KANYAPUR

Govt. POLYTECHNIC
Of West Bengal

INDUSTRIAL
DRIVES
Syllabus

Course Code EEPE 301/2

Course Title INDUSTRIAL DRIVES

Number of Credits 3 (L:3,T: 0, P: 0)

Prerequisites NIL
Course Category PE

Course Objective
The aim of this course is to help the student to attain the following industry identified competency
through various teaching learning experiences –
• Maintain electric AC and DC Drives.

Contents (Theory): Hrs./Unit

12
Unit : 2 Special Motors
2.1 Characteristics, Control strategies and application of
a. DC servo motor
b. AC servomotor
07
c. Stepper motor
d. Brushless DC Motors.
2.2 Determination of Motor Rating.
2.3 Specification of motor.

Special Motors

Special motors refer to the term where any motor other than the general purpose motor has its
special operating capacity by customisation or manual design. There a various types of special
motors , which are as follows :

Department of Electrical Engineering, R.K. Mission Road, Asansol-05

Prepared by A.K. Majee, Lecturer in Electrical Engineering
 KANYAPUR
Govt. POLYTECHNIC
Of West Bengal

1. Stepper motor

2. Brushless DC motors

3. Universal motor

4. Servo motors

Servo Motor

A servomotor is a rotary actuator or linear actuator that allows for precise control of angular
or linear position, velocity and acceleration. It consists of a suitable motor coupled to a
sensor for position feedback. It also requires a relatively sophisticated controller, often a
dedicated module designed specifically for use with servomotors. For these reasons, the
Servomotor is often referred to as a "Premium Performance" alternative to a stepper motor
system.

An advantage of the Servomotor system is that the system "knows" it's location when it is
energized, based on the feedback system. In a stepper motor system, since there is no
feedback device, the controller must move the motor to a "specific" or "home" position
when it is started up in order to know where it's located. The better servomotors use rotary
encoders as the feedback device which offers excellent results.

The ultimate servomotor package will offer the customer a "Brushless AC Motor" having
permanent magnet fields. When this motor is coupled with a digital controller and encoder,
the customer can be assured of precise operation and long life.

Contact A.R.&E. for additional information and assistance in applying a "Servo" system to
your next project.

Stepper motor – The stepper motor is basically a "brushless DC motor, that converts input
digital Pulses into mechanical shaft rotation. It converts a train of Input pulses (square wave
pulses) into a precisely defined increment in the shaft position (a specified number of
degrees of rotation). Every pulse of the square wave moves the shaft of the stepper motor
through a fixed angle so we can define the stepper motor as “This is an electromechanical
device which actuates train of step movements of the shaft with respect to the train of input
pulses.. It is a brushless synchronous type of electric motor , the working principle of a
stepper motor is closely related to that of a switched reluctance motor, here the rotation is
purely controlled by the number of pulses received

The angle through which the motor rotates or shaft moves for each pulse is known as the
step angle  expressed in degrees.

Let

Department of Electrical Engineering, R.K. Mission Road, Asansol-05

Prepared by A.K. Majee, Lecturer in Electrical Engineering
 KANYAPUR
Govt. POLYTECHNIC
Of West Bengal

Nr  Number of rotor poles.

Ns  Number of stator poles

m  Number of phases.

360
Step angle β=
mNr

When Nr  Number of rotor poles.

Ns  Number of stator poles

(N ¿ ¿ s−N r )
Or β=360 NsNr
¿

The step angle decides the resolution of positioning of a stepper motor i.e. smaller the step
angle, the higher is the resolution of positioning of the motor.

The resolution or step number of a stepper motor is defined as the number of steps it
makes in one revolution of the rotor, i.e.,
Number of steps
Resolution=
Number of revolutions of the rotor

Hence, higher the resolution, the greater is the accuracy of positioning of objects by the
stepper motor.

