ABB Automation & Power World: April 18-21, 2011

WCS-120-1 (presentation code)

Three easy steps to sizing motors
and drives
© ABB Inc.
July 13, 2011 | Slide 1
Automation & Power World 2011
April 18-21, 2011 in Orlando, Florida
Automation & Power World 2011
April 18-21, 2011 in Orlando, Florida

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WCS-120-1 (presentation code)
Three easy steps to sizing motors and drives

 Speaker name: Steve Weingarth

 Speaker title: Director, Application Eng.
 Company name: ABB, Inc
 Location: New Berlin, WI

© ABB Inc.
July 13, 2011 | Slide 7
Drive and motor sizing made easy

 Size your drive and motor in three easy steps

 Determine the application requirements
 Size the motor to meet the application
 Size the drive to meet the motor and the application
Determine the application requirements

 What are the torque requirements?

 Motor torque (not power) is usually the decisive factor
 Torque requirement establishes current requirement
 Continuous torque requirements
 Variable torque vs. constant torque
 Intermittent (peak) torque requirements
 Starting torque
 Acceleration torque
 What is the speed requirement?
 Maximum speed
 Minimum speed
Torque, what is it?

 A measure of the effect of a force applied at a distance to

an axis
 Torque is a force that tends to rotate or turn things
 Torque(lb-ft) = Force (lb) x Radius (ft)
Force (lb)
Radius (ft)

Center of
Rotation
Torque (lb-ft)
Variable torque

 Variable torque changes as the

operating speed changes
 Fans
 Centrifugal pumps
 Centrifugal blowers
 Mixers (material dependent)
Variable torque (fan with no static head)

Variable torque
120%

Flow varies linearly

100% with speed

80%
% Flow, % Torque, %Power

Torque requirement varies

as the square of speed
60%

40%

Power requirement varies

20%
as the cube of speed

0%
0% 20% 40% 60% 80% 100% 120%
Speed

Flow Fan Torque Fan Pow er

Variable torque (pump with static head)

Variable torque
120%

Flow varies linearly

with speed
100% Torque requirement varies
with the speed

80%
% Flow, % Torque, %Power

60%

40%
Power requirement varies
with the speed
20%

0%
0% 20% 40% 60% 80% 100% 120%
Speed

Flow Pump Torque Pump Pow er

Constant torque

 Constant torque remains the same as

the speed changes
 Conveyers
 Positive displacement pumps
 Extruders
 Crushers
 Mixers (material dependent)
 Rotary kilns
 Hoists
 Elevators
Constant torque

Constant torque
100%

90%

80%

70%
Torque requirement is
constant vs. speed
60%
% Torque

% Power
-------

50%

40%

30%
Power requirement is
20%
proportional to speed

10%

0%
0 10 20 30 40 50 60 70
Frequency (Hz)
Constant Vs. variable torque

 Why should I care?

 Isn’t all torque the same?
 Yes. But O.
 Motor current is proportional to torque
 Motor heating is proportional to current
 In the case of a TEFC motor, cooling is proportional to speed
 Result --- a TEFC motor’s ability to thermally handle torque
varies with speed
 A constant torque load often requires a larger TEFC motor than
that required for an equivalent variable torque load
 Alternative is a separately driven fan, TEBC motor
TEFC motor torque

TEFC motor
120

Motor torque
100

2:1 CT
80
% Torque

60 1000:1 CT

40 VT Pump load

20

0
0 25 50 75 100
% Speed

Motor Torque Pump Torque 1000:1 CT 2:1 CT

Intermittent torque

 Intermittent torque is torque that is required for a relatively

short period of time. Examples:
 Torque to breakaway the load and start motion
 Friction
 Torque to accelerate the load
 Inertia
Torque example

 Torque (lb-ft) = F (lb) x r (ft)

r = 1 ft
F= 100 lb

T = 100 (lb-ft)

100 lb
Speed

 With direct mechanical drive, motor speed is determined by

mechanical speed and physical dimensions
 Speed (RPM) = v (ft/min) / (r (ft) x 2 x pi)

ft/min

RPM
Speed example

 Speed (RPM) = v(ft/min) / (r(ft) x 2 x pi)

 Speed (RPM) = 750(ft/min) / (1 (ft) x 2 x pi) = 119 (RPM)

r = 1 ft
v= 750 ft/min

S = 119 RPM

100 lb
Power

 Power is the product of torque times speed

 Power (HP) = Torque (lb-ft) x Speed (RPM) / 5252
 For our example:
 Torque = 100 lb-ft
 Speed = 119 RPM
 Power = 100 (lb-ft) x 119 (RPM) / 5252 = 2.3 HP
Motor sizing

