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Design And Construction Of An Automatic 3-Phase Induction Motor Starter

Electrical Electronics Engineering | Industrial Physics | Physics

The design and construction of an automatic three-phase induction motor starter encompass a comprehensive process integrating electronic components and control mechanisms to initiate and manage the operation of a three-phase induction motor seamlessly. This system typically incorporates a variety of components such as relays, contactors, sensors, and microcontrollers to facilitate the automatic starting, stopping, and protection of the motor against overcurrent, under-voltage, and other potential faults. The design focuses on optimizing efficiency, reliability, and safety while ensuring compatibility with diverse industrial applications. Through meticulous construction and programming, this automatic starter enhances operational convenience, reduces manual intervention, and promotes energy efficiency, thereby fulfilling the demands of modern industrial automation systems effectively.

A direct on line starter, often abbreviated DOL starter is an electrical/electronic circuit composed of electro-mechanical and electronic devices which are employed to start and stop an electric motor. Regardless of the motor type (AC or DC), the types of starters differ depending on the method of starting the motor. A DOL starter connects the motor terminals directly to the power supply. Hence, the motor is subjected to the full voltage of the power supply. Consequently, high starting current flows through the motor.

The Direct On Line Motor Starter (DOL) consist a MCCB or Circuit Breaker, Contactor and an overload relay for protection. Electromagnetic contactor which can be opened by the thermal overload relay under fault conditions.

Typically, the contactor will be controlled by separate start and stop buttons, and an auxiliary contact on the contactor is used, across the start button, as a hold in contact. I.e. the contactor is electrically latched closed while the motor is operating

CHAPTER ONE

1.1 INTRODUCTION

An electric motor converts electrical energy into mechanical energy. The reverse of this would be the conversion of mechanical energy into electrical energy and is done by an electric generator.

In normal motoring mode, most electric motors operate through the interaction between an electric motor’s magnetic field and winding currents to generate force within the motor. In certain applications, such as in the transportation industry with traction motors, electric motors can operate in both motoring and generating or braking modes to also produce electrical energy from mechanical energy.

Found in applications as diverse as industrial fans, blowers and pumps, machine tools, household appliances, power tools, and disk drives, electric motors can be powered by direct current (DC) sources, such as from batteries, motor vehicles or rectifiers, or by alternating current (AC) sources, such as from the power grid, inverters or generators. Small motors may be found in electric watches. General-purpose motors with highly standardized dimensions and characteristics provide convenient mechanical power for industrial use. The largest of electric motors are used for ship propulsion, pipeline compression and pumped-storage applications with ratings reaching 100 megawatts. Electric motors may be classified by electric power source type, internal construction, application, type of motion output, and so on.

However, for a motor to work or achieve the purpose they are made to do whether in industrial or workshop, they must be controlled. The direct, speed and torque must be controlled by a controller.

A motor controller is a device or group of devices that serves to govern in some predetermined manner the performance of an electric motor. A motor controller might include a manual or automatic means for starting and stopping the motor, selecting forward or reverse rotation, selecting and regulating the speed, regulating or limiting the torque, and protecting against overloads and faults.

Different starting methods are employed for starting induction motors because Induction Motor draws more starting current during starting. To prevent damage to the windings due to the high starting current flow, we employ different types of starters.

The simplest form of motor starter for the induction motor is the Direct On Line starter. The Direct On Line Motor Starter (DOL) consist a MCCB or Circuit Breaker, Contactor and an overload relay for protection. Electromagnetic contactor which can be opened by the thermal overload relay under fault conditions.

Typically, the contactor will be controlled by separate start and stop buttons, and an auxiliary contact on the contactor is used, across the start button, as a hold in contact. I.e. the contactor is electrically latched closed while the motor is operating.

1.2 OBJECTIVE OF THE PROJECT

The objective of this work is to design a device for starting and stopping the motor, selecting forward or reverse rotation, selecting and regulating the speed, regulating or limiting the torque, and protecting against overloads and faults.

1.3 SCOPE OF THE PROJECT

This device connect a motor to a power source, such as in small appliances or power tools. The switch may be manually operated or may be a relay or contactor connected to some form of sensor to automatically start and stop the motor. The switch may have several positions to select different connections of the motor. This may allow reduced-voltage starting of the motor, reversing control or selection of multiple speeds. Overload and over current protection may be omitted in very small motor controllers, which rely on the supplying circuit to have over current protection. Small motors may have built-in overload devices to automatically open the circuit on overload. Larger motors have a protective overload relay or temperature sensing relay included in the controller and fuses or circuit breakers for over current protection. An automatic motor controller may also include limit switches or other devices to protect the driven machinery.

1.4 SIGNIFICANCE OF THE PROJECT

Most Economical and Cheapest Starter
Simple to establish, operate and maintain
Simple Control Circuitry
Easy to understand and trouble‐
It provides 100% torque at the time of starting.
Only one set of cable is required from starter to motor.
Motor is connected in delta at motor terminals.

1.5 LIMITATION OF THE PROJECT

It does not reduce the starting current of the motor.
High Starting Current: Very High Starting Current (Typically 6 to 8 times the FLC of the motor).
Mechanically Harsh: Thermal Stress on the motor, thereby reducing its life.
Voltage Dip: There is a big voltage dip in the electrical installation because of high in-rush current affecting other customers connected to the same lines and therefore not suitable for higher size squirrel cage motors
High starting Torque: Unnecessary high starting torque, even when not required by the load, thereby increased mechanical stress on the mechanical systems such as rotor shaft, bearings, gearbox, coupling, chain drive, connected equipments, etc. leading to premature failure and plant downtimes.

1.6 FEATURES OF DOL STARTING

For low- and medium-power three-phase motors
Three connection lines (circuit layout: star or delta)
High starting torque
Very high mechanical load
High current peaks
Voltage dips
Simple switching devices

1.7 APPLICATION OF STAR-DELTA MOTOR

The direct-on-line method is usually only applied to low to medium voltage and light starting Torque motors.

The received starting current is about 30 % of the starting current during direct on line start and the starting torque is reduced to about 25 % of the torque. This starting method only works when the application is light loaded during the start.

If the motor is too heavily loaded, there will not be enough torque to accelerate the motor up to speed before switching over to the delta position.