Module 3 MECHANICAL DRIVE SYSTEMS Topic 3.

1 PRIME MOVERS

Selection of Prime Mover: 1. Functional requirements Required function Advantages and disadvantages of the other available alternatives INTERNAL COMBUSTION ENGINES generally fuelled by gasoline or propane and are commonly employed in mobile equipment and in locations where electric power is not available. Disadvantages: Lower efficiencies Noisy operation Production of toxic fumes Use of highly inflammable fuel Inability to start under load Higher maintenance costs Need for accessory equipments such as filter, radiator, igniter etc.

2 Types of Internal Combustion Engine Usually employed in applications having higher efficiencies beacause they are cheaper IC engines are rated in Brake HP which is the HP delivered at the flywheel after accounting for the friction losses. 1. Spark Ignition Engine atomized fuel is mixed with combustion air before entry into the cylinder Compresses at a ratio of 14:1 to as high as 25:1. The higher the compression ratio the better efficiency 2. Compression Ignition Engine (Diesel Engine) air fuel ratio is further compressed by the piston and later ignited by an electric spark generated by the ignition system. The fuel is injected into the cylinder after compression of the combustion air already introduced into the cylinder. The heat that results from the compression of the air in the cylinder is responsible for igniting the mixture. Tolerant towards a wider range of fuels and also more efficient, although heavier in size HYDRAULIC MOTORS convert the hydraulic energy of a fluid to a mechanical energy Classified as the secondary movers Have a moderate to a very high power range with high power to weight ratio The ratio typically increases with increasing fluid pressure along with the efficiency. AIR MOTORS secondary mover Usually powered by a compressor which is driven by a prime mover such as an electric motor Have an excellent power to weight ratio but limited power and torque range The elastic nature of air reduces the maximum pressures to around 10 bar for general applications Advantages of an AIR MOTOR Cost effective, compact and light in weight They offer safe operation under all conditions

Have low inertia which enables to stop or reverse easily Do not cause any damage on stalling or overloading

STEAM TURBINES usually employed in high speed applications such as centrifugal pumps Generally economical where supply of steam is readily available. Have poer range of up to 100 HP for single stage, while higher power requirements demand multi staging Have notoriously low efficiency levels, increasingly being coopted in combined cycle plants along with gas turbines, resulting in heat recovery and higher efficiencies. GAS TURBINES used in power generation, pump and compressor drives and other applications requiring a dependable shaft output power Compact in design and tremendous energy producing capacity coupled with their inherent flexibility, performance and operational reliability Pressure ratio and temperature are the two important factors governing the efficiency of a gas turbine. Advantages of a Gas Turbine Direct firing Low ratio of weight to horsepower Lack of heavy vibrations Power output in the form of relative motion High performance and reliability ratios Absence of high operating pressures and unbalanced forces Availability of turbine exhaust heat Multiple fuel application Low maintenance and capital cost among the other prime mover. ELECTRIC MOTOR most widely used in terms of number and application Widely used for driving compressors and hydraulic pumps Highly efficient, low initial and running costs with good power to weight ratio and available in various power ranges. AC motors are generally cheaper than the DC motors. Advantages of DC Motors Less complex in design and construction Capable of starting and accelerating torques in excess of 400% of the rated value Less expensive for most horsepower ratings Advantages of AC Motor Smaller and lighter and commonly available Since no brushes are involve, better suited for high speed applications more than 2500 rpm Special enclosure type AC motor are readily available for wet and corrosive conditions Paramaters for selection of electric motor: Power requirements Type of duty and cycle Load-torque characteristics Starting conditions System conditions Speed control Ambient temperature or cooling medium temperature Brakling and reversing operations Power in KW = (M x N) / 975 Power in HP = (M x N) / 716

Where: M Torque in Kgf-meter N speed in rev/min DC MOTORS - consists of rotating armature and a fixed-field winding Depending on the type of connections, they are classified as - series motor runs with its field windings in series with the armature. They have high starting torque with considerable speed increase on reduced load. Mainly used in constant load applications. Also suited for cranes and winches where heavy loads must be moved slowly - shunt motor runs with its fixed windings in parallel with the armature. Majority of the DC motors are shunt motors. The speed is controlled by increasing or decreasing electrical resistance. - compound motor has both series and shunt field windings. Compound motor types are mainly cumulative and differential motors. AC MOTORS can be single or three phase motors usually induction type, either split or capacitor start repulsion type for heavy duty applications largely used in light induatrial or domestic applications where inly a single phase supply is available Single phase motors are mainly fractional HP Motors and have a high starting torque with appreciable speed increase on reduced load and vise versa Three Phase motors - are the fast most commonly used in industrial applications due to higher efficiency, superior performance and low cost. Account for over 90% of installed motor horsepower They are simple in construction, rugged, cheap and quite reliable in nature and are therefore extensively used Two Types of AC Electric Motors each type can be powered by a single phase or a 3 phase current A. Induction Motor the motor speed varies with the load and therefore used in applications where speed control is not necessary. Simplest and the most rugged of all electric motors. The motor basically consists of a fixed outer portion stator and a rotor spinning inside it to provide mechanical output. B. Synchronous Motor most used in certain special applications requiring constant speed AC Motor Speed the rotational speed of an AC Motor depends only on the frequency or number of cycles per second of the electric supply and the number of magnetic poles in the motor. Speed = (120 x frequency) / number of poles AC SYNCHRONOUS MOTORS operates exactly at synchronous speed without slip Normally require a separate starting arrangement since they produce very little torque at zero speed When the motor speed reaches a certain percentage of the synchronous speed, the rotor is energized and the squirrel cage becomes ineffective. Runs at a constant speed regardless of load variations up to a point known as the pull-out point At loads higher than this value, the motor will tend to stop