5
953.4
1257.2
1807.2
2849.6
5578.7
10947.8
12.4
13.1
31.0
42.0
74.8
32.4
12.5
20.3
29.5
38.8
48.2
57.1
46.7
14.0
23.3
30.0
37.8
44.1
51.4
61.2
66.4
63.2
MOTOR
INPUT
VOLTAGE
NOMINAL
~
w
64
80
Tablo 4 Cvnt'd.
---_ .. - ---_.-
PRSTOLITE MODEL MTC-4001 DC MOTOR
GENERAL ELECTRIC EV-l CONTROLLER
PRESTOLITE CHOPPED DC TESTS, 25-45
0
C TEMPERATURE RANGE, 80 VOLTS CONTROLLER INPUT TAP
CHOPPER CHOPPER
CHOPPER INPUT CHOPPER CHOPPER OUTPUT CHOPPER
TEMPERATURE OC INPUT CURRENT INPUT OUTPUT CURRENT OUTPUT
FIELD FIELD VOLTAGE (AMPS) POWER VOLTAGE (AMPS) POWER SPEED
11 12 ARMATURE AVG. RMS AVG. RMS (WATTS) AVG. RMS AVG. RMS ( WATTS) (RPM)
44 44 52 80.5 81.4 52.8 60.5 4293.2 63.5 71.0 55.5 61.7 4123.6 5000
45 45 53 79.9 80.6 61.4 69.7 4949.9 63.2 70.7 66.0 72.1 4817 .6 4500
45 45 54 78.3 79.1 77.1 86.6 6100.7 63.5 70.2 83.8 90.3 5942.9 4000
45 45 55 76.3 77.1 103.0 113.8 7859.9 63.0 68.7 110.7 117.6 7649.6 3500
45 45 57 71.1 72.0 163.4 172.4 11658.4 62.9 65.9 171.4 175.8 11231.0 3000
45 45 58 64.8 65.4 245.3 250.3 16097.7 59.4 61.3 249.9 253.4 15385.6 2500
45 45 59 58.1 59.3 319.8 324.9 18951.3 52.8 54.1 327.7 333.8 17703.8 2000
40 39 50 78.9 79.3 72.2 74.0 5804.8 74.9 76.6 73.8 75.4 5708.7 5000
42 41 51 78.1 78.3 86.0 88.0 6786.3 73.3 75.2 89.3 90.0 6673.1 4500
41 41 54 75.4 76.6 105.9 108.9 8183.8 71.9 73.3 108.9 111.7 7924.4 4000
40 39 55 13.5 73.8 137.1 140.5 10158.4 68.5 70.4 140.3 142.9 9949.0 3500
39 39 59 69.6 70.1 182.6 187.0 12875.0 64.5 66.7 187.5 190.4 12404.B 3000
45 45 60 64.6 65.1 244.4 248.6 15971 .3 59.7 61.3 249.3 251.9 15359.6 2500
D ~ ' ; 3 - 1 ~ 3
MOT 0 R OUT PUT
TORQUE POWER EFFi:IENCY
(Nm) (lI/AnS) ( %1
4.3 2252.4 54.6
6.2 2922.9 60.7
9.5 3981.0 6
7
.0
14.9 5463.4 71.4
27.3 8580.2 76.4
45.3 11864.5 77 .1
64.2 13451.7 76.0
7.6 3981.0 69.7
10.3 4855.8 72.8
14.5 6076.3 76.7
21.0 7700.1 7
7
.4
31.2 9805.9 79.0
45.3 11864.5 71.2
"'"
"'"
Table 5
PRESTOLITE MODEL MTC-4002 DC MOTOR
GENERAL ELECTRIC EV-l CONTROLLER
PRESTOLITE CHOPPED DC TESTS, 130-150
o
C TEMPERATURE RANGE, 96 VOLTS CONTROLLER INPUT TAP
MOTOR. CHOPPER CHOPPER CHOPPER
INPUT TEMPERATURE OC INPUT I NPUT OUTPUT
DEN3-123
MOT 0 R 0 U T PUT
VOLTAGE FIELD FIELD VOLTAGE
CHOPPER
