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Metalworking (rec.crafts.metalworking) Discuss various aspects of working with metal, such as machining, welding, metal joining, screwing, casting, hardening/tempering, blacksmithing/forging, spinning and hammer work, sheet metal work. |
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#1
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Motor/Generator Analysis
I have measured the DC resistance of a split-phase capacitor run
induction motor's two windings. They are 53 and 35 ohms. The motor is impedance protected. Using the nameplate voltage and current, I have calculated the total impedance at 60 Hz to be 110 ohms. This total impedance is larger than the DC resistance, and so I have algebraically subtracted the resistance from the total impedance to get the inductive impedance, but I don't know if I did that step right: http://users.aol.com/DGoncz/Publicat...orAnalysis.bmp I am pretty sure about R1/R2 = X1/X2 although the winding *are* different colors and could be different gages, but I am not sure about 1/(1/(R1+X1) + 1/(R2+X2)) = 110 ohms I don't know if you can add a resistance and an inductive impedance arithmetically this way. I have seen things like R1 at angle 0 degrees + X1 at angle 90 degrees = sqrt(R1^2 + X1^2) I have invested hundreds of dollars into this motor/generator and while I would like to avoid a rewind, these high resistances make a rewind look inevitable. If I can get a good model, though, I may find a Q1 for some capacitance, and that would indicate, I think, that self-excitation could commence. What is not shown in MotorAnalyis.bmp is R1 in series with L1 and so X1, and R2 in series with L2 and so X2, and R1/L1/X1 in parallel with R2/L2/X2 and the capacitor C. Yours, Doug Goncz Replikon Research Falls Church, VA 22044-0394 |
#3
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Doug, you don't simply add reactance and resistance, since they are
orthogonal quanities (at right angles to one another).. To compute Impedance, Z, simply use the same formula as you would use for computing the hypotenuse of a right triangle (The Pythagorean Thorem). In this case: Z = SQRT(Resistance Squared + Reactance Squared). A simple empirical method of determining the impedance is simply to connect a variable resistor (potentiometer) in series with the generator, apply a 60-Hz AC voltage (say 24-Volts), then adjust the variable resistor until the AC voltage across it is equal to the AC voltage across the generator windings. You can then measure the resistance of the adjustable resistor with a simple ohm meter and its value will be numerically equal to the impedance of the generator, since the voltage drop across each will be equal. E = IZ = IR, where the AC current passing though both the generator and the variable resistor (when connected in series) are of course equal. Harry C. |
#4
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Doug, as a follow on, it is important to note that the current draw of
a motor is typicallly stated for its maximum horsepower load, hence tells you almost nothing about its impedance/reactance. Harry C. |
#5
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Harry C. wrote:
Z = SQRT(Resistance Squared + Reactance Squared). Thanks, Harry, that was what I meant when I wrote sqrt( R1^2 + X1^2) You've confirmed that these are vector quantities. I have a calibrator output on my 'scope that is a 60 Hz *square wave* but I'd need a sine wave to use the potentiometer method, right? Doug |
#6
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Doug, since reactance varies with frequency you really need a 60-hz
sinewave source (something like a doorbell transformer or toy train transformer should do nicely). A pulse or square wave contains many higher frequency harmonics which would confuse the measurement. Hope this helps, Harry C. |
#7
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I have ordered two 10-1134 motors and eleven 5 mfd capacitors from
Surplus Center. I have ordered an 11.1111 mfd 50 VDC cap sub box from Electronic Parts. I intend to mate the hanger threads on the end bells of the motors with a close nipple and install a threaded rod and cap nuts to join the shafts. One motor will be the prime mover, and the other will be the test generator. I have written to Terry Given to see if he will recruit me into the IEEE. |
#8
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I have ordered an LCR meter and a less expensive cap sub box that
should be rated 200 VDC instead of 50 VDC. Doug |
#9
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I wrote: I have ordered an LCR meter and a less expensive cap sub box that should be rated 200 VDC instead of 50 VDC. The LCR meter is on the way from a private ebay seller overseas by air mail. The cap sub box has not been shipped yet. The motors are on their way by Parcel Post. Doug |
#12
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#13
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I find the rotor has 48 conductive bars. I could have this wrong.
