By Bernard Chiaw

TACHOGENERATORS
Introduction
Tachogenerators are electromechanical sensors or devices that measure the rotational speed of motors, engines,
and machinery by producing an output voltage directly proportional to their shaft speed. They are commonly
used for precise, real-time speed feedback in control systems, such as in conveyor belts, machine tools, and
industrial automation, acting as reliable, rugged, and accurate speed detectors.

Key Aspects of Tachogenerators:

 Operating Principle: They operate based on Faraday's Law of Induction, where a rotating armature
(or magnetic field) induces an electromagnetic force (voltage) proportional to the speed, often allowing
direction to be determined by the voltage polarity.
 Types:
DC Tachogenerators: Provide a DC voltage output directly related to speed.
AC Tachogenerators: Produce an AC voltage that generally requires rectification.
Brushless DC/Permanent Magnet: Modern, robust types with high linearity between speed and
voltage.
 Applications: Essential in feedback loops for motor speed control, industrial robotics, elevator systems,
textile machines, and paper manufacturing.

Tachogenerator Circuit Components & Operation

 Generator Mechanism: A rotor/armature spins within a fixed magnetic field, inducing an EMF
(voltage).
 Output Signal:
DC Tachogenerator: Produces a DC voltage with polarity indicating direction, commonly used in
servo systems for speed feedback.
AC Tachogenerator: Produces sinusoidal voltage (amplitude proportional to speed), needing
rectification for DC speed control, but is more reliable due to lack of brushes.
 Circuit Connection: The output terminals are connected to a high-impedance load (voltmeter or
controller input) to minimize loading effects.
 Components: Often includes a series resistor to limit current under load and variable resistors for
calibration, enabling precise scaling of output voltage to RPM.

Advantages:
 Excellent linearity, allowing precise speed measurement.
 Robust construction for heavy-duty industrial environments.
 Low time constant for fast response.

Performance Metrics: They are often characterized by their voltage output per 1000 RPM (e.g., 50V or 100V
per 1000 RPM).

Tachogenerators are different from encoders as they provide an analog signal directly proportional to speed,
rather than discrete pulses.

DC Tachogenerators
DC tachogenerators are electromechanical devices that produce a precise, linear DC voltage output directly
proportional to rotational shaft speed. Used for velocity feedback in motors and industrial, they offer high
sensitivity, direction sensing, and, through Baumer LongLife technology, durable, low-maintenance
performance.

Construction
DC tachogenerators are small, permanent-magnet DC generators designed for speed measurement, featuring a
rotor (armature), stator (magnets), commutator, and carbon brushes. The rotating armature, often with many
slots for high linearity, produces a voltage directly proportional to the shaft's rotational speed, which is measured
via a DC voltmeter.

Constructional Variations

1|Page
  Frameless Designs: Allow direct mounting onto the motor shaft to reduce size and improve
performance.
 Low-Inertia Rotors: Use hollow, ironless, or wire-wound rotors held by resins to ensure fast, accurate
feedback in control systems.
 Axial Magnets: Used to minimize the overall length of the tachogenerator.

Key Components of a DC Tachogenerator

Permanent magnet, armature, commutator, brushes, variable resistor, and the moving coil voltmeter are the main
parts of the DC tachometer generator. The machine whose speed is to be measured is coupled with the shaft of
the DC tachometer generator.
 Permanent Magnet Stator: Provides a fixed magnetic field, ensuring the output voltage is only
dependent on speed.
 Armature (Rotor): A wound, cylindrical rotor connected to the shaft whose speed is measured.
 Commutator and Brushes: Convert the internal AC voltage to DC and collect the current.
 High-Quality Core: Often designed with many slots for improved output linearity and reduced ripple.

Working Principle
The DC tachometer works on the principle that when the closed conductor moves in the magnetic field, EMF
induces in the conductor. The magnitude of the induced EMF depends on the flux link with the conductor and
the speed of the shaft. The armature of the DC generator revolves between the constant field of the permanent
magnet. The rotation induces the EMF in the coil. The magnitude of the induced EMF is proportional to the shaft
speed.
The commutator converts the alternating current of the armature coil to the direct current with the help of the
brushes. The moving coil voltmeter measures the induced EMF. The polarity of the induced voltage determines
the direction of motion of the shaft. The resistance is connected in series with the voltmeter for controlling the
heavy current of the armature.

EMF Induced in the DC Tachometer Generator

Where: E - Generated voltage, Φ – Flux per poles in Weber, P- Number of poles, N – Speed in revolution per
minutes, Z – The number of the conductor in armature windings and a – Number of the parallel path in the
armature windings.
And,

Hence,

Principle Features

2|Page
 By Bernard Chiaw

 Voltage Proportionality: The induced voltage E is proportional to angular velocity ω (E + KTω),

allowing the attached voltmeter to be calibrated directly in RPM.
 Direction Detection: The polarity of the output voltage indicates the direction of rotation.
 Linearity: High-end tachogenerators are designed for excellent linearity between speed and voltage.
 Limitations: The brush-commutator assembly can generate high-frequency ripples and requires regular
maintenance.