INPUT
CURRENT
(AMPS) POWER VOLTAGE
CHOPPER
OUTPUT
CURRENT
(AMPS)
AVG. RMS
CHOPPER
OUTPUT
POWER
(WATTS)
SPEED TORQUE POWER EFFICIENCY
NOMINAL 11 12 ARMATURE AVG. RMS AVG. RMS (WATTS) AVG. RMS (RPM) (Nm) (WATTS) (%)
36
64
80
141
141
142
142
143
145
146
145
143
141
141
144
145
142
147
136
137
137
137
135
139
141
141
142
142
143
145
145
144
143
141
141
144
145
142
147
135
137
137
137
135
139
173
175
176
179
181
182
184
186
187
149
150
153
156
156
157
155
156
158
159
159
159
98.8
98.3
97.8
97.7
97.1
96.3
94.6
89.5
74.1
99.8 22.8 43.4 2225.7
99.3 25.3 46.9 2442.2
99.0 28.4 50.7 2724.7
99.1 32.3 57.3 3152.2
98.2 37.2 63.2 3522.8
97.8 45.6 76.1 4258.3
96.7 62.5 103.1 5659.6
92.7 125.6 188.3 9845.6
80.2 305.2 380.9 18367.8
35.8 55.1 29.0 47.5 2145.0 5000
35.8 56.1 33.2 51.3 2337.0 4500
36.2 57.2 37.9 55.7 2608.9 4000
36.4 58.4 44.4 63.2 2978.3 3500
36.3 58.9 54.5 71.7 3390.9 3000
36.5 59.0 72.3 88.8 4071.4 2500
36.4 57.9 105.6 124.5 5456.5 2000
36.1 54.4 208.7 229.4 9449.5 1500
35.9 48.0 432.0 441.1 17249.1 1000
95.5 97.0 51.1 65.5 ~ 9 2 5 . 1 62.9
94.9 96.4 58.0 73.5 5550.8 63.4
93.6 95.2 73.6 92.3 6919.8 63.4
91.3 93.2 99.0 120.8 8950.2 63.4
86.4 88.2 153.6 180.3 12909.5 63.0
75.4 78.0 280.4 299.6 20809.3 63.1
93.5 94.7 79.3 87.5 7508.0 79.4
91.5 92.7 100.3 109.7 9288.1 79.1
87.5 89.0 145.3 153.3 12877.4 79.4
82.6 83.5 206.0 211.3 17281.7 77.6
77.6 78.6 265.4 272.1 20902.8 72.8
71.5 73.0 333.5 339.7 23983.0 65.7
76.9 57.9 70.0 4793.4
77.5 66.4 77.6 5353.0
77.1 86.6 99.2 6721.2
75.2 116.9 129.6 8716.1
72.7 179.9 193.1 12566.2
67.7 302.6 309.9 20031.2
85.9 83.7 89.6 7374.1
84.6 106.1 112.6 9115.2
82.8 151.3 156.2 12637.7
79.4210.5214.6 16797.0
74.5 271.5 275.7 20512.6
67.3 341.3 345.7 23292.0
5000
4500
4000
3500
3000
2500
5000
4500
4000
3500
3000
2500
1.0
1.6
2.2
3.2
4.8
8.0
15.1
37.2
91.1
5.6
7.5
10.8
17.1
30.4
58.8
9.9
14.5
23.8
36.9
51.0
68.5
523.8
754.3
921.9
1173.4
1508.6
2095.3
3163.9
5845.8
9544.0
2933.4
3535.8
4525.8
6270.1
9554.5
15400.3
5185.8
6835.8
9973.5
13530.2
16028.9
17940.8
24.4
32.3
35.3
39.3
44.4
51.5
58.0
61.9
55.3
61.2
66.1
67.3
71.9
76.0
76.9
70.3
75.0
78.9
80.6
78.1
77.0
~
(.J1
MOTOR
INPUT
VOLTAGE
NOMINAL
96
Tablo 5 Cont1t.