By substituting the rotor, could I increase the efficiency of this motor? That might be much easier than rewinding. I have removed and replaced rotors from shafts before. It seems any rotor with the right number of bars and less than or equal to the linear size, with the right or smaller bore, would do to make *some* improvement. I'm guessing I'd want a rotor with fewer bars, but I don't know the physics. Can any reader show me the math relating 60Hz, 36 poles, 400 rpm, 48 bars, and 225 rpm? I don't get it. I take 7200 / 32 = 225. To get it, I need to go to Falls Church's library, the Mary Riley Stiles library. There are not one but two editions of Audel's there. Doug |
#14
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I find the following encouraging note at:
http://www.ecmweb.com/mag/electric_m..._ac_induction/ "As seen in the Table above, smaller motors and lower-speed motors typically have higher relative slip. However, high-slip large motors and low-slip small motors are also available." I need a low-slip small motor. Doug |
#16
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I understand that leakage inductance is a defect in an otherwise
perfect transformer, and it is clear why toroidal transformers would have low leakage inductance. But "where" is the leakage inductance in a motor? Restated, in what way is a motor like a transformer? I've looked all over the web and haven't found this information. I did find many documents referring to leakage inductance in motors. I've only put a few hundred dollars into this generator. Perhaps I should let go of it. I have a DC generator that has produced loads of power with little drag. Doug |
#17
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#18
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#19
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To properly use an LCR meter, I believe the following would be
appropriate. 1) Realize the meter measures total impedance and computes inductance using the impedance figure in the place of reactance. (I read this on a web page) 2) Measure the inductance and resistance, or capacitance and resistance. 3) Find the impedance associated with the inductance, using the meter's test frequency. 4) Recombine the impedance and resistance to find the reactance using Pythagoras. 5) Once again using the meter's test frequency, find the new inductance or capacitance associated with the reactance. Right? Assuming the real component is strictly L-R or R-C. Doug |
#21
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#22
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I have found a candidate motor for use as a generator:
http://surpluscenter.com/item.asp?UI...tname=electric I believe this motor has 8 poles, a synchronous speed of 900 rpm and full load slip of 12%. So it should be around 70-75% efficient, shouldn't it? Would this be a suitable motor for further experiments with self-excited induction generators? It's used, but it's cheap, small, and seems efficient enough. Doug |
#23
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In article ,
wrote: On 12 Jun 2005 16:59:08 -0700, wrote: To properly use an LCR meter, I believe the following would be appropriate. 1) Realize the meter measures total impedance and computes inductance using the impedance figure in the place of reactance. (I read this on a web page) 2) Measure the inductance and resistance, or capacitance and resistance. 3) Find the impedance associated with the inductance, using the meter's test frequency. 4) Recombine the impedance and resistance to find the reactance using Pythagoras. 5) Once again using the meter's test frequency, find the new inductance or capacitance associated with the reactance. Right? Assuming the real component is strictly L-R or R-C. Doug Most LCR meters are pretty crude devices and simply indicate the scalar impedance of the test device. However the dial calibration is based on the assumption that the test device is a pure lossless L or C. The only ~$200 handheld LCR meter that doesn't make the assumption of lossless (pure) inductance or capacitance that I know of is the Extech model 380193 LCR Meter. I have one, and it works well. It measures L, C, or R at 120 Hz or 1000 Hz (but not R at DC), and for L and C also reports parasitic R. The B+K model 875B LCR meter did not work for me because they only worked with very pure inductances. I have heard that the Wavetek meters also have the problem. The test is to take a relatively pure inductance, like one winding of a power transformer, and put a potentiometer in series. Does the reported inductance vary as the series resistance is increased? With the B+K, it just explodes, with the indicated inductance becoming a large factor bigger than the true value, so a 2-henry inductor was reported as 45 henries. Complete nonsense, rendering the meter useless. Note that one-frequency and two-frequency LCR meters cannot detect self-capacitance in an inductor, or self-inductance in a capacitor. Only parasitic resistance can be detected. Joe Gwinn |
#24
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My meter uses a test frequency of 100 Hz.
