New Era University

College Of Engineering and Technology

EE 472
Energy Conversion Laboratory

Application of DC Motor:
Groschopp Grain Hopper

Submitted by: John Kenneth P. Magabo

BSME-IV

Submitted to:Engr.Tim Limsiaco

Introduction
A DC motor relies on the fact that like magnet poles repel and unlike magnetic
poles attract each other. A coil of wire with a current running through it generates
an electromagnetic field aligned with the center of the coil. By switching the
current on or off in a coil its magnetic field can be switched on or off or by
switching the direction of the current in the coil the direction of the generated
magnetic field can be switched 180. A simple DC motor typically has a stationary
set of magnets in the stator and an armature with a series of two or more
windings of wire wrapped in insulated stack slots around iron pole pieces (called
stack teeth) with the ends of the wires terminating on a commutator. The
armature includes the mounting bearings that keep it in the center of the motor
and the power shaft of the motor and the commutator connections. The winding
in the armature continues to loop all the way around the armature and uses
either single or parallel conductors (wires), and can circle several times around
the stack teeth. The total amount of current sent to the coil, the coil's size and
what it's wrapped around dictate the strength of the electromagnetic field
created. The sequence of turning a particular coil on or off dictates what direction
the effective electromagnetic fields are pointed. By turning on and off coils in
sequence a rotating magnetic field can be created. These rotating magnetic fields
interact with the magnetic fields of the magnets (permanent orelectromagnets) in
the stationary part of the motor (stator) to create a force on the armature which
causes it to rotate. In some DC motor designs the stator fields use electromagnets
to create their magnetic fields which allow greater control over the motor. At high
power levels, DC motors are almost always cooled using forced air.
The commutator allows each armature coil to be activated in turn. The current in
the coil is typically supplied via two brushes that make moving contact with the
commutator. Now, some brushless DC motors have electronics that switch the DC
current to each coil on and off and have no brushes to wear out or create sparks.
Different number of stator and armature fields as well as how they are connected
provide different inherent speed/torque regulation characteristics. The speed of a
DC motor can be controlled by changing the voltage applied to the armature. The
introduction of variable resistance in the armature circuit or field circuit allowed
speed control. Modern DC motors are often controlled by power
electronics systems which adjust the voltage by "chopping" the DC current into on
and off cycles which have an effective lower voltage.

Since the series-wound DC motor develops its highest torque at low speed, it is
often used in traction applications such as electric locomotives, and trams. The DC
motor was the mainstay of electric traction drives on both electric and dieselelectric locomotives, street-cars/trams and diesel electric drilling rigs for many
years. The introduction of DC motors and anelectrical grid system to run
machinery starting in the 1870s started a new second Industrial Revolution. DC
motors can operate directly from rechargeable batteries, providing the motive
power for the first electric vehicles and today's hybrid cars and electric cars as
well as driving a host of cordless tools. Today DC motors are still found in
applications as small as toys and disk drives, or in large sizes to operate steel
rolling mills and paper machines.
If external power is applied to a DC motor it acts as a DC generator, a dynamo.
This feature is used to slow down and recharge batteries on hybrid car and
electric cars or to return electricity back to the electric grid used on a street car or
electric powered train line when they slow down. This process is
called regenerative braking on hybrid and electric cars. In diesel electric
locomotives they also use their DC motors as generators to slow down but
dissipate the energy in resistor stacks. Newer designs are adding large battery
packs to recapture some of this energy.

ABOUT GROSChOPP
Overview
Groschopp Inc. is a manufacturer of highly engineered fractional horsepower
motors, electric motors and gearmotors for OEM and distribution products. Our
technical team is experienced in providing integrated solutions for demanding
applications. Groschopp offers a full line of AC, DC, brushless and universal
motors along with a full line of right angle worm, planetary, right angle planetary
and parallel shaft gearboxes
Groschopps manufacturing facility is located in Sioux Center, Iowa and all
Groschopp products are manufactured and assembled in the United States. As an
ISO 9001:2008 registered company, Groschopp delivers expert technical
assistance, superior product performance and over 70 years of quality-honed
workmanship and industry experience. Through years of service to meet the
demands of numerous OEMs, Groschopp has perfected product designs, systems
and manufacturing techniques to offer customers many distinct advantages
including: A full-service engineering department, able to create custom
motors/gearmotors or modify standard designs Fast service for prototypes, OEM
and replacement motors Standard catalog motors/gearmotors built to ship in 48
hours or less 8,000 standard motor designs built-to-order
History
Roots of Quality
The foundation of Groschopp, Inc. began in 1930 as a company called Wincharger.
Based in Sioux City, Iowa, Wincharger was a pioneer in the development of wind
powered generators, primarily marketed in rural areas of the U.S. where modern
electrical service had yet to reach. By the late 1930s, the fledgling company
attracted the attention of Zenith Radio Corporation, who sought to bring radios
powered by Winchargers generators to rural regions.
The foundation of Groschopp, Inc. began in 1930 as a company called Wincharger.
Based in Sioux City, Iowa, Wincharger was a pioneer in the development of wind

