1.1 INTRODUCTION

An electric motor converts electrical energy into mechanical energy. The reverse of this would be the conversion of mechanical energy into electrical energy and is done by an electric generator.

In normal motoring mode, most electric motors operate through the interaction between an electric motor's magnetic field and winding currents to generate force within the motor. In certain applications, such as in the transportation industry with traction motors, electric motors can operate in both motoring and generating or braking modes to also produce electrical energy from mechanical energy.

Found in applications as diverse as industrial fans, blowers and pumps, machine tools, household appliances, power tools, and disk drives, electric motors can be powered by direct current (DC) sources, such as from batteries, motor vehicles or rectifiers, or by alternating current (AC) sources, such as from the power grid, inverters or generators. Small motors may be found in electric watches. General-purpose motors with highly standardized dimensions and characteristics provide convenient mechanical power for industrial use. The largest of electric motors are used for ship propulsion, pipeline compression and pumped-storage applications with ratings reaching 100 megawatts. Electric motors may be classified by electric power source type, internal construction, application, type of motion output, and so on. 

However, for a motor to work or achieve the purpose they are made to do whether in industrial or workshop, they must be controlled. The direct, speed and torque must be controlled by a controller.

A motor controller is a device or group of devices that serves to govern in some predetermined manner the performance of an electric motor. A motor controller might include a manual or automatic means for starting and stopping the motor, selecting forward or reverse rotation, selecting and regulating the speed, regulating or limiting the torque, and protecting against overloads and faults.

Different starting methods are employed for starting induction motors because Induction Motor draws more starting current during starting. To prevent damage to the windings due to the high starting current flow, we employ different types of starters.

The simplest form of motor starter for the induction motor is the Direct On Line starter. The Direct On Line Motor Starter (DOL) consist a MCCB or Circuit Breaker, Contactor and an overload relay for protection. Electromagnetic contactor which can be opened by the thermal overload relay under fault conditions.

Typically, the contactor will be controlled by separate start and stop buttons, and an auxiliary contact on the contactor is used, across the start button, as a hold in contact. I.e. the contactor is electrically latched closed while the motor is operating.

1.2 OBJECTIVE OF THE PROJECT

The objective of this work is to design a device for starting and stopping the motor, selecting forward or reverse rotation, selecting and regulating the speed, regulating or limiting the torque, and protecting against overloads and faults.

1.3 SCOPE OF THE PROJECT

The scope of this work covers the building of a forward and reverse direct online motor starter. This device connects a motor to a power source, such as in small appliances or power tools. The switch may be manually operated or may be a relay or contactor connected to some form of sensor to automatically start and stop the motor. The switch may have several positions to select different connections of the motor. This may allow reduced-voltage starting of the motor, reversing control or selection of multiple speeds. Overload and over current protection may be omitted in very small motor controllers, which rely on the supplying circuit to have over current protection. Small motors may have built-in overload devices to automatically open the circuit on overload. Larger motors have a protective overload relay or temperature sensing relay included in the controller and fuses or circuit breakers for over current protection. An automatic motor controller may also include limit switches or other devices to protect the driven machinery.

1.4 SIGNIFICANCE OF THE PROJECT

Direct On-Line is the simplest and cheapest method used for starting three-phase motor. Dol is used for up to 5 HP motor. DOL starter is more popular due to the low price. 

DOL starter connects the motor directly to supply without a reduction in supply voltage and apply full line voltage to 3 phase motor. This is the main disadvantage of DOL starter. 

Small HP motor can be started simply plugging into the power supply. But large HP motor required special unit called a motor starter. 

Small size DOL starter is operated manually but for larger HP motor, dol motor starter are operated using electromechanical contactor (relay) to switch motor ON and OFF.

DOL Motor Starter can be used, if high starting current cannot cause an excessive voltage drop in the motor circuit.

1.5 LIMITATION OF THE PROJECT

1. It does not reduce the starting current of the motor.

2. High Starting Current: Very High Starting Current (Typically 6 to 8 times the FLC of the motor).

3. Mechanically Harsh: Thermal Stress on the motor, thereby reducing its life.

4. Voltage Dip: There is a big voltage dip in the electrical installation because of high in-rush current affecting other customers connected to the same lines and therefore not suitable for higher size squirrel cage motors

5. High starting Torque: Unnecessary high starting torque, even when not required by the load, thereby increased mechanical stress on the mechanical systems such as rotor shaft, bearings, gearbox, coupling, chain drive, connected equipments, etc. leading to premature failure and plant downtimes.

1.6 ADVANTAGES OF DOL STARTER(DIRECT ONLINE STARTER)

i. Direct On-Line motor starter is Cheapest motor Starter.

ii. DOL is the simplest motor starter to design and maintain. 

iii. 100% starting torque.

iv. D O L starter used up to 5HP motor depending upon insulation class of motor. 

1.7 DISADVANTAGES OF DOL STARTER

i. High starting current 

ii. typically 7 to 8 time rated current applied at starting

iii. due to high current stress applied on motor winding. 

iv. not suitable for high rating motor. 

v. create a voltage dip on the power system

vi. High starting torque 

1.8 APPLICATION OF THE PROJECT

D O L starter use for :

i. starting the small motor,
ii. compressor,
iii. small water pumps,
iv. industrial conveyor belts.
v. Fans,
vi. air curtains,
vii. exhaust fan,
viii. blower, etc.