Motors:

a System Approach
Kurt Heinzmann
DEKA Research & Development Corp.

January 2007

General Topics

Example problems
Problem formulation and analysis
Manufacturers' torque curves and specification sheets
Temperature rise
Power loss in battery, wires and other components
Gear ratio
Review of motors from a previous Kit of Parts

Background

Energy
Power
Power loss
Analysis
Test

Energy
Work is energy.
Example: effort times displacement
Force is effort
Distance is displacement

Power
Power is how fast work gets done.
Example: effort times speed

Power
Power is a measure of how fast work gets done.
POWER = EFFORT x FLOW (speed)
EFFORT
force
torque
pressure
voltage
thinking

FLOW
travel speed
rotating speed
flow of fluid
flow of electrons
doing

Power Loss in the

Mechanism
Some power from the motor is lost due to
friction in the mechanism
Gears, belts, cables
Bearings, guides
Tires, balls, or other deformable items
Damage
Contamination

Power loss is heat

Power required at the motor

Power at the motor = power required at the point of use + power
lost in the mechanism
Power loss is heat

Power loss in the motor

Power is lost in the motor due to friction, damping,
and electrical resistance
Power loss is heat. Overloading will cause excessive
temperature rise. Use appropriate gear ratio.

Analysis
Example problems
Important motor parameters
Motor model revised to include other losses
(wires, battery, switches, fuses, etc.)
Gear ratio

Basic Theory
Torque is rotating EFFORT, speed is
rotating FLOW
Torque = force x radius

Voltage is electrical EFFORT, current is

FLOW of electrons
Power = EFFORT x FLOW
Mechanical power P(mech) = torque x speed
Electrical power P(elec) = voltage x current

Units, Conversions
International System (SI) of units
Item
Force
Distance
Speed

Symbol
used
Comment
here
Mechanical effort
Mechanical displacement
Travelling speed

AbbrevSI unit
iation
newton
N
metre
m
metre/second m/s

Alternate
unit
lb.
In.
mph

Turning effort
Angular displacement

newton metre Nm
radian
rad

lb-in
degree
rpm
min., h

360 = 2 rad
1 rpm = 0.105 rad/s
1 h = 3600 s

hp

1 hp = 746 W

Torque
Angle

Speed
Time

Rotating speed
Dont have much

radian/second rad/s
second
s

Voltage

Electrical effort

volt

Current
Power

i
P

Electrical flow
Rate of work

ampere
watt

A
W

Resistance

Cause of power loss as heat ohm

Energy

Work

joule (Nm)

Pressure

Fluid effort

pascal (N/m2) Pa

Flow

3
Fluid flow (at stated pressure) cubic metre/s m /s

Conversion
1 lb. = 4.45 N
1 in. = 0.0254 m
1 mph = 0.45 m/s

ft-lb
psi

1 psi = 6900 Pa

CFM

1 CFM = 0.00047 m3/s

Prefixes: m = milli- = one thousandth (mm, mNm)

k = kilo- = one thousand (km, kW)

Why use SI units?

Fewer mistakes than when using U.S.
Customary units
A motor converts electrical power to mechanical
power.
If we express electrical power and mechanical power
in the same units (watts), we know whats happening
at both ends of the motor, and inside it.

Many are named after famous scientists

Advice: Convert each parameter to SI units
before doing any other calculation.
Consolation: you can always convert back to
US customary units.