 In our example
 Torque = 100 lb-ft
Base Rated
HP Speed Torque
 Speed = 119 RPM
3 1790 9
 Power = 100 x 119 / 5252 = 2.3 HP 5 1790 15
 What size motor do we pick? 7.5 1790 22
10 1790 29
 3 HP @ 1790 RPM?
15 1790 44
 40 HP @ 1790 RPM? 30 1790 88
40 1790 117

A motor only develops its nameplate power at its

nameplate speed. At a reduced speed it develops
a proportionately reduced power.
Motor sizing
Base Rated  What if we add a gear box?
HP Speed Torque
3 1790 9  Torque at motor = torque / gear ratio
5 1790 15  Speed at motor = speed x gear ratio
7.5 1790 22
10 1790 29  Now what motor do we pick?
15 1790 44
30 1790 88
40 1790 117

Gear Ratio 1 2 5 10 15
Torque at
motor (lb-ft) 100 50 20 10 6.7
Speed at
motor (RPM) 119 239 597 1194 1790
Intermittent torque

 Torque for Acceleration

 Torque = Inertia x Acceleration rate
 If you know:
 Inertia (WK2) in lb-ft2
 Acceleration time in sec.
 Change in motor speed in RPM
 Then:
 Torque = WK2 (lb-ft2) x Speed(RPM) / (Accel time(sec.) x 307.6)
Intermittent torque

 Torque for Acceleration

 Assume for our example:
 Total WK2 = 1.2 lb-ft2
 Includes 100 lb load, drum, 15:1 gear box and motor
 Change in speed is 1790 RPM
 If accel time is 10 seconds
 Accel Torque = 1.2(lb-ft2) x 1790(RPM) / (10(sec.) x 307.6)
 Accel Torque = 0.7(lb-ft)
 Total torque = 6.7 + 0.7 = 7.4 lb-ft; less than rated motor torque
 If accel time = 1 second
 Accel Torque = 1.2(lb-ft2) x 1790(RPM) / (1(sec.) x 307.6)
 Accel Torque = 7.0 (lb-ft)
 Total torque = 6.7 + 7.0 = 13.7 lb-ft, 150% of rated motor torque
Pick a drive

 Assume for our example:

 Motor is 3 HP, 1790 rpm, 4.2 FLA, 9 lb-ft
 Torque to lift load and accel in 10 s is 7.4 lb-ft
 Max current is less than 4.2 amps
 Use 3 HP normal duty drive, 4.9 amps, with 110%
O.L. (5.4 amps peak)
 Torque to lift load and accel in 1 s is 13.7 lb-ft
 Max current is about 6.4 amps
 Use 3 HP heavy duty drive, 5.6 amps, with 150%
O.L. (8.4 amps peak)
Sample rating table
Special cases

 Intermittent torque is required for a relatively long time

 Large inertias
 Results in long accel time, several minutes
 Drive and motor sized for acceleration torque
 Examples
 Centrifuges
 Kilns
 Long periods of breakaway torque
 Mixer starting with product
Watch the limits
 Limits that can come in to play
 Torque
 AC Motors have max torque limits, about 200% (Drive limits
motor to about 70% of motor’s rated breakdown torque)
 Speed
 Limited by maximum safe mechanical speed
 Limited by maximum drive frequency
 Limited by reduced maximum torque above base speed
(Constant HP operation)
 Current
 Limited by inverter
 Full speed motor current rises when line voltage is low
 Regenerative (braking) torque
 If less than 10% flux braking may be good enough
 If more than 10% but intermittent, such has stopping only, use
brake chopper and resistor
 If more than 10% and continuous, consider a regenerative drive
Variable torque above base speed

200%
Variable torque
180% Torque and power exceed motor
rating
160%

140%
Flow varies linearly
% F lo w , % T o rq u e, % Po w er

with speed
120%
Torque requirement varies
100% as the square of speed
80%

60%

40%
Power requirement varies
as the cube of speed
20%

0%
0% 20% 40% 60% 80% 100% 120% 140%
Speed

Flow Fan Torque Fan Pow er

Conclusion
 Drive sizing made easy
 Determine the application’s requirements
 Torque
 Continuous
 Intermittent
 Speed
 Pick the motor
 Try to gear in to run at base speed
 Size on torque not power!
 Pick the inverter
 Continuous current
 Overload current

Now, that’s easy!

Automation & Power World 2011
April 18-21, 2011 in Orlando, Florida
Workshop statistics
Over 400 hours of training

 ~45customer presented case

studies
 87
sessions in the Technology
and Solution Center
 11hours of panel discussions
consisting of customers, industry
experts and ABB executives
 Nearly50 hours of hands on
© ABB Oy
July 13, 2011 | Slide 34 technical training
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© ABB Group
July 13, 2011 | Slide 38