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NEW ERA UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

TOPIC :
DC motors using extruder drive motors

How an extruder works:

The solid plastic, or resin, is a fed continuously to a heated chamber where it is


compressed and melted, then pushed out of the chamber at a constant rate and
though a pre determined die. As it cools, the plastic solidifies with a cross
section that matches the pattern of the die. Dies are created in such a way so the
melted plastic flows in a precise manner to get the desired shape.
A feederscrew within is used to carry the plastic along. This feedscrew is driven by
a motor or drive that relies on appropriate speed and torque control to get
quality results. No matter what type of extrusion process is used, speed control is
essential to assure that an adequate amount of resin is being fed into the the heat
chamber. Its also crucial that even pressure is maintained so the flow will remain
consistent. The extrusion machine should have good response to changes in
torque while keeping a steady speed for high friction loads. This challenge can be
meet by using a high quality extruder controller.
Whether using an AC or DC motor/ drive for the extruder, there are various
extruder control products that can handle basic and advanced control algorithms.

NEW ERA UNIVERSITY


COLLEGE OF ENGINEERING AND TECHNOLOGY

DC motors using extruder drive motors

Submitted by :
Dela Cruz, Marlon T.
Submitted to:
Engr. Tim Limsiaco

DESCRIPTIONS:

Silent, space-saving, energy-efficient, and high-torque, a new generation of ring-shaped


motors is gaining a foothold in extrusion. A couple of hundred are already in use. Though
most machine builders are reacting cautiously, adventurous processors are using them
happily. You might call it a quiet invasion. A whole new category of extruder motor is
emergingring-shaped, high-torque, permanent-magnet synchronous motors. Be sides
be ing unusually compact and eerily quiet, they use less energy than their predecessors
10% to 20% less than a DC motor and 5% to 10% less than a three-phase AC motor. And
their already high torque capabilitywhich permits higher outputsis getting higher all
the time. Still, visible use of the new motors is very small. Most plastics applications are in
the plasticating units of injection molding machines rather than extruders. Nonetheless, a
half-dozen European machine builders are developing extruders with these new motors.
But most extruder manufacturers dont even own a sample of a permanent-magnet,
synchronous torque motor. The surprise is that these motors arent really as
experimental as most of the market thinks. The builders of this new type of motor have
delivered well over 150 of them to makers of extruders that are already in production at
processing plants. Although most of these motors are in Europe, there are a few of the
ring-shaped torque motors in U.S. extrusion plants.

Commercial extrusion applications for the motors include tubing, blown film, sheet, and
continuous-extrusion blow molding. Hundreds have also been used on downstream
components of an extrusion line like chill rolls, winders, and rewinders.

The new motors create virtually no vibration or noise and need almost no maintenance.
Theyre water-cooled and dust-free and use less oiladvantages for makers of medical
and food-packaging films. The motors are compact, an advantage for coextrusion. They
also deliver constant torque over their entire speed range, starting from zero, whereas AC
and DC motors lose torque at low speeds. The new motors are smaller than an AC motor
and gearbox combined. Theyre also easier to install and require less wiring.
Synchronous torque motors have a distinctive hollow cylinder or ring shape, and contain
a very high number of magnetic pole pairsup to 10 times more than other types of
electric motors. Thats how they generate such high torque (2000 to 11,000 Nm) at low
speeds (20 to 500 rpm). At that speed range, the motors can connect directly to the thrust
bearing of an extruder without gears (though gears may be used). Conventional AC and
DC motors require high speeds (2000 to 3000 rpm) and gear boxes to generate high
torque.

APPLICATIONS:

Extruder applications which require high torque are a common use for DC Motors and
offer a cost effective solution on larger sizes compared to AC Inverter drives. Digital DC
motor controllers can be 98&percent; efficient, an important point in an ever increasing
green world, offer a simple control design with low cost options of dynamic and four
quadrant regenerative braking systems. DC motor speed controllers also benefit from
high reliability and low maintenance and have lower power line harmonics without the
use of expensive chokes.
A growing area for DC motors is the use of low voltage motors for battery powered
application often used in mobile applications using 12,24,36,48 volt configurations both
on land or water. Our Technodrives range of DC Electric Motors is available in both low
and standard voltages and can easily connected to gearbox to make a geared DC motor

unit. We welcome your enquiries for low voltage DC Motors and geared DC Motor units
that are available on short lead times with specials available in small batch quantities.
Also, Extruders are commonly used in rubber and plastic product manufacturing as well
as food processing industries. Historically, plastics manufacturers have used DC motors
to power extruders while some turned to larger traditional AC induction motors.
Other uses for the small DC Motors are:

Mobile

Medical

Textile applications and

Robotics

Permanent Magnet Technology


By reducing rotor losses, the patented radial magnet rotor technology greatly improves
the drives system efficiency and improves the machines footprint. With the LSRPM
series motors, this innovative technology is now available in an IP 55 mechanism (TEFC
equivalent), the most commonly used throughout the industry.
Energy Efficiency
At the equivalent rated speed, LSRPM motors in the DYNEO range have significantly
better efficiency than high-efficiency induction motors. This difference in efficiency
becomes even more significant when operating below this rated speed, which is by
definition the case in variable speed applications!
Unidrive M Enhanced Motor Control
The new Unidrive M high performance motor drive is designed to work directly with
LSRPM permanent magnet motors. The resulting motor control package combines the
high efficiency inherent in permanent magnet synchronous motors with the efficiency of

variable frequency drive technology for optimized uptime, throughput and energy savings
in extruder and other manufacturing applications.
The Unidrive M delivers a robust design for long productive operation including:
Confromal coating for enhanced environmental protection
Built-in power reactors that also reduce harmonics
Built-in EMC filters to prevent interference with sensitive equipment
Onboard intelligence for extruder control that:
Protects the extruder screw
Adapts easily to existing control systems
Connects to any industrial network

METHODOLOGY
This study tends to investigate the perception regarding Dc motors using extruders in the
industry. Moreover, this study will help to determine how this product works. To explain
further more :
Synchronous torque motors are ring-shaped and hollow. The outer part of the ring
consists of an electrified stator with copper windings. The inner part is a rotor with strips
of permanent magnet material (neodymium-iron-boron) mounted lengthwise. No
electricity is supplied to the rotor.
Torque is generated in the gap between the magnetic pole pairs on the rotor and pole
pairs in the windings on the stator. Magnets run lengthwise on the rotor, with al-

ternating positive and negative poles. The number of circuit windings on the stator equals
the number of magnets on the rotor.
Each circuit winding on the stator is also either positive or negative. When AC voltage is
applied to the motor, the windings alternate their polarity (plus/minus). They change
several times a second at a speed that is the same as the motor speed. (Thats the origin of
the term synchronous.) When you want to go faster, you supply more current, which
produces more torque, a Siemens engineer notes.
The larger the rotor diameter, the greater the number of pole pairs to generate power. A
synchronous torque motor may have from eight to 40 pole pairs, dramatically more than
a brushless DC motorwhich has two, four, or six pairsor AC motor, which has four to
six. Conventional DC and AC motors are magnetized only when electricity is flowing
through them. This absorbs power to create the magnetic field and is less efficient than a
permanent-magnet motor. A brushless DC servo motor has permanent magnets on the
rotor and the windings on the stator, but with a smaller diameter and many fewer poles.
Synchronous torque motors have been available for several years in a number of standard
diameters and lengths. Torque increases with both diameter and with length. Smalldiameter motors are shaped like a donut or cylinder; larger-diameter motors are shaped
like thin, flat rings. But motor length has practical limits. Making the strips of permanent
magnet longer generates more torque, but at a certain length, the torque is so great that
the rotor literally comes apart.
In addition, Motor builders developed the first synchronous permanent-magnet torque
motors in the 1980s. But at that time they were large and prohibitively expensive, so only
the military could afford them. They were built first for applications like powering radar
or telescopes or tracking missiles, and later were used for elevators and machine tools.
When more torque was needed to power machine tools, multiple permanent-magnet
motors were lined up in series, which was also expensive.
By the mid 1990s, motor manufacturers de-veloped the first standard permanent-magnet
models and stead ily increased their torque. They targeted injection molding as the
biggest plastics market and one for which this type of motor has the advantage of

delivering constant torque at all speeds, even when ramping up and down to zero.
Injection molding still accounts for three-to-four times more applications for these
motors than extrusion, motor builders say.
People think the torque motor is more expensive, but it isnt really, says Stephan
Halstrick, managing director of Kuhne GmbH in Germany. The motor itself may be more
expensive, but the whole system is cheaper. The first two synchronous torque motors
ever used in extrusion were on Kuhne film lines, one installed in 1997 and the second in
2001. The motors were custom built by Etel Motion Technology in Switzerland. (The
customer still considers the motors a competitive advantage and doesnt want to be
identified.)
Standard models of synchronous torque motors with enough torque for use on extruders
have been available for only three to four years. Most extrusion applications of these
motors are less than a year old, and nearly all are in Europe.
Motor builders are constantly raising their torque capacity. Currently, their upper limit is
10,000 to 11,000 Nm, sufficient for extruders up to 100-mm diam, but still not enough for
high-output blown and cast film lines, which typically use 5- or 6-in. extruders.

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