- -
PRESTOLITE MODEL MTC-4002 DC MOTOR
GENERAL ELECTRIC EV-1 CONTROLLER
PRESTOLITE CHOPPED DC TESTS, 130-150
o
C TEMPERATURE RANGE, 96 VOLTS CONTROLLER INPUT TAP
CHOPPER CHOPPER
CHOPPER INPUT CHOPPER CHOPPER OUTPUT CHOPPER
TEMPERATURE OC INPUT CURRENT INPUT OUTPUT CURRENT OUTPUT
FIELD FIELD VOLTAGE (AMPS) POWER VOLTAGE (AMPS) POWER SPEED
11 12 ARMATURE AVG. RMS AVG. RMS (WAITS) AVG. RMS AVG. RMS (WATTS) (RPM)
139 139 158 91.8 92.6 101.0 103.9 9467.0 87.5 89.3 103.4 105.7 9347.1 5000
140 139 160 90.2 91.6 112.4 115.2 10342.2 87.0 88.3 114.7 116.8 10241.6 4750
142 142 162 89.3 90.1 124.3 127.8 11363.9 85.9 87.1 127.0 130.0 11163.2 4500
144 144 164 88.5 88.9 140.6 144.5 12589.6 83.2 85.7 143.7 146.8 12389.6 4250
142 142 166 85.6 87.2 158.4 162.0 13871.9 82.0 83.9 161.5 164.6 13621.6 4000
141 141 166 84.3 85.5 180.1 184.8 15446.3 80.7 82.0 185.4 188.4 15203.5 3750
137 137 167 82.7 83.4 206.9 211.8 17310.8 78.1 80.0 211.6 215.1 16952.8 3500
145 145 168 80.3 81.4 230.4 237.1 18818.6 76.5 77.7 238.1 239.1 18307.9 3250
DEN3-123
MOT 0 R OUT PUT
TORQUE POWER EFF ICIENCY
(Nm) (WATTS) (%>
13.7 7176.3 76.7
15.9 7912.3 77 .3
18.8 8863.0 79.4
22.2 9884.5 79.8
26.2 10979.2 80.6
31.0 12178.8 80.1
36.6 13420.2 79.2
42.7 14538.6 79.4
-I=a
0'1
Table 6
PRESTOLITE MODEL MTC-4002 DC MOTOR
GENERAL ELECTRIC EV-l CONTROLLER
DEN3-123
PRESTOLITE CHOPPED DC TESTS, 130-150
o
C TEMPERATURE RANGE, 80.VOLTS CONTROLLER INPUT TAP
CHOPPER
CHOPPER
INPUT
CURRENT
(AMPS)
CHOPPER CHOPPER
CHOPPER
OUTPUT
CURRENT
(AMPS)
CHOPPER
OUTPUT
POWER
(WATTS)
INPUT TEMPERATURE OC INPUT I NPUT OUTPUT
VOLTAGE FIELD FIELD VOLTAGE POWER VOLTAGE
NOMINAL 11 12 ARMATURE AVG. RMS AVG. RMS (WATTS) AVG. RMS AVG. RMS
36
64
80
141
142
143
142
143
143
142
143
138
139
141
141
140
144
131
131
133
132
131
134
141
142
143
142
142
142
142
143
1'38
138
140
140
139
143
131
131
132
132
131
134
171
172
175
176
178
181
182
182
170
172
175
175
177
178
173
174
176
178
179
181
82.1
81.9
81.7
81.1
80.5
78.1
72.3
53.9
79.4
78.6
76.9
74.6
69.8
64.2
18.2
76.4
74.5
72.0
69.0
63.8
83.1 24.2 39.8 1971.0
82.7 26.5 42.5 2142.3
82.3 29.3 46.1 2359.1
82.1 33.2 51.1 2650.3
81.9 38.8 58.9 3082.7
79.7 68.3 100.1 5062.8
75.3 139.8 187.8 9147.2
58.4 361.9 402.5 17312.7
80.0 52.0 59.1 4203.3
79.4 60.6 69.2 4851.7
78.1 76.3 85.2 5973.2
75.5 103.7 113.8 7761.0
70.5 164.6 172.0 11546.7
64.6 238.8 243.0 15240.1
78.4 70.5 72.5
77.3 84.7 86.8
75.4 105.1 108.0
5611.3
6641.4
8022.5
73.1 135.7 139.0 9970.6
69.5 178.3 183.3 12449.7
64.3 128.6 242.7 15238.9
36.2
36.3
36.4
36.5
36.5
36.3
36.6
36.0
63.0
62.9
63.4
62.9
62.8
59.3
73.7
72.9
71.6
68.2
64.0
59.3
52.4 29.1 41.7 1889.5
53.2 32.8 46.3 2056.3
54.0 36.9 49.9 2243.6
44.1 55.9 2547.4
54.2 53.9 65.7 2966.7
52.5 104.1 116.2 4877.9
50.1 203.7 218.8 8849.9
42.3 428.8 438.3 16445.6
70.6 55.8 61.1 4060.1