I measured the two windings and got R1 = 38.5 ohms, L1 = 0.149 H, R2 = 123.5 ohms, L2= 0.457 H. So I got X1 = 94 ohm, X2 = 287 ohm. And X1v = 85 ohm, X2v = 259 ohm, with sqrt(X1^2 - R1^2) etc... And L1v = 0.136 H, L2v = 0.413 H. Doug |
#25
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On 13 Jun 2005 04:58:15 -0700, wrote:
wrote: IF the loss component of an inductance is pure series R loss AND you know the value at the test frequency (which may be considerably higher than the DC value), as you have assumed, the true value of L can be arrived at by quadrature addition. Wouldn't that be quadrate subtraction, Jim? Subtracting the resistance at 0 degrees from the impedance associated with the mismeasured inductance at an unknown phase angle... That is, Xt = 2 * pi * f * L (measured) Xl = sqrt( Xt^2 - R^2) L ( compensated ) = Xl / ( 2 * pi * f ) ? ********************* sorry " quadrature addition" was just a careless reference to the fact that the impedances were in quadrature. ********************* Doug My meter uses a test frequency of 100 Hz. I measured the two windings and got R1 = 38.5 ohms, L1 = 0.149 H, R2 = 123.5 ohms, L2= 0.457 H. So I got X1 = 94 ohm, X2 = 287 ohm. And X1v = 85 ohm, X2v = 259 ohm, with sqrt(X1^2 - R1^2) etc... And L1v = 0.136 H, L2v = 0.413 H. Doug ************** This is an example of how easy it is to attribute spurious accuracy to inductance measurements made with an LCR meter. There is no way that the measurement is accurate to three significant figures and even the second figure is pretty dubious. *************** I have found a candidate motor for use as a generator: http://surpluscenter.com/item.asp?UI...tname=electric I believe this motor has 8 poles, a synchronous speed of 900 rpm and full load slip of 12%. So it should be around 70-75% efficient, shouldn't it? Would this be a suitable motor for further experiments with self-excited induction generators? It's used, but it's cheap, small, and seems efficient enough. Doug ***************** Certainly a more suitable than your existing 36 pole device but I'm still pretty doubtful. Small multipole induction motors suffer from low efficiency and comparatively high leakage inductance. Given a free choice I would go for a 2 or 4 pole motor with full load load slip of no more than 5%. Even with a motor as good as this there would still be a small chance that the rotor residual magnetism be too low to initiate self excitation. However the advertised machine is a nice little motor at an attractive price Even if it doesn't work it's all useful experience and a handy motor to add to your stock. Jim |
#26
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I wrote:
I measured the two windings and got R1 = 38.5 ohms, L1 = 0.149 H, R2 = 123.5 ohms, L2= 0.457 H. So I got X1 = 94 ohm, X2 = 287 ohm. And X1v = 85 ohm, X2v = 259 ohm, with sqrt(X1^2 - R1^2) etc... And L1v = 0.136 H, L2v = 0.413 H. I do understand that L1v is accurate to about two digits. I can show the tolerance buildup if anyone cares to see it. For example 2 is an exact number, pi can be brought in to any precision, but L is, judging from what Jim has written, accurate to maybe 10%. So with a tolerance on each number, the tolerance or precision on the result can be had. And L is of course, suspect as well. However, I have computed the resonant capacitor for the 1 winding as 51. blah blah blah microfarads, and understand that I can pick out 50 ufd of capacitor and even measure the cap and still be off by 10%. But I did include an extra digit. So sorry. Mea culpa. Correct me if I am wrong, but it seems, looking at a Bode plot, that generator operation should be arranged at the nose of the curve, the inflection point between positive and negative curvature, where bandwidth is measured. Yes? Behavior is linear there. Doug |
#27
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wrote:
On 12 Jun 2005 16:59:08 -0700, wrote: To properly use an LCR meter, I believe the following would be appropriate. 1) Realize the meter measures total impedance and computes inductance using the impedance figure in the place of reactance. (I read this on a web page) 2) Measure the inductance and resistance, or capacitance and resistance. 3) Find the impedance associated with the inductance, using the meter's test frequency. 4) Recombine the impedance and resistance to find the reactance using Pythagoras. 5) Once again using the meter's test frequency, find the new inductance or capacitance associated with the reactance. Right? Assuming the real component is strictly L-R or R-C. Doug Most LCR meters are pretty crude devices and simply indicate the scalar impedance of the test device. However the dial calibration is based on the assumption that the test device is a pure lossless L or C. IF the loss component of an inductance is pure series R loss AND you know the value at the test frequency (which may be considerably higher than the DC value), as you have assumed, the true value of L can be arrived at by quadrature addition. Based on AC and DC LCR measurements on an air cored coil this method can give reasonably accurate results. However, if the test piece is an iron cored component the measurement does not take into account the shunt losses (iron eddy currents, hysteresis etc.) and permeability variation both with frequency and flux density. These are all second order effects but mean that the "true" inductance of an iron cored device is a pretty variable quantity unless the measurement conditions are closely defined. Fortunately, with power frequency electric motors, the low working frequency and the significantly air gapped iron circuit reduces the effect of these second order components. However measurement accuracies are likely to be limited to one, or at best, two significant figures, Jim If you want to call RF/AF bridges crude. Just not uP I guess. Some are. Owner and long time user of low tech to high tech versions. Martin -- Martin Eastburn @ home at Lion's Lair with our computer lionslair at consolidated dot net NRA LOH, NRA Life NRA Second Amendment Task Force Charter Founder ----== Posted via Newsfeeds.Com - Unlimited-Uncensored-Secure Usenet News==---- http://www.newsfeeds.com The #1 Newsgroup Service in the World! 120,000+ Newsgroups ----= East and West-Coast Server Farms - Total Privacy via Encryption =---- |
#28
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On Tue, 14 Jun 2005 00:00:42 -0500, "lionslair at consolidated dot
net" "lionslair at consolidated dot net" wrote: snip If you want to call RF/AF bridges crude. Just not uP I guess. Some are. Owner and long time user of low tech to high tech versions. Martin My comments referred only to LCR "METERS". A good RF/AF Bridge could well handle the highlighted problems. Jim |
#29
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OK, I went to my hoarding/clutter group tonght and put a deadline on
the motor/generator project. Basically, what I am hearing is: Slow motors don't generate well. Small motors don't generate well. Both, because the poles are small. Well, this is a small, slow motor, so I am going to try to see if the Q at the nose of the curve is greater than one with math and measurement. And I will try to make it work, but at some point I am going to have to let this one go. Pity. Doug |
#30
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Well, I received two motors and eleven capacitors from Surplus Center.
I used a short 1/8 pipe nipple to join the motors and added a handle made from another nipple and a bit of 1/4-20 threade rod between the mounting brackets. I ran another rod through the hollow shafts and added finishing washers on the ends to keep the rod concentric. I topped the rod with cap nuts. The motors turn together with a pronounced squeal. So now I am sitting here with a $143 cap sub box I don't dare use because another is coming UPS from ebay today. If that box tests out, I'll return the expensive one ordered in haste. I plan to run the motors together and use various capacitances on the driven motor with the oscilloscope to look for generator action, one value at a time. Doug |
#31
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I got the capacitance sub box from ebay! Lenny, our UPS driver, brought
it by at 5:37 PM. The sub box checked out with a few slightly unreliable switches. With the sub box in place the motor/generator pair produced an odd looking wave on the scope. With more capacitance, the waveform adopted a more nearly sine wave form. There was a very small change in amplitude. I need to add more of the capacitors. I think I have to wire up a 10, 20, 20 uf sub box. Doug |
#32
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The waveform produced by the motor/generator spans 15 milliseconds.
