Linear Induction Motor Electrical and Computer Engineering Tyler - - PowerPoint PPT Presentation

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Linear Induction Motor Electrical and Computer Engineering Tyler - - PowerPoint PPT Presentation

Nov 03, 2022 276 likes โ€ข897 views

Linear Induction Motor Electrical and Computer Engineering Tyler Berchtold, Mason Biernat and Tim Zastawny Project Advisor: Professor Steven Gutschlag 4/21/2016 2 Outline of Presentation Background and Project Overview Microcontroller

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SLIDE 1

Linear Induction Motor

Electrical and Computer Engineering

Tyler Berchtold, Mason Biernat and Tim Zastawny Project Advisor: Professor Steven Gutschlag 4/21/2016

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SLIDE 2

Outline of Presentation

  • Background and Project Overview
  • Microcontroller System
  • Final Design
  • Economic Analysis
  • Hardware
  • State of Work Completed
  • Conclusion

2

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SLIDE 3

Outline of Presentation

  • Background and Project Overview
  • Microcontroller System
  • Final Design
  • Economic Analysis
  • Hardware
  • State of Work Completed
  • Conclusion

3

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SLIDE 4

Alternating Current Induction Machines

  • Most common AC machine in industry
  • Produces magnetic fields in an infinite loop of rotary

motion

  • Current-carrying coils create a rotating magnetic field
  • Stator wrapped around rotor

4

[1] [2]

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SLIDE 5

Rotary To Linear

5

[3]

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SLIDE 6

Linear Induction Motor Background

  • Alternating Current (AC) electric motor
  • Powered by a three phase voltage scheme
  • Force and motion are produced by a linearly moving

magnetic field

  • Used in industry for linear motion and to turn large

diameter wheels

6

[4]

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SLIDE 7

Project Overview

  • Design, construct, and test a linear

induction motor (LIM)

  • Powered by a three-phase voltage

input

  • Rotate a simulated linear track and

cannot exceed 1,200 RPM

  • Monitor speed, output power, and

input frequency

  • Controllable output speed

7

[5]

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SLIDE 8

Initial Design Process

  • Linear to Rotary Model
  • 0.4572 [m] diameter
  • 0.3048 [m] arbitrary stator

length

  • Stator contour designed for

a small air gap

  • Arc length determined from

stator length and diameter

  • Converted arc length from a

linear motor to the circumference of a rotary motor

  • Used rotary equations to

determine required frequency and verify number

  • f poles

8

๐‘€ = ๐›ด๐‘  [6] (1.1)

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SLIDE 9

9

Rotational to Linear Speed

(1.2) (1.3)

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SLIDE 10

Pole Pitch and Speed

  • For fixed length stator ฯ„= L/p
  • L = Arc Length

10 10

ฯ„

A B C A B C

(1.4) [7]

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SLIDE 11

11 11

10 20 30 40 50 60 70 80 90 100 110 120 5 10 15 20 25 30 35 40 45

Ideal Linear Synchronous Speed vs. Frequency Frequency [Hz] Output Synchronous Speed [m/s]

2-Pole Machine (stator length 0.3048m) 4-Pole Machine (stator length 0.3048m)

Linear Synchronous Speed

[8]

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SLIDE 12

Outline of Presentation

  • Background and Project Overview
  • Microcontroller System
  • Final Design
  • Economic Analysis
  • Hardware
  • State of Work Completed
  • Conclusion

12 12

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SLIDE 13

Variable Frequency Drive

  • VFD
  • 0-10V signal correlates to 0-120 Hz
  • A/D Converter
  • Onboard the ATmega128
  • 250 ms interrupt service routine
  • Resolution is 0-5V
  • D/A Converter
  • External chip
  • Provides 0-10V reference signal to VFD

to control output frequency

13 13

[9]

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SLIDE 14

System Block Diagram

14 14

[10]

Atmega 128 Microctonroller D/A A/D Variable Freqeuncy Drive

Start/ Stop 0-10V Signal Analog 0-10V Analog 0-10V

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SLIDE 15

Tachometer Subsystem

  • Main Components
  • Photo-interruptor
  • Transparent Disk with Notches
  • External Interrupt
  • Counts pulses
  • 4 pulses per rotation
  • 250 ms interrupt service routine

15 15

[11]

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SLIDE 16

LCD Subsystem

  • LCD Displayed Values
  • RPM
  • Calculation to obtain RPM
  • Convert to string
  • Input string to LCD
  • Output frequency
  • Calculation to obtain VFD output frequency
  • Convert to string
  • Input string to LCD