powered generators, primarily marketed in rural areas of the U.S. where modern
electrical service had yet to reach. By the late 1930s, the fledgling company
attracted the attention of Zenith Radio Corporation, who sought to bring radios
powered by Winchargers generators to rural regions.
In 1980, a German-based manufacturer of high quality small motor and gear
drives, Groschopp & Co., GmbH, purchased the small motor division of DynaTechnology. The company was acquired by a private trust in 1996 and still
operates under the Groschopp name today, even though its separate from
Groschopps European operations.
Groschopp Today
For over three decades, the company has fostered a philosophy of steady growth
and the highest quality standards to meet the demands of our most exacting OEM
customers including some of the worlds most famous brands. An ISO-9001
company, Groschopp delivers expert technical assistance, superior product
performance and quality-honed from over 70 years of workmanship and industry
experience.
Growing Advantages
Through years of service to meet the demands of numerous OEMs, Groschopp
has honed its designs, systems and manufacturing techniques to offer customers
many distinct advantages including:
Customized motors, most built to ship in just 48 hours.
USA based operations, manufacturing and products Single-plant efficiency
on everything from customer service, engineering and logistics, to
manufacturing and shipping.
Factory-direct sales enhances communications and reduces costs.
The fastest service for prototypes, OEM and replacement motors.
Free MotorTec online design and performance evaluationincluding
speed, torque, and thermal rating with text and graphical output of any
motor, gearbox or combination.

 A growing line of over 8,000 proven, standard motor designs built-toorder

and the FastTrack engineering modification program to quickly solve
applications outside of standard specifications.
Groschopp DC Motor Selection
When talking with a customer, there are
three specs we like to know first: speed,
torque and voltage. This is a good starting
point for us, as we decide what motor best
suits an application. Once we have those
details, we can help the customer find
either a catalog or custom motor, to suit
their needs. In some cases, more than one
motor or gearmotor could fit the required
specs for an application. Below we have an
example to show just such a situation. The benefits of each option are
considered, showing various details to think through when choosing a motor.
A customer has requested a Permanent Magnet DC motor with the following
application requirements:
Application Requirements:
340 RPM running speed
9 in-lbs torque
24VDC supply
There are several available designs to meet these specifications. Here we will
compare two designs, a motor only and a gearmotor, and discuss the potential
that each option offers an application. While both would run the example
application successfully, with additional information regarding the application, we
can determine which designs strengths would be most beneficial for the project

Solution Comparison:
Both designs can meet the continuous duty torque requirement and the cost of
each is equal; however, the addition of a speed control for the motor only will add
some cost.

Summary
There are other things to consider before choosing between the two options. For
example, backlash can be important in applications that require tight positioning
or reversing. Also, faster acceleration can be achieved with the motor only design
since there is more voltage available from the control. The gearmotor will work
well however, for most industrial applications like pumps and conveyors
This is just one example of how two motors can meet certain specs. Keep in
mind, that as the required torque is increased, it will become very impractical to
use a motor only to drive the application. This is because the motor size increases
exponentially in order to meet the torque requirement.
Selecting a Gearmotor in 4 Simple Steps
Lets face it - sometimes choosing a motor is like a high school popularity contest.
Its easy to look at what everyone else is using and assume it will work for you
too. Its time to re-think that strategy.
For design engineers in the process of selecting components for an application,
the motor or gearmotor can be one of the more difficult components to source.
There are so many types of motors and gearmotors all screaming for your
attention and promising to be the most efficient, the highest quality or
boasting about high precision. Groschopp uses 4 simple steps to lead designers
to the best motor/gearmotor choice for a particular application. There are several
key design parameters that should be considered when selecting a motor or
gearmotor for a motion control application.

Table 1: Gearmotor Selection Process steps to complete to ensure a gearmotor

properly matches the application

As the motor or gearmotor selection process begins, the designer must gather the
relevant technical and commercial requirements. This first step is often
overlooked, but it is a critical component in the design process. The gathered
design inputs information will then be used in the selection process and will
dictate the ideal motor for the application. Failure to gather the proper inputs can
lead the designer down an untended path. For this reason, it is helpful to use the
Application Checklist (Table 2) when developing the motor specification. These
parameters, along with some project specific requirements, will be helpful when
navigating the selection process.

Table 2: Application Checklist use this checklist to help formulate the specific
requirements to ensure the gearmotor vendor has the critical information
necessary to achieve the best match between the gearmotor and the application

Next, the designer must consider what type of motor technology best suits the
intended application. Using the design inputs, the Motors Quick Reference Guide
(Table 3) can be used as a selection matrix in the first step of the decision process.
This reference guide details four common motor types and provides general
information to consider when selecting each motor. Because each application has
its own unique characteristics, it is important to determine which of the
parameters (e.g. horsepower, efficiency, life, starting torque or noise ratings) are
most important to the application under consideration. During the motor
selection process, by looking at the required speed and torque of the application,
it should become evident to the designer if the motor chosen requires a gearbox
to meet the necessary requirements. If a gearmotor is necessary for the
application, another level of complexity will be added and several additional
criteria need to be evaluated.