Problem 1
Accelerate to a speed

Problem 1
Mass: m = 150 lb. = 68 kg
Speed: v = 6 ft./s = 1.8 m/s
Acceleration: a = 1.8 m/s per second = 1.8 m/s 2
Force = m x a = 68 kg x 1.8 m/s2 = 122 N
Force from each wheel: F = 122 N / 2 = 61 N
Power: P = F x v = 61 N x 1.8 m/s = 110 W

Problem 2
Lift a weight a distance within a time

Problem 2
Gravitational constant: g = 9.8 m/s 2
Weight: W = 14 lb. = 61 N
Force: F = W = 61 N
Height: h = 6 ft. = 1.8 m
Time: t = 4 s
Speed: v = 1.8 m/ 4 s = 0.45 m/s
Power: P = F x v = 61 N x 0.45 m/s = 28 W

Basic Motor Theory

Electrical Components

Basic Motor Theory

Basic Motor Theory

Important motor parameters
Applied voltage ( V )

Stall current

( stall )
( istall )

Free speed

( free )

Stall torque

Resistance ( R )

Fisher-Price Motor

Fisher-Price Motor (2005)

From data sheet:

Stall torque

Stall current

istall = 148 A

Free speed

stall

= 0.65 Nm

free

= 2513 rad/s

Reference voltage V = 12 V
Calculate:

Resistance R = 12 V /148 A = 0.081

Fisher-Price Motor Current

(For detailed analysis, see " Getting the Most
From Your Motors" by Kurt Heinzmann, 2006)
Fisher-Price motor
160

148 A
140

120

Current, A

100

80

60

40

20

0
0.00

0.10

0.20

0.30

0.40

Torque (Nm)

0.50

0.60

0.70

Fisher-Price Motor - Speed

Fisher-Price motor
2500

Speed (rad/s)

2000

1500

1000

500

0
0.00

0.10

0.20

0.30

0.40

Torque (Nm)

0.50

0.60

0.70

Fisher-Price Motor - Power output

Fisher-Price motor
2000

Power (W)

1500

1000

500

407 W

0
0.00

0.10

0.20

0.30

0.40

Torque (Nm)

0.50

0.60

0.70

Fisher-Price Motor - Input Power

Fisher-Price motor
2000

1800 W

Output power, W
Input power, W

Power (W)

1500

1000

500

407 W
0
0.00

0.10

0.20

0.30

0.40

Torque (Nm)

0.50

0.60

0.70

Fisher-Price Motor - Power loss

Fisher-Price motor
2000

Output power, W

1800 W

Power loss, W
Input power, W

Power (W)

1500

1000

500

407 W

0
0.00

0.10

0.20

0.30

0.40

Torque (Nm)

0.50

0.60

0.70

Fisher-Price Motor - Efficiency

Fisher-Price motor
100
90
80

76%

Efficiency, %

70
60
50
40
30
20
10
0
0.00

0.10

0.20

0.30

0.40

Torque (Nm)

0.50

0.60

0.70

Motor performance based on data sheet

Fisher-Price motor
2500

Output power, W

2000

Speed (rad/s); Power (W)

Speed, rad/s
1500

1000

500

407 W
0
0.00

0.10

0.20

0.30

0.40

0.50

0.60

Stall

0.70

Torque (Nm)

Peak power occurs when torque =

and when speed =

free

/2

stall

/ 2,

Real World: Power loss

14 AWG wire:
12 AWG wire:
10 AWG wire:
6 AWG wire:

3.0 m/ft.
1.9 m/ft.
1.2 m/ft.
0.5 m/ft.

(Copper at 65 C)

Resistance of electrical
system components
Component (Resistance is
expressed in ohms)
Motor (nominal)
Hot motor (40% increase)
Battery
Wires (10 ft. of 12 AWG)
Breakers, connectors, switch
Total
Ratio
R(system)/R(motor nominal)

FisherPrice
JIDECO
Power
CIM
window lift
Wheels
motor
motor
motor
0.570
0.081
0.105
0.798
0.030
0.019
0.020
0.867

0.113
0.030
0.019
0.020
0.182

0.147
0.030
0.019
0.020
0.216

1.5

2.3

2.1

Simplified electrical system

model

System model
Additional resistance reduces stall torque
proportionally.
Divide the stall torque on the torque/speed
diagram by the factor Rsystem/Rmotor(nominal)
Fisher-Price: stall = 0.65 Nm/2.3 = 0.28 Nm