16 16

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SLIDE 17

Outline of Presentation

  • Background and Project Overview
  • Microcontroller System
  • Final Design
  • Economic Analysis
  • Hardware
  • State of Work Completed
  • Conclusion

17 17

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SLIDE 18

Initial Design

  • 3-phase, 2-Pole machine
  • Salient pole arrangement
  • Operating at a max frequency of 120 [Hz]
  • 18โ€ (0.4572 [m]) diameter track
  • Desired 12โ€ (0.3048 [m]) length for the stator
  • Max rotational speed of 1200 [RPM] corresponding to a

max linear speed of 28.72 [m/s]

18 18

A B C A B C

[12]

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SLIDE 19

19 19

10 20 30 40 50 60 70 80 90 100 110 120 5 10 15 20 25 30 35 40 45

Ideal Linear Synchronous Speed vs. Frequency Frequency [Hz] Output Synchronous Speed [m/s]

2-Pole Machine (stator length 0.3048m) 4-Pole Machine (stator length 0.3048m)

Rotational to Linear Speed

[13]

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SLIDE 20

10 20 30 40 50 60 70 80 90 100 110 120 5 10 15 20 25 30 35 40 45

Ideal Linear Synchronous Speed vs. Frequency Frequency [Hz] Output Synchronous Speed [m/s]

2-Pole Machine (stator length 0.3048m) 4-Pole Machine (stator length 0.4542m)

20 20

Rotational to Linear Speed

[14]

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SLIDE 21

21 21

Turns Per Phase

(1.5)

๐‘ผ๐’’๐’Š = ๐‘ธ๐’‘๐’—๐’– เตŸ ๐Ÿ•. ๐Ÿ•๐Ÿ•{๐’’๐’๐’๐’•๐‘ช๐’ƒ๐’‰๐‘ฉ๐’’๐’๐’™๐‘ฑ๐’’๐’Š๐œฝ ๐‘ธ๐‘ฎ

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SLIDE 22

[15]

Previous Data

22 22

Rotational Speed (RPM) Output Power [W]

1106 510.78 1343 619.16 TABLE I: PREVIOUS DATA FROM MAGNETIC LEVITATION SENIOR PROJECT [16]

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SLIDE 23

Final Design

  • 4-Pole machine
  • Salient pole arrangement
  • Laminated stator segments
  • Operating at a max frequency of 120 [Hz]
  • 16 AWG with current rating of 3.7 [A]
  • Stator Tooth Length of 3.5โ€ (0.0889 [m])
  • Mounting holes on stator
  • Theoretical 213 turns per stator tooth
  • Achieved 235 turns per tooth

23 23

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SLIDE 24

Wiring Diagram

24 24

N N N N N N S S S S S S [17]

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SLIDE 25

Insulated Bobbins

  • Glass cloth tape used between the stator teeth and coils
  • Electrical tape used at ends to secure glass cloth tape
  • Necessary to prevent shorting between copper coils and

the stator core

  • Plastic pieces in stator slots to further prevent shorting

25 25

[18]

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SLIDE 26

Outline of Presentation

  • Background and Project Overview
  • Microcontroller System
  • Final Design
  • Economic Analysis
  • Hardware
  • State of Work Completed
  • Conclusion

26 26

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SLIDE 27

Bill of Material

27 27

Component Supplier Price Quantity Total Price

Laminated Stator Core Laser Laminations $375 1 $375 2,000 ft. Dipped Copper Wire Illinois Switchboard $176 1 $176 Scotch Glass Cloth Tape Grainger $11.55 5 $57.75 Scotch Vinyl Electrical Tape Grainger $8.95 3 $26.85 Power First Cable Tie Bag (100) Grainger $13.95 2 $27.90 3/8" 6" Steel Bolts Ace Hardware $3.20 6 $19.20 3/8" 6" Steel Bolts Ace Hardware $1.49 2 $2.98 3/8" Nuts Ace Hardware $0.30 24 $7.20 Angle Irons Ace Hardware $13.99 1 $13.99

$706.87

TABLE II: BILL OF MATERIAL

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SLIDE 28

Outline of Presentation

  • Background and Project Overview
  • Microcontroller System
  • Final Design
  • Economic Analysis
  • Hardware
  • State of Work Completed
  • Conclusion

28 28

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SLIDE 29

Completed Stator

29 29

[19]

  • Manufactured by Laser Laminations
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SLIDE 30

Simulated Linear Track Mounting Solution

  • Using previous mounting hardware used with new

base mounting

  • Smaller air-gap then anticipated was achieved
  • Under 1/8โ€ air-gap

30 30

[20]

