Motor Calculation

Volts = 220V

Current (I) = .32

Cos () =.8

Power= V * I * Cos ()

= 220*.32*.8

=56.32 W

Pin input power, measured in watts (W);

I current, measured in amperes (A);
V applied voltage, measured in volts (V).

Motors supposed to do some work and two important values

define how powerful the motor is. It is motor speed and torque
the turning force of the motor. Output mechanical power of the
motor could be calculated by using the following formula:
Pout = *

Where Pout output power, measured in watts (W);

torque, measured in Newton meters (Nm);
angular speed, measured in radians per second (rad/s).
It is easy to calculate angular speed if you know rotational speed
of the motor in rpm:
= rpm * 2 / 60
= 6000 * 2 / 60
=628 rad/s
Where angular speed, measured in radians per second
(rad/s);
rpm rotational speed in revolutions per minute;
mathematical constant pi (3.14).
60 Number of seconds in a minute.
If the motor has 100% efficiency all electrical power is converted
to mechanical energy. However such motors do not exist. Even
precision made small industrial motors such as one we use as a
generator in generator kit have maximum efficiency of 50-60%.
Motors built from our kits usually have maximum efficiency of
about 15% (see Experiments section on how we estimated this).
Dont be disappointed with 15% maximum efficiency. All our kits
are intended for education and not designed for real applications.
This efficiency is not bad at all it is actually much better than
most of other self-made designs on Internet can provide. The
motors have enough torque and speed to do all kinds of
experiments and calculations.
Measuring the torque of the motor is a challenging task. It
requires special expensive equipment. Therefore we suggest
calculating it.
Efficiency of the motor is calculated as mechanical output power
divided by electrical input power:
E = Pout / Pin
Therefore
Pout = Pin * E
After substitution we get
*=I*V*E
and the formula for calculating torque will be
= (I * V * E *60) / (rpm * 2)
Connect the motor to the load. Using the motor from generator kit
is the best way to do it. Why do you need to connect the motor to
the load? Well, if there is no load there is no torque.
Measure current , voltage and rpm. Now you can calculate the
torque for this load at this speed assuming that you know
efficiency of the motor.
Our estimated 15% efficiency represents maximum efficiency of
the motor which occurs only at a certain speed. Efficiency may be
anywhere between zero and the maximum; in our example below
1000 rpm may not be the optimal speed so the for the sake of
calculations you may use 10% efficiency (E = 0.1).
So
= (I * V * E *60) / (rpm * 2)
T = (.32 * 220 * .1 * 60) / (6000 * 2* 3.14)
T = (422.4) / (37680)
T = 0.0112101 N.m
T= .0112101 *10^6
T = 11210.1 N mm
So the Pout = 6000 * 2 *3.14 *.0112101
Pout = 422.6 W
Motor torque changes with the speed. At no load you have
maximum speed and zero torque. Load adds mechanical
resistance. The motor starts to consume more current to
overcome this resistance and the speed decreases. If you
increase the load at some point motor stops (this is called stall).
When it occurs the torque is at maximum and it is called stall
torque. While it is hard to measure stall torque without special
tools you can find this value by plotting speed-torque graph. You
need to take at least two measurements with different loads to
find the stall torque.

Force Calculation

T= F * x
Where
T is torque
F is force acting on the piston
x is displacement (or the perpendicular distance)

But we know that torque =11210.1 N-mm

So the Force = T/x

Force = 11210.1/20
Force = 560.505 N
At any point of time only on cylinder will be discharging at a time,
so the force acting of each cylinder is equal.

Cylinder Volume

V= /4 * D2 * S
Where
D = diameter of cylinder
S = Stroke of cylinder.

We have selected Phoenix cylinder of 25 X 100

So the diameter of cylinder is =25mm

Stroke of cylinder is =100mm

So the volume =3.14 * 25 * 25 * 100 /4

V=4906.25 mm3

Let us consider that the piston head surface is of 25 mm.

So the effective surface area of the piston = r2

Surface Area= 3.14 * 25 * 25
Surface Area = 1962.5mm

So the pressure at the delivery end will be

P = F/A
=560.505/1962.5
=0.28560 N/ mm2

We know that 1 bar =.1 N/mm2

So Pressure P at the delivery end will be 2.8560 Bars

So the pressure developed by each cylinder individually will

be 2.8560.

So we started from the initial pressure P1 = 1.013 Bar

(atmospheric Pressure)

So the pressure at the discharge end P2 = 2.8560 Bars

So the rise in Pressure P = P2 P1

P = 2.8560 1.013
P = 1.8430 Bars
Compression ration = P2/P1

CR = 2.8560/1.013

CR = 2.819

To check if the design is safe or not, now that we have the force acting
on the piston to give us the required pressure rise, there will be
compressive force acting on the piston.

So Force = 560.25 N

The diameter of the piston rod = 10mm

So the area of the piston = * 10 * 10 /4

= 78.5 mm2

Induced compressive Stress = F/area of piston

= 560.25/78.5

= 7.1369 N/mm2

The allowable compressive stress of MS is 155N/mm2 so the design is

safe.