HISTORY

1740s – Inventions began

Early incarnations of the electric motor first appeared in the 1740s through the work
of Scottish Benedictine monk and scientist, Andrew Gordon. Other scientists such as
Michael Faraday and Joseph Henry continued to develop early electric motors,
experimenting with electromagnetic fields and discovering how to convert electrical
energy into mechanical energy.

1834 – The first electric motor is made

History was made when Thomas Davenport of Vermont invented the first official
battery-powered electric motor in 1834. This was the first electric motor that had
enough power to perform a task and his invention was used to power a small-scale
printing press.

Thomas Davenport The First Powerful

Electric Motor
1886 – The invention of the DC motor

William Sturgeon invented the first DC motor that could provide enough power to
drive machinery but it wasn’t until 1886 that the first practical DC motor that could
run at constant speed under variable weight, was produced. Frank Julian Sprague was
its inventor and it was this motor that provided the catalyst for the wider adoption of
electric motors in industrial applications.

William Sturgeon DC Motor

Late 1880s – Motors are used for commercial use

Despite Davenport’s great discovery many years previously, electric motors were not
widely used on a commercial level for another 50 years. Scientists and engineers
continued to develop various types of electric motors with the objective of making
them suitable for use in commercial settings. Before long, electric motors began being
used throughout industry, in factories and in the home.

1888 – The AC induction motor is patented

In 1887, Nikola Tesla invented an AC induction motor that he successfully patented a

year later. It wasn’t suitable for road vehicles but it was later adapted by
Westinghouse engineers. In 1892 the first practical induction motor was designed,
followed by a rotating bar winding rotor, making the unit suitable for use in
automotive applications.

AC Induction
Nikola Tesla
Motor

1891 – The development of three-phase motors

In this year, General Electric started developing three-phase induction motors.

In order to utilize the bar-winding rotor design, GE and Westinghouse signed a cross-
licensing agreement in 1896.

Three-phase motors are a type of AC motor that is a specific example of a

polyphase motor. These motors can be either an induction motor (also called an
asynchronous motor) or a synchronous motor. The motors consist of three main
components – the stator, the rotor, and the enclosure.

The stator consists of a series of alloy steel laminations around which are wound with
wire to form induction coils, one coil for each phase of the electrical power source.
The stator coils are energized from the three-phase power source.

The rotor also contains induction coils and metal bars connected to form a circuit. The
rotor surrounds the motor shaft and is the motor component that rotates to produce the
mechanical energy output of the motor.
The enclosure of the motor holds the rotor with its motor shaft on a set of bearings to
reduce the friction of the rotating shaft. The enclosure has end caps that hold the
bearing mounts and house a fan that is attached to the motor shaft which spins as the
motor shaft turns. The spinning fan draws ambient air from outside the enclosure and
forces the air across the stator and rotor to cool the motor components and dissipate
heat that is generated in the various coils from the coil resistance. The enclosure also
typically has raised mechanical fins on the exterior that serve to further conduct heat
to the outside air. The end cap will also provide a location to house the electrical
connections for the three-phase power to the motor.

To understand three-phase motors, it is useful to first understand three-phase

power.

In electrical power generation, alternating current (AC) that is created by a generator

has the characteristic that its amplitude and direction changes with time. If shown
graphically with the amplitude on the y-axis and time on the x-axis, the relationship
between the voltage or current vs. time would resemble a sine wave as shown below:

Electrical power carried to homes is single-phase, meaning that there is one current-
carrying conductor plus a neutral connection and a ground connection. In three-phase
power, which is used in industrial and commercial settings to run larger machinery
that has greater power needs, there are three conductors of electrical current, each of
which is operating at a phase difference of 120o of 2π/3 radians apart. If viewed
graphically, each phase would appear as a separate sine wave, which then combines
as shown in the image below:

How does a 3-Phase Motor Work?

Three-phase motors operate by the principle of electromagnetic induction

which was discovered by the English physicist Michael Faraday back in 1830.
Faraday noticed that when a conductor such as a coil or loop of wire, is placed in a
changing magnetic field, there is an induced electromotive force or EMF that is
generated in the conductor. He also observed that current flowing in a conductor such
as wire will generate a magnetic field and that the magnetic field will vary as the
current in the wire changes in either magnitude or direction. This is expressed in
mathematical form by relating the curl of the electric field to the rate of change in
time of the magnetic flux:
 These principles form the basis for understanding how a three-phase motor
works.