70.5 65.5 72.2 4646.7
69.7 82.9 88.5 5743.5
60.1111.1117.2 7507.5
171.9 176.2 11234.5
60.9 245.7 248.7 14734.7
75.6 73.5 74.8 5496.8
74.5 87.1 891.0 6484.7
72.5 108.3 110.5 7862.4
69.9 139.9 141.9 9799.5
65.9 184.9 187.9 12241.9
60.6 245.9 247.4 14793.9
MOTOR OUTPUT
SPEED TORQUE POWER EFFICIENCY
(RPM) (Nm) (WATTS) (%)
5000
4500
4000
3500
3000
2000
1500
1000
5000
4500
4000
3500
3000
2500
5000
4500
4000
3500
3000
2500
0.8
1.3
2.0
2.9
4.3
14.2
35.8
89.7
5.2
6.8
10.3
16.1
28.8
45.2
8.1
10.8
15.0
21.5
31.5
45.4
419.1
612.7
838.1
1063.4
1351.5
2975.3
5625.8
9397.3
2723.9
3205.8
4316.3
5903.4
9051.6
11838.3
4242.9
5091.5
6285.8
7883.5
9900.2
11890.7
22.2
29.8
37.4
41.7
45.6
61.0
63.6
57.1
67.1
69.0
75.2
78.6
80.6
80.3
77.2
78.5
79.9
80.4
80.9
80.4
11
1i01M,,1 Nu I 2. GovII"mlnl Acc,ulon No. l. R.cllllftnl', rA'lluu Nt)
NASA CR-165382
4. Tolle and Sublotle STRAIGHT AND CHOPPED DC PERFORMANCE
5. Report D ~ l e
AprU 1981
DA TA FOR A PRESTOLITE MTC-4001 MOTOR AND A GENERAL 6. Performing Organization Code
ELECTRIC EV-l CONTROLLER 778-36-06
7. Author(s) 8. Performing Organization Report No.
Paul C. Edie ERC TR- 80169
10. Work Unit No.
9. Performing Organization Name .nd Address
Eaton Corporation
Engineering & Research Center
11. ContrlCt or Grant No.
26201 Northwestern Hwy., P.O. Box 766 DEN 3-123
Southfield, Michigan 48037
13. Type of Report and Period Covered
12. Spon.oring Agencv Nlme Ind Addr ....
Contractor Report
U. s. Department of Energy
14. Sponsoring Agency Code
Office of Transportation Programs
DOE/NASA/0123-2
.
Washington D. C. 20585
15. Supplemenlary Note.
Final Report. Report prepared under Interagency Agreement DE-AIOl-77CS 51044,
Project
Manager, Edward F. McBrien, Transportation PropulSion Division, NASA Lewis Research
Center Cleveland. Ohio 44135
16. Ab.tract
I
Both straight and chopped DC motor performance data for a Prestolite MTC-4001 motor and a
General EI ectric EV -1 controller is presented in tabular and graphical formats.
Effects of motor
temperature and operating voltage are also shown.
The maximum motor efficiency is between
I
76% and 82%, regardless of temperature or mode of operation.
Chopper efficiency' can be as-
i
sumed to be 95% under all operating conditions.
For equal speeds, the motor operated in the
chopped mode develops Slightly more torque and draws more current than it does in the straight
DC mode.
I
I
17. Key Words (Suggested by Author(s))
18. Distribution Stltement
DC motors
Unclassified - unUmlted
Chopper controll er
STAR Category 33
Performance and efficiency
DOE Category UC-96
19. Securitv Classil. (01 this report)
1
20
. Security Cllssif. (of this page)
121. No. of Pages /22. Price
Unclassified
Unclassified
For sale by the National Technical Information Service, Springfield, Virginia 22161
NASAC-168 (Rev. 10-75)
End of Document