That's 67 Hz. I was expecting a slower wave, a lower frequency. But of course! The motor isn't running under a full load, so the speed is closer to the synchronous speed. Still, the output should be a lower frequency than the input. Doug |
#33
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OK, the waveform might span 16, 17, or 18 microseconds. That would be
about right. I have found something quite heartening, an easy DOS program to analyze RCL/LCR parallel tanks: http://www.smeter.net/software/lcr.exe "Introduction C is in parallel with L and R in series. Z is the impedance measured across C. This deceptively simple circuit is found in narrow-band tuned amplifiers, wideband video amplifiers, impedance-matching L-networks and in filters, etc. When R is less than 1.554*Sqrt(L/C) there is a hump, Zmax, in the Z vs frequency response. As R decreases, Zmax increases and moves to higher frequencies. When R Sqrt(L/C) the angle of Z is always -ve and unity power, commonly defined as the resonant condition, does not occur at any frequency. For smaller values of R the angle of Z is +ve at low frequencies and passes through zero (unity power factor) on the LF side of the frequency of Zmax which is itself lower than the LC series resonant frequency. At much smaller values of R, giving high Q, all three frequencies converge on a common value." When I try my values for R, L, and C, the program says, in effect, "No resonance". Still with 30 ufd across the main winding, 1 VAC is present, and a mighty clean sine wave at that. I have ordered a 1 pole, 12 position switch and will add 10 ufd per position. It's a shorting switch. I may build a second switch up with 50 ufd per position. We will see.... Doug |
#34
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On 17 Jun 2005 15:29:32 -0700, wrote:
OK, the waveform might span 16, 17, or 18 microseconds. That would be about right. I have found something quite heartening, an easy DOS program to analyze RCL/LCR parallel tanks: http://www.smeter.net/software/lcr.exe "Introduction C is in parallel with L and R in series. Z is the impedance measured across C. This deceptively simple circuit is found in narrow-band tuned amplifiers, wideband video amplifiers, impedance-matching L-networks and in filters, etc. When R is less than 1.554*Sqrt(L/C) there is a hump, Zmax, in the Z vs frequency response. As R decreases, Zmax increases and moves to higher frequencies. When R Sqrt(L/C) the angle of Z is always -ve and unity power, commonly defined as the resonant condition, does not occur at any frequency. For smaller values of R the angle of Z is +ve at low frequencies and passes through zero (unity power factor) on the LF side of the frequency of Zmax which is itself lower than the LC series resonant frequency. At much smaller values of R, giving high Q, all three frequencies converge on a common value." When I try my values for R, L, and C, the program says, in effect, "No resonance". Still with 30 ufd across the main winding, 1 VAC is present, and a mighty clean sine wave at that. I have ordered a 1 pole, 12 position switch and will add 10 ufd per position. It's a shorting switch. I may build a second switch up with 50 ufd per position. We will see.... Doug Long range diagnosis is pretty dangerous but the following comments may help. The fact that there is any output means the rotor is retaining significant residual magnetism. The amount depends on its previous history. It could be maximised by temporarily DC energising the stator with the rotor stationary. Use about twice the rated full load current. With output generated by residual magnetism the output should rise roughly directly proportional to speed and be at synchronous frequency - it's a "permanent" magnet alternator. Regenerative generation is signalled by a much more rapid rise in output with speed as stator resonance is approached. Significant regenerative generation can only occur if the stator resonance is of high enough Q. The necesary minimum Q depends mainly on motor efficiency. As a pure guess I would expect Q2 to be essential and it may need to be as high as 5. Jim |
#35
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Thanks, Jim, that's enormously helpful. I am in search of Q, be it with