Table 3: Motors Quick Reference Guide provides a comparison of common

parameters used during the motor selection process

Conceptually, motors and gearboxes can be mixed and matched as needed to

best fit the application, but in the end, the complete gearmotor is the driving
factor. There are a number of motors and gearbox types that can be combined;
for example, the right angle worm, planetary and parallel shaft gearboxes can be
combined with permanent magnet DC, AC induction, or brushless DC motors.
Though there are a vast number of different motors and gearboxes combinations
available, not just any one will work for the application. There will be certain
combinations that will be more efficient and cost-effective than others. Knowing
the application and having accurate ratings for the motor and gearbox is the
foundation for successfully integrating the gearmotor into the system
As the designer looks at selecting a gearmotor, there are two methods that can be
used.
Method 1: Select motor and gearbox separately and assemble
Method 2: Select a pre-engineered gearmotor

While both methods 1 and 2 are effective means of finding the most compatible
gearmotor, Method 2 reduces design time and project risk for the designer. When
selecting a pre-engineered solution, the manufacturer has done much of the
heavy lifting to ensure that the motor and gearbox combination will work
properly together. Since performance calculations and testing have been
performed by the manufacturer, gearmotor failures caused by miscalculations or
improper component matching will be minimized. Due to the complexity of
Method 1 this article focuses on Method 2.
Once again, looking back to the gearmotor performance data gathered from the
Application Checklist (Table 2), the speed and torque required for the application
is critical in selecting the gearmotor combination. Using the speed and torque
measurements the designer can then select the manufacturers performance
curves that match the application needs. The gearmotor curve (Figure 1)
combines the performance of the motor and gearbox by displaying speed, torque
and efficiency. If a complete gearmotor assembly is purchased from a
manufacturer this curve is provided by the vendor.
Finally, after selecting a few performance curves that appear to meet the
application needs, it is important to review the design limitations. Look for the
following information in the manufacturers performance calculations and use it
to determine if the chosen gearmotor will cause any issues within the application.
Thermal characteristics

Full-load gearbox torque

Gearbox input speed
Gearbox yield strength
Intermittent duty considerations

Figure 1: Gearmotor Performance Curves the Speed / Torque and Efficiency /

Torque curves for a PM gearmotor.

GROSCHOPP GRAIN HOPPER

Dirt, particulates, mud, grain, heat, cold, water and vibration. Can it get any
uglier? These are just a few of the critical application considerations faced by this
OEM. Their new product design for an automated hopper motor assembly retrofi
ts commercial duty grain trailers and wagons, replacing the mechanical hand
crank system. With this tough environmental challenge, they came to Groschopp
for OEM gear motor design expertise in executing their product concept.
We started by performing a complete MOTORTEC analysis to determine the
exact speed/torque parameters, said Matt Decker, Groschopp Mechanical
Engineer. The OEMs engineering team knows agricultural environment well, and
required a rugged duty gearmotor for the extremes. The overall physical design
was equally critical to success as the performance, Decker continued.
Tight space requirements and cost objectives led the team to a Right Angle (RA)
DC gearmotor, which fit the applications 12 VDC power supply, but exceeded the
100A available current another tough design constraint. High starting torque
and the DC power source made the PMDC a good motor choice, but the RA
gearbox needed more power to provide the needed torque output. Power loss
relates to torque loss, said Decker. There wasnt enough power available to
compensate for the gearbox efficiency loss.
The final design gave them everything they wanted, plus a lot more, said
Decker. Instead of the initial Right Angle gearbox design, for the final product we
used a higher effienciency Planetary Speed Reducer with special material
enhancements for the overall strength of the output gears. Separate testing of
the motor and speed reducer is a technique used by Groschopp to push the
limits of the components and prove out high torque performance.
Once the gearmotor performance fit was determined, the harsh environmental
specifications were tackled. We drew from our experience with heavy
automotive motor assemblies to quickly apply environmental protection
techniques, said Kamstra. The gearmotors are built to IP66 standards, and

withstand submersion testing at 1 meternot a test requirement, but we felt

important given this harsh agricultural environment.
The Challenge
This OEM, a premier supplier to the agricultural equipment industry, had a new
product design for an automated grain hopper motor assembly to retrofit trailers
and wagons. The gearmotor specs included:
Ingress protection (IP) against dust and particulates (meet or exceed IP66
ratings)
High vibration, harsh environment package
High torque output for intermittent loads
12 VDC, 100A power supply limitation
The Solution
Permanent magnet DC motor operating at 12 volts, 100 Amp current limit
High efficiency planetary speed reducer with strengthened output gears
Special corrosion protection features and rugged duty package
enhancements