Figure 3 below is an illustration of Faraday's law of induction. Note that the presence
of an EMF depends on the motion of the magnet which results in a changing magnetic
field to exist.

For induction motors, when the stator is powered from a three-phase electrical
energy source, each coil generates a magnetic field whose poles (north or south)
change position as the AC current oscillates through a complete cycle. Since each of
the three phases of the AC current are phase-shifted by 120o, the magnetic polarity of
the three coils are not all identical at the same instant of time. This condition results in
the stator producing what is known as an RMF or Rotating Magnetic Field. As the
rotor sits in the center of the stator coils, the changing magnetic field from the stator
induces a current in the rotor coils, which in turn results in an opposing magnetic field
being generated by the rotor. The rotor field seeks to align its polarity against that of
the stator field, the result being a net torque is applied to the motor shaft and it begins
to rotate as it seeks to bring its field into alignment. Note that in the 3-phase induction
motor, there is no direct electrical connection to the rotor; magnetic induction causes
the motor rotation.

With three-phase induction motors, the rotor seeks to maintain alignment with
the RMF of the stator, but never achieves it, which is why induction motors are also
called asynchronous motors. The phenomenon which causes the rotor speed to lag the
speed of the RMF is known as slip, as is expressed as:

where Nr is the speed of the rotor, and Ns is the synchronous speed of the
rotating field (RMF) of the stator.

Synchronous motors operate in a similar fashion to induction motors except that in the
case of a synchronous motor, the stator and rotor fields are locked into alignment so
that the stator RMF will cause the rotor to turn at the exact same rate of rotation (in
synch – therefore the slip is equal to 0). For more information on how this is
accomplished, refer to these articles on reluctance motors and brushless DC motors.
Note that synchronous motors, unlike induction motors, need not be powered by AC
power.

Motor Controllers for 3-Phase Motors

The speed that is generated by a three-phase AC motor is a function of the AC

supply frequency since it is the source of the RMF in the stator coils. Therefore, some
AC motor controllers operate by using the AC current input to generate a modulated
or controlled frequency input to the motor, thereby controlling the speed of the motor.
Another approach that can be used to control motor speed is by altering the slip
(described earlier). If the slip increases, the motor speed (i.e. the speed of the rotor)
decreases.
2000s – Use of motors today

In the 21st century, AC and DC electric motors are now widely used in

industries across the globe and are an integral part of many applications.
From powered wheelchairs and stairlifts to industrial automation, transport and solar
panels, Parvalux motors have led the field in designing and manufacturing effective
drive solutions for a wide range of challenging applications. The world would
certainly be a very different place without the electric motor.

DETAILED HISTORY OF ELECTRIC MOTORS (TIMELINE)

Timetable 1800 – 1834: First experiments with electromagnetic devices

1800 For the first time Allessandro Volta (Italian) produces a continuous
electrical power (as opposed to a spark or static electricity) from a stack of silver and
zinc plates.

1820 Hans Christian Oersted (Danish) finds the generation of a magnetic field by
electric currents by observation of the deflection of a compass needle. This was the
first time a mechanical movement was caused by an electric current

1820 André-Marie Ampère (French) invents the cylindrical coil (solenoid).

1821 Michael Faraday (British) creates two experiments for the demonstration of
electromagnetic rotation. A vertically suspended wire moves in a circular orbit around
a magnet.

1822 The first rotating device driven by electromagnetism was built by the
Englishman Peter Barlow (Barlow’s Wheel).

1825 William Sturgeon (British) invents the electromagnet, a coil of wires with an
iron core to enhance the magnetic field.

1827 Jedlik (Hungarian) invents the first rotary machine with electromagnets and a
commutator. However, Jedlik publicly reported his invention only decades later and
the actual invention date is uncertain.
1830 Johann Michael Ekling, mechanic in Vienna, builds a motor according to the
plans and ideas of Prof. Andreas von Baumgartner (Austrian physicist) this apparatus
was acquired in 1830 by the University of Innsbruck for the price of 50 Austrian
florins. The year of construction is unknown, but must have been before 1830 as the
date of purchase is proven.

