PROJECT REPORT ON

TO STUDY DC MOTOR CONTROL

TECHNIQUES
(DC DRIVES) WITH SPECIAL INFUSES ON
AVTRON DRIVES.


BRIEF PROFILE OF THE COMPANY
ELECTRIC MOTORS
TYPES OF MOTORS
SPEED CONTROL OF DC MOTOR










CONTENT
MOTOR GENERATOR SET
INTRODUCTION TO ELECTRIC DRIVES
BLOCK DIAGRAM OF DC MOTOR CONTROL
FACTORS AFFECTING DC DRIVE SELECTION
VARIABLE DC DRIVE
ADJUSTABLE SPEED DRIVE
REASONS FOR USING ADJUSTABLE SPEED DRIVE
TYPES OF DRIVES
ADVANTAGES -32 DC DRIVE FAMILY
FLEXIBILITY AND CONTROL
PURPOSE
APPLICATIONS
STANDARD FEATURE SUMMARY
CONCLUSION


CONTENT
With the ongoing technical revolution where innovations are
taking place at the blink of an eye, it is impossible to keep
the pace with the emerging trends. In organization where
making things right in the first instances is the driving motto,
perfection and inaccuracy is inevitable.

Excellence is an attitude that the whole of the human race is
born with. It is the environment that makes sure that
whether the result of this attitude is visible or otherwise.

A Well-planned properly executed and evaluated industrial
training helps a lot in inculcating a professional attitude. It
Provides a linkage between the student and industry to
develop an awareness of industrial approach to problem
solving ,based on a broad understanding.


PREFACE
ACKNOWLEDGEMENT
Before focusing on my report WE would like to thank few people who made
this report come true. First of all we would like to thank Mr. ARUN SINGH,
MED ELECTRICAL for providing help as desired from time to time. who
guided and encourage me. I am very grateful for their help and support. I
would like to thank my parents & project co-ordinator for their help and
moral support. Last but not the least, all the workers out there for their tit-
bit of information.

This report deals with important component of the plant and their working.
It adds detail from the processing of MOTOR CONTROL to the AVTRON
drives. This report reflects the experience I have gained during the
vocational training at Tata Steel Ltd. Jamshedpur.

last but not the least I also want to thanks our RESPECTED principal MR.
K.V.NAIR our HOD MRS.PREETA JHON and our section in charge
MR.APURVA RANJAN PATRA .who have given the chance to do industrial
project in multilevel company TATA STEEL

ABOUT TATA STEEL
Established in 1907 as Asia's first integrated private sector steel company, Tata
Steel Group is among the top-ten global steel companies with an annual crude
steel capacity of over 29 million tones per annum. It is now the world's second-
most geographically-diversified steel producer, with operations in 26 countries and
a commercial presence in over 50 countries. The Tata Steel Group, with a turnover
of US$ 24.82 billion in FY 13, has over 80,000 employees across five continents and
is a Fortune 500 company.
Tata Steels larger production facilities comprise those in India, the UK, the
Netherlands, Thailand, Singapore, China and Australia. Operating companies
within the Group include Tata Steel Limited (India), Tata Steel Europe Limited
(formerly Corus), Tata Steel Singapore and Tata Steel Thailand.
The Tata Steel Groups vision is to be the worlds steel industry benchmark in
Value Creation and Corporate Citizenship through the excellence of its people,
its innovative approach and overall conduct. Underpinning this vision is a
performance culture committed to aspiration targets, safety and social
responsibility, continuous improvement, openness and transparency.

BRIEF PROFILE OF THE COMPANY
Motors
Motors convert electrical energy to mechanical
energy
Motors make things move

LINEAR
ELECTROSTATIC
DC BRUSH
STEPPER
INDUCTION
UNIVERSAL
Other kinds of electric motors

In ordinary DC motors, like the ones we've just
considered, the rotor spins inside the stator. AC
motors work a slightly different way: they pass
alternating current through opposing pairs of
magnets to create a rotating magnetic field, which
"induces" (creates) a magnetic field in the motor's
rotor, causing it to spin around. You can read more
about this in our article on AC induction motors. If
you take one of these induction motors and
"unwrap" it, so the stator is effectively laid out into a
long continuous track, the rotor can roll along it in a
straight line. This ingenious design is known as a
linear motor, and you'll find it in such things as
factory machines and floating "maglev" (magnetic
levitation) railroads.