1. Define: Stepper motor

Stepper motor is a motor which rotates step by step and not continuous rotation.
When the stator is excited using a DC supply the rotor poles align with the stator
poles in opposition such that reluctance is less.
2. What are the advantages of Stepper motor?
 Low cost for control achieved
 High torque at startup and low speeds
 Ruggedness
 Simplicity of construction

 Open loop operation (No feedback is normally required for either position control or
speed control, Positional control is non – cumulative, Stepping motor are compatible
with modern digital equipment )
 Low maintenance

Department of Electrical Engineering, R.K. Mission Road, Asansol-05

Prepared by A.K. Majee, Lecturer in Electrical Engineering
 KANYAPUR
Govt. POLYTECHNIC
Of West Bengal

 Will work in any environment

 High reliability
 Precise positioning and repeatability of movement since good stepper motors have an
accuracy of 3–5% of a step and this error is non-cumulative from one step to the
next.
 Excellent response to starting/stopping/reversing.
 Very reliable since there are no contact brushes in the motor. Therefore, the life of
the motor is simply dependent on the life of the bearing.
 It is possible to achieve very low-speed synchronous rotation with a load that is
directly coupled to the shaft.

3. Mention the different types of stepper motor?

Variable Reluctance stepper motor (Single stack, Multi stack), Permanent magnet
stepper motor, Hybrid stepper motor, Outer rotor stepper motor.
4. Mention the features of stepper motor?(Dec 13)
Small step angle, High positioning accuracy, High torque inertia ratio, Stepping rate,
Pulse frequency
5. Define: Step Angle of stepper motor?(June 2013, Dec 13, June 2016)
A stepping motor rotates through a fixed angle for every pulse. The rated value of
this angle is called the step angle and expressed in degrees.
6. Define: Holding torque and Detent torque of stepper motor? (Dec 15)
Holding torque is defined as the maximum static torque that can be applied to the
shaft of an excited motor without causing continuous rotation.
It is defined as the maximum static torque that can be applied to the shaft of an
unexcited motor without causing continuous rotation.
7. Define: Resolution of stepper motor?
It is defined as the accuracy of positioning of the rotor pole at a particular step angle
with respect to stator pole.
8. Define: Pull – in torque of stepper motor?
These are alternatively called the starting characteristics and refer to the range of
frictional load torque at which the motor can start and stop without loosing steps for
various frequencies in a pulse strain.
1. 9. Define: Pull – out torque of stepper motor?

2. Brushless DC motor – In this type of motor, the coils are not placed on the rotor. Instead,
the rotor itself is a permanent magnet. The rotation is achieved by changing the direction of
the magnetic field by stationary coils. To control the rotation, only the magnitude of and
direction of the current moving in these coils needs to be controlled.

3. Universal motor – Its working principle is identical to the DC series motor. They are
known as universal motors because they have the capacity to operate in both AC and
DCsupplies.

What is a Servo Motor?

Contents show

Department of Electrical Engineering, R.K. Mission Road, Asansol-05

Prepared by A.K. Majee, Lecturer in Electrical Engineering
 KANYAPUR
Govt. POLYTECHNIC
Of West Bengal

Definition of Servo Motor:

Ezoic

A servo motor is defined as a linear or rotary type of actuator that provides fast precision position
control for closed-loop position control applications.

As compared to large industrial electric motors, servo motors are not useful for continuous energy
conversion. These motors have a high-speed response due to how inertia and are designed with
small diameters and long rotor lengths.

Servo motors have a mechanism that uses position feedback to control the speed and final position
of the motor. Internally, a servo motor combines a motor, feedback circuit, controller, and another
electronic circuit.

These types of motors are best suited for smaller applications. With the advancement of
microprocessors and power transistors, AC servo motors are used more often due to their high
accuracy control.

Construction of Servo Motor

It uses an encoder or speed sensor to provide speed feedback and position. This feedback signal is
compared with the input command position (desired position of the motor corresponding to a load)
and produces the error signal (if there exists a difference between them).

Department of Electrical Engineering, R.K. Mission Road, Asansol-05

Prepared by A.K. Majee, Lecturer in Electrical Engineering
 KANYAPUR
Govt. POLYTECHNIC
Of West Bengal

The error signal available at the output of the error detector is not enough to drive the
motor. So the error detector followed by a servo amplifier raises the voltage and power level of the
error signal and then turns the shaft of the motor to the desired position.

Essentially, servo motors are divided into AC and DC servo motors based on the supply used for
their operation. Brushed permanent magnet servo motors are used for simple applications due to
their low cost, efficiency, and simplicity of working.