1831 Michael Faraday (British) discovers and investigates electromagnetic induction,

i.e. the generation of an electric current due to a varying magnetic field (the reversal
of Oersted’s discovery). Faraday lays the foundation for the development of the
electric generator.

1834 After many other attempts with relatively weak rotating and reciprocating
apparatus the German-speaking Prussian Moritz Jacobi created the first real rotating
electric motor that actually developed a remarkable mechanical output power.

1838 Jacobi sets a world record only four years after creating the rotating electric
motor in 1834. His second motor was powerful enough to drive a boat with 14 people
across a wide river.

1837 Thomas Davenport patents the electric motor. There are several texts of dripping
pathos in US-American literature that celebrate Thomas Davenport as inventor of the
electric motor. This assertion is based on the undisputed fact that Davenport was the
first American who created a usable electric motor and also the first to receive a
patent for such a device. From 1837 to 1866 about 100 patents on electric motors
were granted to other inventors in England alone. Since Davenport redesigned his
motor in 1837, his patent became practically worthless.

The Beginning of Magnet Wire

1907 George A. Jacobs, an American inventor, created an insulating process that
allowed copper wire to be made in extremely precise gauges. This enamel insulation
was long-lasting, less bulky, and more economical. At this time, Jacob formed the
Dudlo Company which soon became the largest producer of insulated copper magnet
wire.

1911 George Jacobs and his associate, Victor Rea further developed wire of any
thickness to be coated evenly with a chemical insulation that could be baked on in
special ovens and yet remain flexible enough to be wound into coils.

1927 Dudlo Company merged with two other companies to form General Cable
Corporation.

1929 General Cable produced the first 75,000-volt submarine cable in the United
States for the Delaware River Crossing. It was manufactured in 4,050-foot lengths —
the longest ever without joints.

1933 Victor Rea forms Rea Magnet Wire, and receives its first order form Jefferson
Electric Company for 10,000 pounds of 38-gauge enameled wire on three-inch spools.

1936 Essex entered the magnet wire manufacturing business by acquiring a vacant
industrial complex that had formerly been the Dudlo Manufacturing Company in Fort
Wayne, Indiana. Dudlo was the originator of the modern magnet wire enameling
process (see 1906).

Fast-forward to the 1940’s, where we see magnet wire manufacturers working

tirelessly to provide support WWII efforts. Essex was producing enough magnet wire
to build the millions of transformers used by America and its allies during World War
II, produced thousands of miles of field telephone wire for the Army Signal Corps,
and wiring harnesses for B-24 bombers.

1954 Essex moves its headquarters to Fort Wayne, Indiana. Five years later, Rea
would move its headquarters to Fort Wayne as well.

1963 Ultra-fine wire developed by Sumitomo Electric.

1966 Elektrisola arrives in the market with the first 10-kg-spool for 0.05 mm wire.
1970 Thermal resistance ATZ-300 developed.

1977 Super-fine rectangular wire developed by Sumitomo Electric.

1994 Magneflex is introduced, which features aluminum conductors insulated with a

high temperature resin. The advanced polymer coatings have been very successful in
transformer applications.

1997 REA introduces Pulse Shield, which is resistant to voltage stresses generated by
high frequency, rapid rise time and voltage spikes typically introduced by IGBT-type
inverters.

1998 Essex acquired Active Industries, a converter/fabricator of electrical insulation

products used mainly by OEMs and motor repair shops.

2014 Nano Shield introduced by Rea, which shows exceptional resistance to voltage
stresses generated by high frequency, rapid rise time, and voltage spikes typically
introduced by IGBT-type inverters, increased motor life significantly over standard
MW-35C magnet wire under these voltage stresses and across a wide temperature.

Magnet wire can be found in electric motors, which translate electrical energy into
mechanical motion through the interaction of magnetic fields and current-carrying
conductors. These electric motors contain copper coils, which produce the magnetic
fields.
Electric motors are featured in a variety of products, including fans, household
appliances, heavy machinery, and automobiles. They come in a range of shapes and
sizes, with the smallest being found in electric wrist watches, and the largest in large
ships. Some benefits of the electric motor include low cost, low maintenance
requirements, no fossil fuels, and many more.

