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Features of Ironless Rotor DC Motors
The rotor of a conventional iron core DC motor is made of copper wire which is wound around the poles of its iron
core. Designing the rotor in this manner has the following results:
? A large inertia due to the iron mass which impedes rapid starts and stops
? A cogging effect and rotor preferential positions caused by the attraction of the iron poles to the permanent magnet.
? A considerable coil inductance producing arcing during commutation. This arcing is responsible on the one hand for an
electrical noise, and on the other hand for the severe electro—erosion of the brushes. It is for the latter reason that carbon
type brushes are used in the conventional motors.
A self supporting ironless DC motor from Portescap has many advantages over conventional iron core motors:
? high torque to — inertia ratio
? absence of preferred rotor positions
? very low torque and back EMF variation with armature positions
? essentially zero hysteresis and eddy current losses
? negligible electrical time constant
? almost no risk of demagnetization, thus fast acceleration
? negligible voltage drop at the brushes (with multiwire type brushes)
? lower viscous damping
? linear characteristics
REE System proven to increase
motor life up to 1000 percent
The two biggest contributors to the commutator life in a brush DC motor
are the mechancical brush wear from sliding contacts and the erosion
of the electrodes due to electrical arcing. The superior surface finish,
commutator precision along with material upgrades such as precious
metal commutators with appropriate alloys has helped in reducing the
mechanical wear of the brushes. To effectively reduce electro erosion
in while extending commutator life Portescap innovated its proprietary
REE (Reduced Electro Erosion) system of coils. The REE system reduces
the effective inductivity of the brush commutation by optimization of the
mutual induction of the coil segments. In order to compare and contrast
the benefits of an REE system Portescap conducted tests on motors
with and with out REE coil optimization. The commutator surface wear
showed improvements ranging from 100 -300 percent as shown in Figure
5. Coils 4, 5 and 6 are REE reinforced while 1, 2 & 3 are without REE
reinforcement.
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