Another interesting design is the brushless DC
(BLDC) motor. The stator and rotor effectively
swap over, with multiple iron coils static at the
center and the permanent magnet rotating
around them, and the commutator and
brushes are replaced by an electronic circuit.
You can read more in our main article on hub
motors. Stepper motors, which turn around
through precisely controlled angles, are a
variation of brushless DC motors

TYPES OF MOTORS
1.DC motor- DC shunt motor
-separately excited motor
-series motor
-permanent magnet direct current
-compound motor
2.AC motor induction motor
-synchronous motor

OTHERS MOTORS
-stepper motor
-Brushes DC motor
-hysteresis motor
-reluctances motor
-universal motor

DC motor is a electrical machine which
converts dc electrical energy into
mechanical energy.
When power supply is connected to the
motor then it is divided into two parts field
winding and armature winding. Field
winding makes electromagnet in this
magnetic field current carrying armature
winding experience the mechanical force
and start rotating due to this shaft is also
rotating.

DC MOTOR
Flux control method:- In this method
when flux per pole increases the speed
of dc motor decreases and if flux per
pole decreases speed increases.
Armature control method:-when overall
resistance of armature circuit increases.
The voltage drop across armature
increases. Therefore, back e.g. decreases
because
Eb=V-Ia.Ra
Hence , speed get decreased.

SPEED CONTROL OF DC MOTOR
Types of generation of control DC MOTOR
1
st
generation :- resistor control method set.
2
nd
generation :-MG set (motor generator set).
3
rd
generation :-Thermonic valves.
4
th
generation :-Semiconductor devices i.e.,
thyristor.
An electric drive is defined as a form of machine
equipment designed to convert electrical energy into
mechanical energy and provide electrical control of
this process.

The basic elements of an electric drive are the
electric motor, the transmission, and the electrical
control system. Electric drives often include
conversion equipment (frequency changers , rectifier
units , motor-generator sets etc.)to attain smoother
and more versatile control and make the motor
operate on specific speed-torque characteristics
INTRODUCTION TO ELECTRIC DRIVES
Capital costs vary with rating of the drive.
Larger drives with more performance features
will cost more. By way of comparison, A.C.
drive controllers cost more than D.C. drive
controllers, but A.C. motors cost less and have
lower maintenance costs than brushed D.C.
motors. While D.C. drives have a wide speed
range, they may require thyristors with higher
ratings due to the higher currents associated
with low speed operation. Efficiency is the
ratio of output power to input power.

Low efficiency has two disadvantages:
(1) costly wasted energy and
(2) excessive heating of the drives
components and the motor. D.C. drives
typically have high efficiencies; however, at
low speeds, they have a low power factor. D.C.
drives have a power-to-weight ratio advantage
over Ward-Leonard electric drives but less so
compared to A.C. drives

Process control and energy conservation are the two primary reasons for using
an adjustable speed drive. Historically, adjustable speed drives were developed
for process control, but energy conservation has emerged as an equally
important objective.
Adjusting speed as a means of controlling a process
The following are process control benefits that might be provided by an
adjustable speed drive:
Smoother operation
Acceleration control
Different operating speed for each process recipe
Compensate for changing process variables
Allow slow operation for setup purposes
Adjust the rate of production
Allow accurate positioning
Control torque or tension
Allow catching of spinning load (e.g., column of water) after outage.

REASONS FOR USING ADJUSTABLE SPEED
DRIVES
An adjustable speed drive can often provide smoother
operation compared to an alternative fixed speed mode of
operation. For example, in a sewage lift station sewage
usually flows through sewer pipes under the force of
gravity to a wet well location. From there it is pumped up
to a treatment process. When fixed speed pumps are used,
the pumps are set to start when the level of the liquid in
the wet well reaches some high point and stop when the
level has been reduced to a low point. Cycling the pumps
on and off results in frequent high surges of electric current
to start the motors that results in electromagnetic and
thermal stresses in the motors and power control
equipment, the pumps and pipes are subjected to
mechanical and hydraulic stresses, and the sewage
treatment process is forced to accommodate surges in the
flow of sewage through the process. When adjustable
speed drives are used, the pumps operate continuously at a
speed that increases as the wet well level increases. This
matches the outflow to the average inflow and provides a
much smoother operation of the process