Performance of the system compared with

motor performance based on data sheet
Fisher-Price motor
2500

Output power, W

Speed (rad/s); Power (W)

2000

Speed, rad/s
1500

1000

DATA SHEET

SYSTEM
500
(Was 407 W)

0
0.00

Stall: 0.28 Nm

173 W
0.10

(Was
0.65 Nm)

0.20

0.30

0.40

Torque, Nm

0.50

0.60

0.70

CIM motor
(also known as Chiaphua and Atwood)

CIM motor data and curves

Stall torque

stall

= 347 oz-in = 2.45 Nm

Stall current istall = 114 A

Free speed

free

= 5342 rpm = 560 rad/s

Free current ifree = 2.4 A

Rsystem/Rmotor(nominal) = 2.1

Comparison of power available from

Fisher-Price Motor and CIM motor
Motor power after including system losses
450
400
Fisher-Price in system
CIM in system

Output power, W

350
300
250
200

173 W

155 W

150
100
50
Stall: 2.45 Nm/2.1 = 1.2 Nm

0
0.00

0.50

1.00

1.50
Torque, Nm

2.00

2.50

Mechanical Components

Gear ratio Ng = in / out

Gear efficiency g = Pout/Pin

out

in

/ N g;

out

= g x Ng x

in

"Gear" ratio:
Mechanical power transmission
efficiency is important

Spur gears: 90% per pair

Worm and gear: 10%-60%
Nut on a screw: 10%-60%
Twist cables: 30%-90%
Chain: 85%-95%
Wire rope (cables): up to 98%
Rack and pinion 50%-80%

System with gearbox

Gear ratio example

Fisher-Price motor with gear reduction
Given:
Gear ratio Ng = 4.6:1
Gear efficiency g = 90%

Calculate:
Output torque out = g x Ng x in = 4.14 x in
Output speed out = motor / Ng = 0.217 x motor

Is the little motor/gearbox combination the

same as the big motor?
Comparison of CIM (straight) with Fisher-Price geared down 4.6:1
(gear efficiency = 90%)
1000

200
CIM speed in system

900

Fisher-Price speed in system, 4.6:1

Fisher-Price power in system, 4.6:1

160

700

140

600

120

500

100

400

80

300

60

200

40

100

20

0
0.0

0.2

0.4

0.6

0.8
Torque, Nm

1.0

1.2

1.4

Output power, W

Output speed, rad/s

CIM power in system

157 W

800

180

The big (CIM) motor will not heat

up as fast as the small motor,
because it contains more material.

Problem 1
( v = 1.8 m/s; F = 61 N)

Motor speed: motor = free /2 = 559 rad/s/2 = 280 rad/s

We wish to try 8" wheels: Rwheel = 4" = 0.1 m
Wheel speed: motor = v / Rwheel = (1.8 m/s)/(0.1 m) = 18 rad/s
Gear ratio: Ng = motor / wheel = (280 rad/s)/(18 rad/s) = 16
Check torque and propulsion force:

Usual limit per stage is 5:1 - need two stages.

Gear efficiency: g = 0.9 x 0.9 = 0.81
Wheel torque:

wheel

= g x Ng x

Force: F =

wheel

stall

/2 = 0.81 x 16 x 1.2 Nm/2 = 7.8 Nm

/Rwheel = (7.8 Nm)/(0.1 m) = 78 N (OK)

Just right
CIM motor as wheel drive motor,
Geared 16:1 (81% gear efficiency)
100

200
CIM speed in system, 16:1

90

CIM power in system, 16:1

80

160
140

125 W

60

120

50

100

40

80

30

60

20

40

10

20

0
0.0

1.0

2.0

3.0

4.0

5.0
Torque, Nm

6.0

7.0

8.0

9.0

0
10.0

Output power, W

70
Output speed, rad/s

180

Problem 2

( v = 0.45 m/s; F = 61 N)

We wish to try a screw with Fisher-Price motor.

