YASKAWA

Frequently Asked Questions

Date: 17.Sept.01 Braking Calculation 03
Page 1 of 1

Example 2: Crane (Hoist Application)

While lowering a load with a crane the motor works in regenerative mode while the whole lowering
process. The motor has to produce a braking torque which causes the DC bus voltage to rise. While
stopping the lowering process the inertia of the system causes an additional energy feed back to the
inverter. Hence the calculation of the braking chopper and braking resistor is a little bit different as for
instance on winder applications. The following example shall clarify the procedure.

Main Hoist Data:

Hoist Speed (v):..........................1.76 m/min
Save Working Load (m L): ..........70.00 tons
Chain Weight (m C): ....................1500 kg
Machine Efficiency (ηM): ............0.85
Roope Groove diameter (d): .....540mm
High of Lift (h):............................17 m
Gearbox Ratio (i):.......................357:1
Pulley Block: 4:1
Required Motor Power PL ..........23.48 kW
Starts per hour: ..........................150

Main Hoist Motor Data:

Brook Hansen Induction Motor
with Encoder
Selected Motor PM: ....................25 KW
Rated Current: ...........................45 A
Voltage: ......................................415V ±10%
Motor Speed (n): ........................1420 rpm
Inertia (Jm): .................................0.141 kgm 2
Encoder:.....................................1024 ppr, RS422 (5V TTL)

Inverter
VS-616G5 in Flux Vector Control Mode
Model:.........................................CIMR-G5C4030
Rated Output Current: ...............65 A
Software Number:......................VSG105143 (Exclusive Crane Application Software)
PG Option Card:.........................PG-X2 (RS-422, max 300kHz)
 YASKAWA
Frequently Asked Questions
Date: 17.Sept.01 Braking Calculation 03
Page 2 of 2

Example 2: Crane (Hoist Application)

Maximum braking power PBmax

At a hoist application while lowering the load the motor works in regenerative mode, i.e. energy comes
back to the DC bus while the whole lowering process. While stopping the fed back energy is even
higher due to the systems inertia. It is calculated as follows:
J (n − n 2 )
MB max = tot 1 − MLoad
9.55 ⋅ t B
The inertia consists of that of the motor armature and that of the load (incl. chain). The load inertia has
be to calculated regarding to the motor shaft using the gear ratio and the pulley block ratio.
2 2
 1   1 
J tot = Jmot + JLoad   ⋅ 


 i Gear   i PB 
2 2 2
 d[m]   1  1 
J tot = Jmot + (m Load + m Chain ) ⋅   ⋅   ⋅  
 2   i   i PB 
2 2 2
 0.54   1   1 
J tot = 0.141kgm 2 + (70000 kg + 1500 kg) ⋅   ⋅  ⋅   = 0.144kgm 2
 2   357   4 
The torque MLoad regarded to the motor shaft can be calculated as follows:
1 1
MLoad = m ⋅ g ⋅ r ⋅ ⋅
i Gear i PB
0.54m 1 1
MLoad = 71500kg ⋅ 9.81m ⋅ ⋅ ⋅ = 132,6Nm
s2 2 357 4
Because of the down direction of the movement the torque is a regenerative torque, i.e. the torque
value gets a negative sign. Now the maximum braking torque is calculated as follows:
0.144kgm 2 ⋅ 1420rpm
MB max = + 132.6Nm = 154.0Nm
9.55 ⋅ 0.5s

Maximum braking power

MB max ⋅ (n1 − n 2 )
PB max =
9.55
154.0Nm ⋅ 1420rpm
PB max = = 22.9kW
9.55

Maximum electrical braking power

Pel = PB max − k ⋅ PrMot − (1 − η Gear ) ⋅ (1 − ηPB ) ⋅ PB max

The efficiency of the pulley is unknown, so we can take 1. The gear efficiency is assumed to be 0.8.
Taking this high efficiency values we get also a little safety factor.

Pel = 22.9kW − 0.08 ⋅ 25kW − (1 − 0.8) ⋅ 22.9kW = 16.3kW

Maximum possible braking resistor value

VB 760V 2
RB ≤ =
Pel 16300W
R B ≤ 35.4Ω
 YASKAWA
Frequently Asked Questions
Date: 17.Sept.01 Braking Calculation 03
Page 3 of 3

Example 2: Crane (Hoist Application)

Maximum continious operation time and duty cycle:

h 17m
t= =
v 1.76m / min
t = 580s

Normally the duty cycle of this application would be 50% because if a weight is lowered the hook must
have been lifted up for the same way and thereby for the same time. In practice the duty cycle is
lower. We can calculate with about 25-30%.

Average electrical braking power

In this application we can take the braking power while lowering with constant speed as the average
braking power. The efficiency of the pulley block is also ignored.

MLoad ⋅ (n 1 − n 2 ) 132.6Nm ⋅ 1420rpm

PLow = = = 19.7kW
9.55 9.55
PelAve = PLow − k ⋅ PrMot − (1 − η Gear ) ⋅ PLow
PelAve = 19.7kW − 0.08 ⋅ 25kW − (1 − 0.8 ) ⋅ 19.7kW = 15.8kW

Braking unit and braking resistor selection:

1. Resistor value 26.5Ω

760V
Imax = = 28,7A
26.5Ω
R ⋅P
t ch = t B ⋅ Bsel 2 elAve
VB
26.5Ω ⋅ 15800W
t ch = 580s ⋅ = 420s
760V 2
Referring to the overload capability curve for CDBR-4045B braking unit, with a braking time of 420s
and a braking current of max. 28.7A the allowable duty cycle is more than 40%, which is much higher
than the assumed duty cycle of 25-30%.
So for this hoist application the CDBR-4045B together with a 26.5 Ω / 15.8kW braking resistor can be
used.

2. Resistor value 20Ω

760V
IB max = = 38 A
20Ω
20Ω ⋅ 15800W
t ch = 580s ⋅ = 278s
760V 2
Referring to the overload capability curve for CDBR-4045B braking unit, with a braking time of 278s
and a braking current of max. 38A the allowable duty cycle is about 30%, which still fits the demand.
So for this hoist application the CDBR-4045B together with a 20 Ω / 15.8kW braking resistor can also
be used.

Now we can decide which resistor will be used. The 26.5Ω resistor is o.k. and there is a big margin in
the duty cycle, but the braking torque capability is only about 105%. Using the 20Ω resistor the duty
cycle margin is lower but the braking torque capability is about 130%. In this case the 20Ω resistor is
the better choice.