this motor or another. I have computed with http://www.smeter.net/software=AD/lcr.exe using input values 136000 microhenries, 51000000 picofarads, 23 ohms, and 0.00006 MHz, that there is "no impedance hump". Can you or any reader verify this by running the program? Can anyone explain why, since R 1.554 * sqrt (L/C), there is no impedance hump? I must be missing the fine print.... Doug |
#36
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In article ,
wrote: On 17 Jun 2005 15:29:32 -0700, wrote: [ ... ] When I try my values for R, L, and C, the program says, in effect, "No resonance". Still with 30 ufd across the main winding, 1 VAC is present, and a mighty clean sine wave at that. I have ordered a 1 pole, 12 position switch and will add 10 ufd per position. It's a shorting switch. I may build a second switch up with 50 ufd per position. We will see.... Hmm ... consider the following: 1) One four-pole 12 position switch 2) One 10 uF capacitor. 3) Two 20 uF capacitors. 4) one 40 uF capacitor Wire switch so in the following positions you have the following caps connected: 0 None 1 Single 10 uF 2 Single 20 uf 3 One 20 uF and one 10 uF in parallel (30 uf total). 4) Two 20 uF in parallel (40uF total) 5 Two 20 uF and one 10uF in parallel (50 uF total) or One 40 uf and one 10uf capacitor in parallel (50 uF total) 6 One 40 uF and one 20 uF in parallel (60 uF total) 7 One 40 uF and one 20 uF and one 10 uf in parallel (70 uF total) 8 One 40 uf and two 20 uf in parallel (80 uF total) 9 One 40 uF, two 20 uF and one 10 uF in parallel (90 uf total So -- you have 0-90 uF in 10 uF steps from four capacitors. This is pretty much how capacitor decade boxes are made. If you want to extend the range a bit, add another 20 uf (and another deck) and you can get up to 110 uF from 12 steps. Essentially, each capacitor has its own deck, and which are connected in is determined by the wiring to the terminals of the switch. I would suggest avoiding the switching while it is powered, as it will burn the contacts each time you switch. An alternative way would be to install one toggle switch for each capacitor, and simply sum the values of the switches which are on. Enjoy, DoN. -- Email: | Voice (all times): (703) 938-4564 (too) near Washington D.C. | http://www.d-and-d.com/dnichols/DoN.html --- Black Holes are where God is dividing by zero --- |
#37
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I do understand that halving the resistance requires halving the number
of turns and this could change R 1.554 * sqrt(L/C) Doug |
#38
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On 18 Jun 2005 11:00:06 -0700, wrote:
Thanks, Jim, that's enormously helpful. I am in search of Q, be it with this motor or another. I have computed with http://www.smeter.net/software?lcr.exe using input values 136000 microhenries, 51000000 picofarads, 23 ohms, and 0.00006 MHz, that there is "no impedance hump". Can you or any reader verify this by running the program? Can anyone explain why, since R 1.554 * sqrt (L/C), there is no impedance hump? I must be missing the fine print.... Doug You're being seduced by illusory accuracy again! With iron cored inductors you are working with only reasonable approximations to the behaviour of a complex component and this is compounded by pretty dubious measurement accuracy. Your DC value of R assumes that this is the only loss mechanism and totally ignores the shunt losses arising from eddy currents and the iron circuit losses. In the same way as Q=(rootL/C)/R for series losses Q=r/(rootL/C) is for shunt losses where r is the effective value of the shunt loss component. The combined effect of both types of losses must be taken into account. With the setup you have there is no method of a accurately measuring the separate or combined losses and, since you are only taking part of the series loss into account for your Q calculation, your result is necessarily pretty optimistic. Jim |
#39
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Even if I run the resistance down near zero, the LCR.EXE program still
says "No impedance hump." Is the program broken? I doubt it. Am I doing something wrong? I don't know. L = 136000 uH, C = 51000000 pf, R = 23 ohms, f = 0.00006 MHz. Doug |
#40
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That's a good design, Don.
Doug |