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SLIDE 31

Simulated Linear Track Mounting Solution Conโ€™t

  • 6 Inch fully threaded steel hex bolts
  • Allow for fine adjustment of wheel height
  • Wheel mounting was raised 1-9/16โ€
  • Put bolts through all linear track

mounting parts to prevent bending of bolts on angled components

31 31

[21]

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SLIDE 32

Stator Mounting Solution

  • Angle irons used to hold bottom mounting holes
  • f stator to base
  • 11/32โ€ bolts used in both base and stator

mounting

32 32

[22]

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SLIDE 33

General Mounting

  • All parts sand blasted to remove rust and

previous paints

  • Spray painted grey for uniform color and rust

prevention

  • Washers used with mounting hardware

33 33

[23]

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SLIDE 34

Issues with Mounting

  • Initial stator mounting holes from stator to base

were off

  • Required re-drilling of mounting holes
  • Simulated linear track is not perfectly balanced
  • Changed the screws holding the copper on

simulated linear track to prevent coil interference

34 34

[24]

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SLIDE 35

Linear Track Run-off

35 35

TABLE III: Total Run-off of Simulated Linear Track

Side

(+) Run-off (-) Run-off Total Run-off Right + 0.015โ€

  • 0.015โ€

0.03โ€ Middle + 0.016โ€

  • 0.013โ€

0.029โ€ Left + 0.018

  • 0.012โ€

0.03โ€ [25]

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SLIDE 36

Coil Materials Used

  • 16 AWG Wire
  • GP/MR-200 Magnet

Wire/ Winding Wire

  • Heat is rated at 210C by

wire

  • Wire diameter calculated

when determining turns per phase and stator tooth width

  • 0.418โ€ of gap between

adjacent coils

36 36

[26]

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SLIDE 37

Mock Stator Tooth

  • Created a mock wood

stator tooth

  • Grooves in base to hold

zip-ties

  • Wrapped brass around

tooth

  • Increase size
  • Allows for coil to be

moved on stator easier

37 37

[27]

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SLIDE 38

Winding Coils

  • Created a replica stator

tooth for winding coil on

  • Initially used a slow

lathe for windings coils

  • Approximately 2 hours

to create one coil

  • Issues with layer quality

38 38

[28]

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SLIDE 39

Winding Coils

  • Changed to a different lathe
  • Benefits included higher quality wraps
  • Increase in speed
  • Only 30 Minutes to complete a coil

39 39

[29]

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SLIDE 40

Winding Methods and Changes

  • Drilled a hole into base of wooden tooth for more

secure winding start

  • Added a layer of Teflon on each coil layer
  • Wrapped outsides of coils with glass cloth tape

for protection and extra support

40 40

[30] [31]

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SLIDE 41

Issues with Winding and Coils

  • Wires crossing back accidently in layers
  • Losing tension in wrapping
  • Results in slinky effect
  • Coils when tightened down collapse

41 41

[32] [33]

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SLIDE 42

Mounting Coils

  • Wire ends were sanded down to remove the

varnish insulation

  • Wires are labeled with inner and outer wire for

connecting coils together

  • Zip-ties are used on each side of the coil to

secure the wires together to prevent

  • Additional zip-ties were used to secure the coils to

the stator to prevent movement when the wheel is in motion

42 42

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SLIDE 43

Outline of Presentation

  • Background and Project Overview
  • Microcontroller System
  • Final Design
  • Economic Analysis
  • Hardware
  • State of Work Completed
  • Conclusion

43 43

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SLIDE 44

Completed Work

  • Stator Built and Designed
  • Frequency vs. Speed simulation
  • Coils designed and created
  • Mounting solution built for simulated linear track and

stator

  • A/D convertor
  • Tachometer and LCD interfacing

44 44

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SLIDE 45

Outline of Presentation

  • Background and Project Overview
  • Microcontroller System
  • Final Design
  • Economic Analysis
  • Hardware
  • State of Work Completed
  • Conclusion

45 45

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SLIDE 46

Conclusion

  • Future Work
  • Update wheel for an improved simulated linear track
  • Update mounting solution for a more balanced wheel

and smaller air-gap

  • Test thoroughly and generate model for simulations
  • Implement more advanced control scheme
  • Reinstall magnetic levitation system

46 46

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SLIDE 47

Questions?