There are three general categories of electric drives: DC
motor drives, eddy current drives and AC motor drives.
Each of these general types can be further divided into
numerous variations. Electric drives generally include
both an electric motor and a speed control unit or
system. The term drive is often applied to the
controller without the motor. In the early days of
electric drive technology, electromechanical control
systems were used. Later, electronic controllers were
designed using various types of vacuum tubes. As
suitable solid state electronic components became
available, new controller designs incorporated the
latest electronic technology
TYPES OF DRIVE

DC drives are DC motor speed control systems.
Since the speed of a DC motor is directly
proportional to armature voltage and inversely
proportional to motor flux (which is a function of
field current), either armature voltage or field
current can be used to control speed. Several
types of DC motors are described in the electric
motor article. The electric motor article also
describes electronic speed controls used with
various types of DC motors.

DC DRIVE

An eddy current drive consists of a fixed speed motor
and an eddy current clutch. The clutch contains a fixed
speed rotor and an adjustable speed rotor separated
by a small air gap. A direct current in a field coil
produces a magnetic field that determines the torque
transmitted from the input rotor to the output rotor.
The controller provides closed loop speed regulation by
varying clutch current, only allowing the clutch to
transmit enough torque to operate at the desired
speed. Speed feedback is typically provided via an
integral AC tachometer.

EDDY CURRENT DRIVE
Advantage of 32 DC drive family
Heat sink over temperature warning.
DC motor temperature sensing with over temperature
protection
AC line fuses and DC link fuse on regenerative units.
Fully rated DC contactor (includes Db pole on most sizes)
Chassis type construction
IOC(instantaneous over current)protection
Phase loss/phase sequence protection
Field current loss protection
Field economy
Low AC line v/g and frequency protection
16 event fault FIFO
All drive information accessible by remote computer over
a RS485 multi drop link.
Advantage of 32 DC drive family
Avtron introduction

Since 1953, Avtron has been a leader in designing
and manufacturing Electrical Control and Test
Equipment. Their Aerospace, Industrial Automation,
and Load Bank facilities occupy four buildings in
Northeast Ohio, to accommodate manufacturing,
sales, and engineering resources. Twenty-five
percent of Avtron's employees are graduate
engineers in electrical, computer, and mechanical
fields. . Anywhere in the world and at any time,
installation, start-up, and support services are
available on all Avtron products.


Avtron drive system
Inner look of drive parts
Drive parts Drive switches
Block diagram of single line diagram of
5HP
BILL OF MATERIAL OF 5HP
Purpose:

Speed and/or Position Feedback to Electrical Drive
Systems
Length, Speed, and/or Position Feedback to Process
Instrumentation and Controls
There are many applications for rotary pulse generators
(also known as incremental encoders, tachs, tachometers)
throughout industry. Avtron manufactures a wide range of
electrical and mechanical configurations to satisfy the
installation requirements of your application. These units
typically mount to the non-drive end of AC and DC motors
for speed feedback applications and in some cases directly
to roll shafts for instrumentation.
Drive interfacing parts
Drives components
ARMATURE CONVERTOR CIRCUIT
Advanced Communication:

IEEE 802.3 (ETHERNET) LAN with Modbus TCP
protocol
IEEE 802.3 (ETHERNET) LAN with Allen-Bradley
ETHERNET/IP protocol
IEEE 802.3 (ETHERNET) LAN with GE EGD
protocol
RS 485 Serial Link with Allen-Bradley DF1
protocol

Applications:

Avtron produces "Mill-Duty", "Heavy, Mill-Duty" and "Severe Duty"
encoders to handle rugged environments encountered in the following
industries:
Pulp and Paper
Metals
Rubber
Plastic Film
Material Handling
Mining
Fiberglas
Roofing
Converting
Test Equipment
Textiles
Non-Wovens
Cement Kilns

Here we familiarize with industrial application of
motor and drives. Its a very precious moment of
our life where we seen a different kinds
component in large parameters . We try to
analyze our knowledge in accordance with their
requirements.

CONCLUSION
THANK
YOU