Greiner: Electronic publication EP 3200 E by Danfoss Bauer GmbH Clause / Page 6/1

6 Shock cIassifications
While objective criteria exist for determining the "time" parameter, the "shock classification" parameter
is usually left to subjective judgement: "Standard" specifications and even standards talk of
"moderate", "medium" or "heavy" shock loads. However, objective limit values for the permissible
torque shocks may be found in the latest specifications produced by Danfoss Bauer.
The following must be distinguished when drawing up shock classifications:
6.1 Torque shocks caused by the motor
Three-phase asynchronous motors develop breakaway (starting) torques (M
A
) when directly switched
on a stiff supply system. These starting torques correspond to approximately 1.5 to 2.5 times the rated
torque (M
N
) depending on the size and design of the system. M
A
/ M
N
= 2 may be taken as a typical
value for standard-size cage motors. This torque is generated irrespective of the demand in question.
Under full load and where the masses to be accelerated are large, the torque flows mainly through the
gear unit; under no load, the torque is fully absorbed by the rotor. The external mass inertia as
described in clause 7 is, therefore, always to be taken into consideration in the assessment of the
torques generated by the motor in switched operation.
Figure 6.1.1
Typical torque/speed characteristic curve
for a cage motor with the characteristic
values
n - Speed
M - Torque
M
N
- Rated torque
M
A
- Starting (breakaway) torque
M
K
- Breakdown torque
M
S
- Pull-up torque
M
L
- Load torque
M
a
- Acceleration torque
Regenerative braking occurs if the instantaneous speed n of the rotor is greater than the synchronous
speed of the stators rotating field. This occurs, for example, where pole-changing three-phase motors
are switched from a lower number of poles to a higher number of poles.
Figure 6.1.2 shows the shape of the torque characteristic curve in the motoring and regenerative
ranges. The regenerative braking torques are considerably greater than the motoring torques.
0 1 2
n / n
sy

-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
M

/

M
N








1500 r/min 1500 r/min 3000 r/min
MOT MOT
GEN GEN
EBGEN42 | 17.3.2000
Figure 6.1.2
Shape of the torque curve when
switching from the lower number of
poles back to a higher number of
poles at a speed ratio of 2:1.
The motoring breakdown torque to
regenerative breakdown torque ratio
is approximately
1 : 4 in this instance
Greiner: Electronic publication EP 3200 E by Danfoss Bauer GmbH Clause / Page 6/2
Although the shock torques generated by the motor sometimes far exceed the rated torque, it is not
necessary to view them directly as a "shock classification" when calculating the service factor. If they
only occur occasionally, their short duration means that they exert only a minor influence on the "load
collective" critical in the design of a gear unit. If, however, a significant proportion of these acceleration
and deceleration torques flow into external mass moments of inertia, i.e. they load the gear unit, they
will be evaluated in the factor of inertia FI (clause 7) and the switching frequency (clause 8).
Figure 6.1.3
Depending on the factor of inertia FI, torque
shocks generated by the motor are partially
absorbed by the rotor mass; only the remaining
torque shocks flow through the gear unit (see
clause 7)
6.2 Torque overIoad caused by the driven machinery
The shock classification is intended to take account of a known or foreseeable torque increase. This is
caused by the way driven machinery commonly operates. Overloading of this nature may be caused,
for example by
o increased torque demand at low ambient temperatures
o initial resistance to stirring of a stiff medium
o occasional transportation of an excessively heavy bulk load
o hard spots encountered when stripping bark off a tree trunk
o shredding hard material in a crusher or mixer.
According to this definition, the overloading at shock classification III is limited to twice the rated torque
this limit results from taking the external transmission components into account and the design of the
driven machinery.
Danfoss Bauer uses clear objective limit values for the shock classification instead of terms which are
open to subjective interpretation, unlike practically all standardized or customary systems for
determining the service factor:
Shock
classification
Description Short-time permissible overloading
I Uniform without shock loads M/M
N
1
II Moderate shock loads 1 < M/M
N
1.6
III Heavy shock loads 1.6 < M/M
N
2
Figure 6.2.1
Objective classification of shock loads according
to the degree of torque overload
Greiner: Electronic publication EP 3200 E by Danfoss Bauer GmbH Clause / Page 7/1
7 Mass moment of inertia
The acceleration torque marked M
a
in graph 6.1.1 developed by the motor is distributed linearly
amongst the masses. This compliance with the laws of physics is important for the loading of the
downstream gear unit.
1 2 3 4 5 6 7 8 9 10
FI
0
0.2
0.4
0.6
0.8
1
M
e
x
t

/

M
a










ANLMAUFT | 17.9.1998
Figure 7.1
Torque passed to mass
Figure 7.2
External proportion of the torque
The mass inertia present in the system is expressed as a "factor of inertia FI" in accordance with the
standard:
ext rot
rot
J J
FI
J
+
=
FI - Factor of inertia
J
ext
- External mass moment of inertia
J
rot
- Rotor mass moment of inertia
Some manufacturers use a "mass acceleration factor" defined differently in this context:
ext
rot
1
J
FB FI
J
= =
FB - Mass acceleration factor
J
ext
- External mass moment of inertia
J
rot
- Rotor mass moment of inertia
The proportion of the acceleration torque flowing out of the system is shown in graph 7.2; this is
calculated from
ext ext rot
a rot
( 1) 1 M J J FI FI
M J J FI FI

= = =

This consideration explains why the factor of inertia FI has an important function in the determination
of the "shock classification". The following factors are decisive in the determination of the service
factors for Danfoss Bauer gear units:
Shock cIassification I II III
Factor of inertia FI 1.3 1.3 < FI 4 FI > 4
Gear loading
as a proportion of M
a
as a proportion of M
N
(approx.)
0.23 M
a

0.5 M
N
0.23 to 0.75 M
a

0.5 to 1.5 M
N

> 0.75 M
a
> 1.5 M
N