Parts of Servo Motor

Following are the main parts of a servo motor:

1. Housing

2. Motor shaft

3. Bearings

4. Rotor

5. Stator

6. Brake

7. Snap ring

8. O ring

9. Bearing keeper

Department of Electrical Engineering, R.K. Mission Road, Asansol-05

Prepared by A.K. Majee, Lecturer in Electrical Engineering
 KANYAPUR
Govt. POLYTECHNIC
Of West Bengal

10. Encoder

#1 Housing

It is about 1 inch thick coated aluminum housing that surrounds the inner parts of the servo motor
so that it protects the motor from external particles. The motor’s housing is designed for quick and
easy disassembly and reassembly.

#2 Motor Shaft

It works similar to a prime mover, whereas the gearbox or belt and pulley system to which it is
attached can use that energy to increase the motor’s torque while reducing the motor’s speed. The
motor is generally made from cold or hot-rolled steel.

#3 Bearings

Bearings can provide high accuracy and very low vibration to the motor. The result is a very smooth
and cool operation. Bearing life will be improved by using new greases and methods to reduce fret.

#4 Rotor

The rotor is usually attached to the shaft of the motor and is placed between two bearings. The
rotor is the moving part of the servo motor. With the given voltage, the rotor of the motor rotates
in the required direction until the error is zero.

#5 Stator

Department of Electrical Engineering, R.K. Mission Road, Asansol-05

Prepared by A.K. Majee, Lecturer in Electrical Engineering
 KANYAPUR
Govt. POLYTECHNIC
Of West Bengal

It is the stationary part of the servo motor. The function of the stator is to create a rotating
magnetic field to generate torque efficiently. It is usually made up of 12 individually wrapped
winding segments connected by a single copper wire.

#6 Brake

Brakes are used to hold things when the machine is turned off or the E-stop is activated, it is made
up of only a few parts. Keep in mind that the spring will let go when voltage is applied, so care
should be taken when releasing the brakes as the motor will fall.

#7 Snap Ring

Using a snap ring minimizes damage to the motor while maintaining the shaft position after a direct
hit or nudge from an unwanted force. Without it, the shaft could easily slide back into the housing.

#8 O Ring

An O-ring is placed between the two parts to form a seal to stop fluid from entering. O rings are
made of plastic polymers and servo motors consist of multiple o-rings.

#9 Bearing Keeper

A bearing keeper is a handheld plate located close to the pulley end that prevents the bearing from
slipping out of place.

#10 Encoder

An encoder is an electro-mechanical device used to transmit the speed and direction of a motor
back to the drive. This allows the operator to observe and adjust certain parameters on demand.
These are light in weight and are quite compact.

Servo Motor Working Principle

The servo motor works on the principle of the pulse width modulation method. In this, the angle
of rotation is controlled by the duration of the applied pulse to its control pin. Essentially, the servo
motor is a type of DC motor controlled by a variable resistor (potentiometer) and some gears.

Read Also: What is a capacitor and how does it work?

Working of Servo Motor

Department of Electrical Engineering, R.K. Mission Road, Asansol-05

Prepared by A.K. Majee, Lecturer in Electrical Engineering
 KANYAPUR
Govt. POLYTECHNIC
Of West Bengal

A DC servo motor consists of a DC motor, a position sensing device, a gear assembly, and a control
circuit. The DC servo motor has a small DC motor is employed for driving the loads at a precise
speed and position.

Now, a DC reference voltage is set to the corresponding desired output. This voltage is applied
using a potentiometer by controlling the pulse width to the voltage converter or via a timer
depending on the control circuitry. The dial on the potentiometer generates a related voltage which
is then applied to the error amplifier.

Department of Electrical Engineering, R.K. Mission Road, Asansol-05

Prepared by A.K. Majee, Lecturer in Electrical Engineering
 KANYAPUR
Govt. POLYTECHNIC
Of West Bengal

In some circuits, a pulse control method is used to create a DC reference voltage corresponding to
the desired position or speed of the motor. It is then applied to the voltage converter by the pulse
width.

Through this converter, the capacitor begins to charge at a constant rate when the pulse is high.
Then the charge on the capacitor is fed to the buffer amplifier when the pulse is low and this charge
is further applied to the error amplifier.

So the length of the pulse decides the voltage applied at the error amplifier as the desired voltage
to produce the desired speed or position.

The feedback signal corresponding to the present position of the load is obtained by using a
position sensor. This sensor is normally a potentiometer that produces the voltage corresponding
to the absolute angle of the motor shaft through the gear mechanism.