47 47

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SLIDE 48

Derivation of Eq. (1.5)

48 48

WHERE:

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SLIDE 49

Salient and Non-Salient

49 49

A B C A B C A B C A B C

Salient Pole Arrangement Non-Salient Pole Arrangement [34] [35]

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SLIDE 50

Final Stator Design

50 50

[36]

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SLIDE 51

Gantt Chart

51 51

[37]

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SLIDE 52

Coil Inductance

52 52

(1.6)

4-Pole: L = 0.30 [ยตH] 2-Pole: L = 2.55 [ยตH]

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SLIDE 53

Star Connection

53 53

[38]

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SLIDE 54

Overall System Block Diagram

54 54

[39]

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SLIDE 55

4-Pole Machine Wiring Diagram

55 55

[40]

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SLIDE 56

References #1-7

[1] Linear Induction Motor. [Photograph]. Retrieved from http://www.mpoweruk.com/motorsac.htm [2] Motor Animation. [GIF]. Retrieved from https://upload.wikimedia.org/wikipedia/commons/9/9e/Asynchronmo tor_animation.gif [3] Force Engineering. How Linear Induction Motors Work. [Photograph]. Retrieved from http://www.force.co.uk/linearmotors/how-linear.php [4] A. Needham. A maglev train coming out of the Pudong International

  • Airport. [Photograph]. Retrieved from

https://en.wikipedia.org/wiki/Maglev#/media/File:A_maglev_train_ coming_out,_Pudong_International_Airport,_Shanghai.jpg [5] T. Zastawny. Simulated Linear Track Shot 1. [Photograph]. [6] T.Zastawny. Arc Length. [Drawing]. [7] T.Zastawny. Pole Pitch. [Drawing].

56 56

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SLIDE 57

References #8-16

[8] M. Beirnat. Ideal Linear Synchronous Speed Vs. Frequency. [Graph]. [9] Electric Wholesale Motor. Lenze Tech MCH250B. [Photograph]. Retrieved from http://www.electricmotorwholesale.com/LENZEESV152N02YXC.html [10] T. Zastawny. System Block Diagram. [Drawing]. [11] T. Zastawny. Photo-interruptor. [Picture]. [12] T. Zastawny. Salient Pole. [Drawing]. [13] M. Beirnat. Ideal Linear Synchronous Speed Vs. Frequency. [Graph]. [14] M. Beirnat. Ideal Linear Synchronous Speed Vs. Frequency โ€“ Differing Length. [Graph]. [15] T. Zastawny. Prior Senior Project. [Photograph]. [16] T. Zastawny. Simulated Linear Track Shot 2. [Photograph].

57 57

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SLIDE 58

References #17-27

[17] T. Zastawny. Wiring Diagram. [Diagram]. [18] T. Zastawny. Wrapped Stator Teeth. [Photograph]. [19] T. Zastawny. Stator. [Photograph]. [20] T. Zastawny. Test Mounting. [Photograph]. [21] T. Zastawny. Wheel Mounting Side Shot. [Photograph]. [22] T. Zastawny. Stator Mounting and Lower Wheel Mounts. [Photograph]. [23] T. Zastawny. Cleaned Metal Vs Dirty. [Photograph]. [24] T. Zastawny. New Screws in Track. [Photograph]. [25] T. Zastawny. Simulated Linear Track Shot 1. [Photograph]. [26] T. Zastawny. GP/MR-200 Thermal Aging. [Graph]. [27] T. Zastawny. Mock Stator Tooth. [Photograph].

58 58

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SLIDE 59

References #28-37

[28] T. Zastawny. Initial Lathe Wrapping. [Photograph]. [29] T. Zastawny. Second Lathe Wrapping. [Photograph]. [30] T. Zastawny. New Coil Shot 1. [Photograph]. [31] T. Zastawny. New Coil Shot 2. [Photograph]. [32] T. Zastawny. Slinky Effect Coil Shot. [Photograph]. [33] T. Zastawny. Collapsed Coil Shot. [Photograph]. [34] T. Zastawny. Salient Pole Arrangement. [Diagram]. [35] T. Zastawny. Non Salient Pole Arrangement. [Diagram]. [36] T. Zastawny. Final Stator Design. [Diagram]. [37] T. Zastawny. Final Presentation Gantt Chart. [Diagram].

59 59

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SLIDE 60

References #38-40

60 60

[38] Star Connection Configuration [Photograph]. Retrieved From http://www.industrial-electronics.com/images/elecy3_20-2.jpg. [39] T. Zastawny. Overall System Block Diagram. [Diagram]. [40] 4-Pole Machine Wiring Diagram [Photograph]. Retrieved From https://www.ibiblio.org/kuphaldt/electricCircuits/AC/02428.png