Magnet wire can also be found in transformers, which are essentially devices that
transfer electrical energy from one circuit to another through copper coils. Power can
be transferred through a magnetic field, rather than a metallic connection between the
two circuits. Aluminum wire can be used, however, copper magnet wire is preferred
because it is more space efficient and can be wound tighter. Transformers are more
influential than one expects- all but a tiny fraction of the world’s electrical power
passes through a series of transformers by the time it reaches the consumer.

Conductivity and Connections

The copper vs. aluminum windings in motors debate is still a hot topic. Today,
engineers in all sorts of industries question whether the quality and performance of
aluminum windings can compare to copper.

In the 1960s, aluminum house wiring faced some controversy due to the fire hazards
it created. Connection problems turned out to be cause of these house fires, not the
wire itself. When in action, the junctions would overheat, causing the heat to transfer
to the wire itself, eventually weakening the wire insulation.
Consequently, aluminum wire tends to receive a negative standing, despite it being
reasonable material for motor windings in many applications.

What Else Can Magnet Wire Do?

Magnet wire can be found in a plethora of everyday items, even in planes. Electrically
powered model aircraft have been flown since the 1970s, with one unconfirmed report
as early as 1957. They have since developed into small battery-powered unmanned
aerial vehicles or drones, which in the twenty-first century have become widely used
for many purposes.

However, while we may see incredibly fast electric sports cars like Tesla’s on earth,
speed in the sky is a different story. Using electrical power to actually propel planes,
specifically large, heavy commercial planes, is a more complicated challenge. In a
conventional jet airplane, the engine sucks air in through its front, a compressor
squeezes it and fuel is sprayed in and lit, creating burning gases and forward thrust.
Electric plane power is much simpler. Batteries power an electric motor that spins a
propeller. It’s more efficient, but involves far less thrust, which is why electric planes
tend to be slow. It may be a lot more eco-friendly, but for now, commercial electric
planes aren’t as efficient with our busy travel schedules.
 Magnet wire can also be used to power
wind tunnels. Wind tunnels are used to
test automobiles and aircrafts.
Specifically, they help engineers
determine the performance of, and
eliminate “bugs” in, new designs of civil
and military aircrafts and vehicles without
risking the safety of a test driver/pilot or
costly aircraft. The biggest wind tunnel on the planet is at NASA’s Ames Research
Center. This subsonic tunnel, which can test planes with wing spans of up to 100 feet,
is more than 1,400 feet long and 180 feet high. It has two test areas: one 80 feet high
and 120 feet wide, the other 40 feet high and 80 feet wide. Air is driven through these
test segments by six 15-bladed fans. Each fan has a diameter equivalent to the stature
of a four-story building. The fans are fueled by six 22,500-horsepower electric motors
that use magnet wire to help power them.

Most Powerful Electric Motor

Northrop Grumman Corporation has developed for the U.S. Navy the world’s first
36.5 megawatt (49,000 horsepower) high temperature superconductor (HTS) ship
propulsion motor, double the Navy’s power rating test record.

Incorporating coils of HTS wire that are able to carry 150 times the power of similar-
sized copper wire, the motor is less than half the size of conventional motors. It will
help make new ships more fuel-efficient and free up space for additional war fighting
capability.

This system was designed and built under a contract from the Office of Naval
Research to demonstrate the efficacy of HTS motors as the primary propulsion
technology for future Navy all-electric ships and submarines. Naval Sea Systems
Command (NAVSEA) funded and led the successful testing of the motor.

REFERENCES

https://www.parvalux.com/us/when-was-the-electric-motor-invented-a-brief-history-of-electric-
motors/

https://www.thomasnet.com/articles/machinery-tools-supplies/what-is-a-3-phase-motor-and-how-
does-it-work/

https://mwswire.com/about-magnet-wire/#:~:text=1800%20For%20the%20first%20time
%20Allessandro%20Volta%20%28Italian%29,observation%20of%20the%20deflection%20of%20a
%20compass%20needle.