Machine tool Drives

Tanuj Kumar (12104025)

Sidharth Singla (12104061)

Overview
Introduction
Reversing
Speed Control, Changepole Motors
Stepless Speed variation, A.C motors
Stepless Speed variation, D.C motors
Stepless Speed variation, Ward Leonard method

Introduction
Machining is any of various processes in which a piece of raw material is
cut into a desired final shape and size by a controlled material-removal
process.
To obtain a machined part by a machine tool, coordinated motions must
be imparted to its working members. These motions are either primary
movements, which removes the chips from the work piece or auxiliary
motions that are required to prepare for machining and ensure the
successive machining of several surfaces of one WP or a similar surface of
different WPs.
Principal motions may be either rotating or straight reciprocating. In some
machine tools, this motion is a combination of rotating and reciprocating
motions. Feed movement may be continuous (lathes, milling machine,
drilling machine) or intermittent (shapers, planers).

Reversing
Reversing is a logical step further in the function of electrics applied to
machine tools.
In case of D.C motor the polarities of the input are changed to reverse the
direction of rotation.
While in case of 3-phase A.C motor, the sequence of the input is changed
to reverse the direction of rotation.

Speed Control, Changepole Motors

One of the fundamental problem associated with the machine tool drive is
that of speed control.
In case only a single speed is required, the squirrel cage induction motor is
the obvious choice of drive.
In this case:
revolutions/sec = (frequency) / (No. of pair of poles)
Unfortunately, No method is available to change the frequency
conveniently, so that speed variation is only possible in steps by pole
changing.

Stepless Speed variation, A.C motors

Slip ring induction motor can give stepless speed variation by reducing the
rotor voltage which is possible in a simple manner by variable resistance in
the rotor.
But this method is not generally recommended because it introduces the
losses and unless the load is held constant the speed varies with the load
for a given setting.
The A.C. commutator motor is designed to overcome the inherent
difficulties of speed control associated with a slip ring induction motor
which works on the principle of injecting voltage regulation.
The former machine has its speed varied by altering the position of the
brushes, and the latter machine has its speed varied by movement of an
external regulator, Either constant torque or constant horse power
characteristics can be obtained

Stepless Speed variation, D.C motors

The main current passes through the armature circuit and a very small
current passes through the branch circuit which supplies the field coils.

Speed increase of 3 to 1 is possible by varying this small current by means of

a variable resistance (i.e., shunt regulation).
Speed decrease can be obtained by inserting a resistance in the armature
circuit, but this has the same objections referred to in connection with the
slip ring motor.

Ward Leonard method

This method is used when a large speed range is required, say in the order
of 10/1.
Ward Leonard method of speed control is used for controlling the speed of
a DC motor. It is a basic armature control method. This control system is
consisting of a dc motor M1 and powered by a DC generator G. In this
method the speed of the dc motor (M1) is controlled by applying
variable voltage across its armature. This variable voltage is obtained using
a motor-generator set which consists of a motor M2(either ac or dc motor)
directly coupled with the generator G. It is a very widely used method
of speed control of DC motor.

Principle of Ward Leonard Method

 speed of motor M1 is to be controlled which is powered by the generator G.

The shunt field of the motor M1 is connected across the dc supply lines.
Now, generator G is driven by the motor M2.
The speed of the motor M2 is constant. When the output voltage of the generator is fed to the
motor M1 then the motor starts to rotate. When the output voltage of the generator varies then
the speed of the motor also varies. Now controlling the output voltage of the generator the
speed of motor can also be controlled. For this purpose of controlling the output voltage, a
field regulator is connected across the generator with the dc supply lines to control the field
excitation. The direction of rotation of the motor M1 can be reversed by excitation current of
the generator and it can be done with the help of the reversing switch R.S. But the motorgenerator set must run in the same direction.

Advantages of Ward Leonard System

1.

It is a very smooth speed control system over a very wide range (from zero
to normal speed of the motor).

2.

The speed can be controlled in both the direction of rotation of the motor
easily.

3.

The motor can run with a uniform acceleration.

4.

Speed regulation of DC motor in this ward Leonard system is very good.

Disadvantages of Ward Leonard System

1.

The system is very costly because two extra machines (motor-generator

set) are required.

2.

Overall efficiency of the system is not sufficient especially it is lightly

loaded.

Application of Ward Leonard System

This Ward Leonard method of speed control system is used where a very
wide and very sensitive speed control is of a DC motor in both the direction
of rotation is required. This speed control system is mainly used in colliery
winders, cranes, electric excavators, mine hoists, elevators, steel rolling mills
and paper machines etc

Electrical Stepless Speed Drive

Figure shows the Leonard set, which consists of an induction motor that
drives the direct current generator and an exciter (E). The dc generator
provides the armature current for the dc motor, and the exciter provides
the field current; both are necessary for the dc motors that drive the
machine tool.

Electrical Stepless Speed Drive

(contd.):
The speed control of the dc motor takes place by adjusting both the
armature and the field voltages by means of the variable resistances A and
F, respectively. By varying the resistance A, the terminal voltage of the dc
generator and hence the rotor voltage of the dc motor can be adjusted
between zero and a maximum value. The Leonard set has a limited
efficiency: it is large, expensive, and noisy. Nowadays, dc motors and
thyrestors that permit direct supply to the dc motors from alternating
current (ac) mains are available and, therefore, the Leonard set can be
completely eliminated. Thyrestor feed drives can be regulated such that
the system offers infinitely variable speed control.

Solid State Drive

SOLID-STATE ac drives for machine tools have seen ever-increasing use in recent
years. They have found a wide range of applications in turning, milling, and
grinding. Fig. 1 shows the horsepower- speed areas covered by these
applications.

 Given drive has a rectifier input to generate a constant-voltage dc bus, a chopper to

obtain a variable-voltage dc bus, and an inverter section to produce variable-voltage
variable-frequency power to operate an ac induction motor. Solid-state dynamic braking
can dissipate power that is transiently returned from the motor to the drive when
decelerating.

 As in most cutting applications, high torque is required at low speed, and

only low torque is needed at high spindle speed. Therefore, most ac drives
are designed for a constant torque range at lower speeds, with motor
voltage and frequency increasing proportionally (constant V/Hz) up to
base speed. Above base speed only motor frequency is increased.

AC vs DC Drives
Compared with dc drives, ac drives can go to higher motor speeds,
because of the lack of a commutator and the rugged squirrel-cage rotor.
DC drives require a field regulator and a tachometer feedback, adding to
cost and complexity, and run into commutation limitations. Normally, the
speed linearity and speed regulation requirements for milling machines can
be met with a standard ac drive, without tachometer feedback. If better
speed regulation is needed, slip compensation can be employed. The
drive load is sensed and the motor frequency is increased to compensate
for speed drop due to motor slip.

Dynamic Braking
Braking torque is developed by
electronically controlled solidstate dynamic braking, dissipating
power returned to the drive in a
resistor. While dynamic braking
with dc drives is possible, it is not
practical for tapping because the
braking torque decreases with
speed, resulting in the nonlinear
deceleration curve shown in Fig.
6. DC drives therefore must
regenerate power back into the
ac line, which takes a more
complicated and costly drive.

Thank you