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Updated 10/03/2008 Electric Motor Comparison Apparatus Figure 1: Electric Motor Comparison--Table 1 Figure 2: Electric Motor Comparison--Table 2 First you will need to locate the module in room 1B60. Make sure to acquire two carts, Figures 1 and 2, which should include: Cradled dynamometer (1 hp DC motor, rectifier, scale, resistors, tachometer) ½ hp 110 V AC motor ¾ hp 110 V AC motor Figure 3 shows a schematic diagram of the dynamometer apparatus. The AC motor is the motor that you are testing. Its current is measured with a current transducer (the black loop with a wire through it) or the ammeter, and its power consumption is measured directly with the power transducer or the kW-hr meter. The rectifier provides the DC current to the field coils of the dynamometer motor. The heating coils and the lamps provide the resistive load to the DC motor. The torque produced by the test motor is measured using a load cell or the scale. Load Cell Lamps kW-hr meter Power Transducer (Current and Ammeter Voltage) Rectifier 24 V DC 110 V DC Breaker Box Scale Switch mA Motor Power Plug Heating Coils DC motor Tachometer Rectifier V DC Motor AC motor Circuit 7 Rectifier Power Field Intensity Board DC volts Hi Lo F1 F2 DC amps GND Circuit 6 Motor Power Rectifier Power Plug Figure 3: Schematic diagram of a dynamometer and motor apparatus Procedure Safety: Persons operating rotating equipment must roll up long sleeves, remove neck-ties, and secure any loose hair and clothing. 1. Plug the USB data-acquisition card (labeled “National Instruments”) into a USB port on the front of the LabStation. 2. Open the NI Measurement and Automation Explorer (MAX) software. On the left side of the screen within the Devices and Interfaces tree, a NI cDAQ-9171 device should be listed. Make sure this device is labeled as “CDAQ1,” and if it is not, re-label it to be “CDAQ1” (right click on the deviceRename). This is necessary for the LabVIEW program to work properly. 3. Make sure that both the motor and the rectifier switches (breaker-box switches) are OFF, Figure 4a. The field-intensity dial (labeled “Increase Field”) of the dynamometer should be turned completely counterclockwise. If a load is applied before the motor has reached operating speed, the system will overload and blow a fuse. Page 2 of 6 Rectifier Socket Motor and Rectifier Switches a) Field-Intensity Dial Rectifier Plug b) Figure 4: Make sure to connect the rectifier plug, turn the field-intensity dial fully counterclockwise and plug in the rectifier to the dedicated rectifier socket. 4. Connect the yellow, three-prong plug from the rectifier to the field-intensity board, Figure 4b. Safety: Be sure to attach rectifier wires to the “field-intensity board” before plugging in the rectifier. 5. Plug the power cord for the rectifier into the socket marked “Rectifier” behind the AC motor, Figure 4a. 6. Next, plug the two 110 Volt power plugs leading to the breaker box into different circuits at the lab station. In order to make sure the two plugs are on different circuits, plug one connector into Circuit 6 and the other connector into Circuit 7, Figure 5. Both are on the side of the LabStation next to the CPUs. Page 3 of 6 Circuit 7 Circuit 6 Figure 5: Power Source 7. Zero the pound scale by turning the screw on the top of the load cell (be sure the turnbuckle does not rotate), and zero the ammeter with the screw at the center of the dial. A screwdriver is in the drawer of the green cart. 8. Open the “ElectricMotorComparison” VI via the shortcut in the Electric Motor Comparison folder within the ITLL Modules folder. 9. Set the voltage toggle switch, located on the rectifier, to 110 VDC and turn ON the breaker-box switch for the rectifier. 10. Start the VI and zero the load within the VI by pressing the zero-load button. Note that the rectifier switch must be on for the load cell to get power. 11. Record which motor is coupled to the generator (½ hp or ¾ hp). Verify that a polyurethane bushing is placed between the couplings of the generator and motor before proceeding. Secure the motor to the table with all four hex bolts if the motor is not already secured (an allen wrench is in the drawer of the green cart). 12. Plug the motor into the outlet below the Motor Circuit Breaker switch. Turn the breaker-box and motor-circuit-breaker switches ON and allow the motor to warm up for at least five minutes. Make sure there is no load being applied to the motor (load selector should be set to off) and the field-intensity dial should be turned fully counterclockwise. 13. Save 10 seconds of data to your “Z:” drive using the Save Data button on the VI. The VI saves the following data: a. Tachometer counts and the associated time for the counts in 0.1 second intervals (notice that these two columns are much shorter than the other four columns of the data file because the time interval is much larger for the tachometer data than for the load, voltage or current data), Page 4 of 6 b. Voltage and current values (and time) for 0.001 second intervals. c. Load from the load cell and the associated time values for 0.001 second intervals, 14. Flip the load switch on the field-intensity board of the dynamometer to high. Do NOT turn on the switch for the lights. 15. Adjust the field intensity with the field-intensity dial until the indicated force on the scale and in your VI is about 0.25 lb. Note: The field-intensity dial varies the applied load to the motor. When turned fully counterclockwise, no additional load is applied to the motor regardless of the position of the load switch. 16. Save 10 seconds of data. Note: After adjusting the field-intensity dial for every load setting, wait at least 10 seconds before pressing the Save Data button in the VI. If the Save Data button is pressed before 10 seconds lapses, the data saved will include incorrect data from the previous load setting. 17. Turn ON the light switch. 18. Increase (or decrease) the field intensity to set the load to 0.50 lb, and save 10 seconds of data. 19. Continue to increase the load level in 0.25 lb increments, saving data at every load level, until the maximum attainable load is reached for the high-load setting. The light bulbs should illuminate at higher load settings. 20. After collecting data for all load settings, decrease the load to zero (turn the fieldintensity dial fully counterclockwise), turn the light switch OFF, and turn OFF the motorcircuit-breaker switch and the motor and rectifier breaker-box switches. 21. Unplug and remove the motor by loosening the four bolts in the aluminum plate. DO NOT REMOVE THE MOTOR USING THE BOLTS AT THE BASE OF THE MOTOR! 22. Mount the other motor to the dynamometer. Caution: A polyurethane bushing must be placed between the couplings of the generator and motor! Use the gold-colored guide pins to align the motor and then secure it to the table with all four bolts using an allen wrench. 23. Repeat entire procedure with the new motor beginning on step 7. Page 5 of 6 Safety: Do not touch bare wires of rectifier. Be sure to turn OFF the all breaker-box switches when finished with the experiment and to unplug the rectifier power cable before removing wires from the “field-intensity board.” 24. Turn OFF all switches and remove cables. Return apparatus to module bay. Return all equipment that may have been checked out. Page 6 of 6