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Permanent Magnet DC Motor Design

About the Course

This course was designed to teach attendees how to:

  • calculate motor performance
  • select motor size and materials
  • analyze motor performance problems
  • reduce engineering and production costs and enhance market responsiveness

Brad FrustaglioAbout the Instructor

Brad Frustaglio is the Vice President of Engineering at Yeadon Energy Systems. He is a graduate of Michigan Technological University and a registered professional engineer. He has 15 years of experience with YES™ as an electric motor designer, electric motor tester, and software developer. Mr. Frustaglio is a member of MCMA, and is a contributor to the Handbook of Small Electric Motors. He is the on-going software developer and software trainer of YES software, an electric motor design tool. He has design expertise in BLDC, PMSM, Single and Polyphase AC Induction, Stepper, Universal, PMDC motors, linear actuators and specialty electromagnetic devices. His design experience includes numerous applications from household appliances, industrial, automotive accessory, automotive traction, medical, aerospace and specialty high temperature motors and actuators.

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All courses include take-home reference materials!

Course Outline

  1. Theory
    1. Forward
    2. Introduction
    3. Properties of Ferromagnetic Materials
    4. Self and Mutual Inductances
    5. Magnetic Circuits
    6. Examples of Magnetic Circuit Calculations
    7. Field Mapping using Curvilinear Squares
    8. The PMDC Motor
    9. Armature Reaction
    10. Reactance Voltage and Commutation
    11. Torque - Speed Characteristics
    12. Permanent Magnets for DC Motors
    13. Efficiency of DC Motors
    14. Energy Approach
    15. Unit Conversions
    16. Conversion Table
    17. Thermal Analysis for a PMDC Motor
  2. Performance Calculations
    1. Introduction
    2. PMDC Construction
    3. Performance Curves
    4. Prediction of Air Gap Flux
    5. Carter's Coefficient
    6. Permeances
    7. Permeance Coefficient
    8. Total Flux Supplied
    9. Armature Calculations
    10. Net Slot Area
    11. Armature Conductors
    12. Armature Slot Fill
    13. Inertia
    14. Magnetic Circuit
    15. Trickey Factor
    16. Armature Reaction and Brush Shift
    17. Commutation
    18. Output
    19. Losses
    20. Current Density
    21. Motor Constants
    22. Design Analysis Procedure
    23. Motor Calculation Example
  3. Practical Design Considerations
    1. Introduction
    2. Motor Construction
    3. Magnets
      1. Material Types
      2. Hysteresis Characteristics
      3. Core Loss in Permanent Magnets
      4. Material Characteristics
      5. Demagnetization
      6. Magnetization
    4. Housings
      1. Magnetic Circuit
      2. Magnetization Curve
    5. Laminations
      1. Hysteresis Loop
      2. Power Loss - Hysteresis
      3. Power Loss - Eddy
      4. Flux Densities
      5. Material Properties
    6. Commutators
    7. Brushes
    8. Commutation
      1. Brush Pressure
      2. Neutral Zone
      3. Commutation Zone
      4. Commutation to Neutral Zone Ratio
      5. Brush Current Densities
      6. Brush Resistance - Contact Drop
      7. Performance Evaluation
      8. Brush Dust-slot Packing
    9. Shafts
    10. Bearings
      1. Ball Bearings
      2. Needle Bearings
      3. Sleeve Bearings
    11. Shaft-bearing Systems
    12. Magnet Wire
    13. Insulation
    14. Armatures
      1. Lap Winding
      2. Wave Winding
      3. Flux Densities
      4. Balance
      5. Cogging Torque
    15. Thermal Considerations
      1. Heat Transfer
      2. Thermal Resistance
      3. Thermal Time Constant
      4. Current Density
    16. Electromagnetic Interference
      1. Filters
    17. Clean Sheet Design Approach
    18. Velocity Profiles

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