Servo Motor Mechanism

A servo system mainly consists of three basic components – a controlled device, an output sensor,
and a feedback system.

This is an automatically closed-loop control system. Here instead of controlling a device by applying
a variable input signal, the device is controlled by a feedback signal generated by comparing the
output signal and reference input signal.

When a reference input signal or command signal is applied to the system, it is compared with the
system’s output reference signal produced by the output sensor and a third signal made by the
feedback system.

This third signal acts as the input signal of the controlled device. This input signal to the device
presents as long as there is a logical difference between the reference input signal and the output
signal of the system.

Department of Electrical Engineering, R.K. Mission Road, Asansol-05

Prepared by A.K. Majee, Lecturer in Electrical Engineering
 KANYAPUR
Govt. POLYTECHNIC
Of West Bengal

After the device achieves its desired output, there will be no longer a logical difference between the
reference input signal and the reference output signal of the system.

Then, the third signal produced by comparing these above signals will not be sufficient to further
operate the device and produce a further output of the system until the next input signal or
command signal is applied to the system.

Hence the primary task of a servo mechanism is to maintain the output of a system at the desired
value in the presence of disturbances.

Read Also: 10 Different Types of Insulators Used In Transmission Lines

Types of Servo Motor

Following are the types of servo motor:

1. DC servo motor

2. AC servo motor

3. Positive rotation

4. Continuous rotation

5. Linear servo motor

#1 DC Servo Motor

This type uses separate DC sources in the field of winding & armature winding. A DC servo motor
consists of some components which are a small DC motor, feedback potentiometer, gearbox, motor
drive circuit, and feedback control loop. It is quite similar to the normal DC motor.

Motor control by controlling armature current or field current. These provide a very precise and
fast response to the start or stop command signal due to low armature inductive reactance. These
motors are used in computerized numerically controlled machines.

#2 AC Servo Motor

AC motors include encoders that are used with controllers to provide feedback and closed-loop
control. This motor can feature high accuracy and has a high design of tolerances. Some designs
also use higher voltages to obtain more torque.

They are used in automation, robotics, CNC machinery, and other applications for the high degree
of accuracy and versatility required.

#3 Positive Rotation

Department of Electrical Engineering, R.K. Mission Road, Asansol-05

Prepared by A.K. Majee, Lecturer in Electrical Engineering
 KANYAPUR
Govt. POLYTECHNIC
Of West Bengal

In this motor, the output shaft of the motor rotates 180 degrees. The motor mainly consists of
physical stops which are in the gear mechanism to prevent the rotation sensor from rotating. These
are commonly seen in radio-controlled water, radio-controlled cars, planes, robots, toys, etc.

#4 Continuous Rotation

These are standard servo motors that have been modified to provide open-loop speed control
instead of their usual closed-loop position control. The control signal is interpreted as the speed
and direction of rotation, rather than determining the position of the servo.

Servo to rotate clockwise or counterclockwise in the range of possible command sources at varying
speeds. The application is found in a drive motor on a mobile robot.

#5 Linear Servo Motor

Linear servo motors fall into a class of positional rotation servo motors, but with an additional set of
gears to convert the O/P back and forth from circular. These servo motors are rarely found but are
sometimes they are used as actuators in higher model airplanes.

Read Also: What are the different types of transformers?

Advantages of Servo Motor

1. They have the ability to produce high output power relative to motor size and weight.

2. It has high efficiency and can reach 90% at light loads.

3. The motor provides high torque to inertia ratio and can accelerate loads rapidly.

4. It can provide quiet operation, run smoothly, and provide high accuracy.

5. The position of servo motors can be controlled more precisely as compared to other DC
motors.

Disadvantages of Servo Motor

1. The drawback of the servo motor is that it demands tuning to stabilize the feedback loop.

2. If something breaks, the motor will be unreliable. Therefore, a protection circuit is required.

3. The overall system cost and installation cost are higher than that of a stepper motor due to
the need for feedback components.

4. It would require a complex controller to provide the encoder and electronic support.

Applications of Servo Motor

Following are the applications of servo motor:

Department of Electrical Engineering, R.K. Mission Road, Asansol-05

Prepared by A.K. Majee, Lecturer in Electrical Engineering