Screw speed = motor speed:
1256 rad/s

screw

screw

= free / 2 = 2513 rad/s/2 =

=(1256 rad/s)/(2 rad/revolution) = 200 rev./s

Screw pitch:
p = v/screw = (0.45 m/s)/(200 rev./s) = 0.00225 m/rev. = 0.00036 m/rad
(11 threads per inch).

Check torque and force:

Assume screw efficiency = 20%
Torque: screw = motor = stall / 2 = 0.28 Nm/2 = 0.14 Nm
Force:
F = g x

screw

/ p = (0.2 x 0.14 Nm)/(0.00036 m/rad) = 78 N (OK)

Summary of motors in the

2005 Kit of Parts
sorted by peak output power

Number on
Supplier motor
Motor name
Fisher- 74550-0642 Power Wheels
Price
CIM
FR801-001 (Chiaphua,
Atwood)
Fisher- 74550-0642 Power Wheels
Price
Globe
409A586
2WD/4WD
transfer mtr.
Taigene 16638628
Sliding (van)
door
Globe
409A587
2WD/4WD
transfer mtr.
Nippon- E6DFWindow Lift
Denso 14A365-BB
Jideco
Window Lift
Mabuchi RS454SH

W/spur gear
ccw

Description
Motor only
Keyed output
shaft, ccw
Motor and
gearbox
Motor only

Peak
power,
Reference
Stall torque Stall
Stall
Free
Free Free
10.5 V
Voltage on Gear (as from
torque current speed speed current supply
data sheet ratio data sheet) (Nm) (A)
(rpm) (rad/s) (A)
(W)
12

647 mNm

12

346.9 oz-in

12

180.8

12
Worm
Gearmotor
Planetary
Gearmotor
Worm
Gearmotor
Worm
Gearmotor
Spur pinion
on shaft

35 oz in
34 Nm cw,
30 Nm ccw

10.5
12

117

0.647

148 24000

Resistance
(ohm)

2513

1.5

312

0.08

2.45

114

5342

559

2.3

261

0.11

77

148

133

13.9

2.5

203

0.08

0.247

21.5

9390

983

0.4

46

0.56

30

44

75

7.9

2.7

44

0.24

13

21.5

80

8.4

0.58

24

0.56

12.6

9.2 Nm

9.2

24.8

92

9.6

2.8

16

0.51

12

8.33 Nm

8.33

21

85

8.9

14

0.57

12

620 g-cm

0.061

5.2

4700

492

0.22

5.7

2.31

Comparison of motors in
the 2005 Kit of Parts
Speed and torque at peak power with 10.5 V supply
100000

Speed, rad/s

10000

Fisher-Price motor alone

1000

Globe motor alone

Mabuchi

500 W
200 W

CIM

100 W
100

50 W
20 W
10 W

10

5W

Nippon
Jideco

1
0.01

0.1

Torque, Nm

Taigene

Globe with
its gearhead
10

Fisher-Price
with
its gearbox
100

Keep batteries charged.

Battery voltage with pulse load:
Discharge current: 50 A for 10 s, 0 A for 10 s (shared between two 30 A breakers).
Battery nominal capacity when discharged at 0.9 A (20 hour discharge rate): 18 Ah
16
14

Discharged capacity, Ah; Voltage, V

12
10
8

Battery voltage

Discharged capacity

6.3 Ah

4
2
0
0

10
Time, minutes

Delivered capacity was only one third of rated capacity.

15

Conclusion
Proper motor selection, good wiring, an
appropriate gear ratio, aligned mechanical
components, and a full battery will keep you alive
in the heat of the battle.
Power loss is often a significant fraction of the
power used to do work. Include all losses in
analysis.
Analyze, but test, too!
Have fun