Dynamic Characteristics:
 Linear Speed-Voltage Relationship: Over a wide operating range, the output voltage (UO) is directly
proportional to the rotational speed ( n), following the relationship UO = K x n, where K is the voltage
constant.
 High Dynamic Response: They provide an instantaneous, continuous analog signal, making them ideal
for high-performance PID speed control loops without the, quantization delays found in encoders.
 Low Inertia: Specifically designed high-performance DC tachogenerators (e.g., coreless or pancake
designs) have very low rotor inertia, ensuring they do not affect the dynamics of the machine being
measured.
 Voltage Ripple: The output voltage contains a small ripple component, typically less than 0.5% to
1.5% of the total voltage, which is crucial to minimize for accurate, low-speed applications.
 Reversing Capability: The polarity of the output voltage indicates the direction of rotation.
 Linearity Tolerance: High-quality units maintain a linear relationship with high accuracy, typically
within ± 0.15% at high speeds.

Operational & Physical Characteristics:

 Linearity Errors at Extremes: Non-linearity can occur at extremely low speeds or very high speeds
due to brush contact resistance variations and armature reaction, respectively.
 Armature Reaction: At higher armature currents (load), the magnetic field can be distorted, causing
non-linearity. To minimize this, high input resistance on the voltmeter/controller is required.
 Temperature Sensitivity: The output voltage can be affected by changes in the permanent magnet
strength due to temperature variations, typically with a coefficient of around 0.02-0.03% per °C.
 Maintenance Requirements: Because they use brushes and a commutator to convert internal AC to
DC, periodic maintenance is required.
 Robustness: They are rugged and suited for harsh environments with high vibrations, dust, or moisture.

Technical Specifications (Typical Examples):

 Output Sensitivity: Ranges commonly from 10 V to 100 V per 1000 RPM (10-100 V/KRPM).
 Speed Range: Capable of operating up to 9,000 RPM or higher.
 Load Resistance: Highload impedance is needed to maintain linearity.
 Time Constant (ɽ): Very low, in the microsecond (µs) to millisecond (ms) range, facilitating rapid,
accurate, and continuous speed feedback.

Advantages and disadvantages of DC Tachogenerators

Advantages of DC Tachogenerators
 Linear Relationship: The output voltage is directly proportional to speed, making speed calculations
simple and direct.
 Direction Sensing: The polarity of the output voltage changes with the direction of rotation, allowing
for direction detection.
 High Sensitivity: Provides high-voltage output even in small sizes.
 No Zero-Speed Error: They generally do not suffer from output voltage at zero speed.
 Temperature Compensation: It is easy to compensate for temperature-related errors.

Disadvantages of DC Tachogenerators
 Maintenance: Brushes and commutators require periodic maintenance and are subject to wear and tear.
 Output Ripple: The output voltage often contains small, undesired ripples.
 Non-linearity at Low/High Speeds: They can be inaccurate at very low speeds and suffer from reduced
accuracy due to loading effects at high speeds.
 Radio Interference: The commutation process can produce electromagnetic interference.
3|Page
  Aging: The permanent magnets used in construction can age and lose their magnetic properties over
time.

Applications of DC Tachogenerators
 Speed Control Systems (Closed-Loop Feedback): They are widely used as feedback devices in speed
control circuits for motors. The generated voltage is fed back to a controller (e.g., a PID controller) to
adjust the motor's speed, commonly in DC drives.
 Industrial Machine Tools & Automation: They monitor the speed of spindles, CNC machines,
conveyors, and production lines to ensure accurate operation.
 Transportation & Automotive Industry:
Automobile Speedometers: Used in cars and two-wheelers to measure RPM or kilometers per hour.
Railway Systems: Applied in electric trains, metros, and trams for speed monitoring.
Elevators and Cranes: Employed in hoisting equipment to control cable speed and ensure smooth
stopping.
 Manufacturing Machinery: Used in industries involving continuous processes, such as:
Paper Manufacturing: Paper mills and printing machinery.
Textile Industry: Textile machines and carpet manufacturing.
Metal & Glass Production: Rolling mills and glass production lines.
 Positioning and Robotics: Used in industrial robots, specifically welding and handling robots, to
monitor arm movement.
 Medical Equipment: Utilized in devices, such as haema-tachometers for measuring blood flow rates.
 General Purpose Speed Measurement:
Engines, Fans, & Mixers: Used to monitor operating speeds in various machinery.
Laboratory Equipment: Employed in rate tables and centrifuges for precise speed indication.

Calculations
 Fundamental Voltage Equation is:

Where: eo = Output Voltage (V), Kg = Tachogenerator voltage constant (V/rpm), Kt = Tachogenerator

voltage constant (V/rads/s), N = Speed in rpm and ω = Angular speed.
 Angular speed in rad/sec is,

 Armature Voltage Calculation:

 Terminal Voltage is:

Where: Ra = Armature resistance and Ia = Armature current.

Examples:
1. A DC tachogenerator has a voltage sensitivity of 15 V/1000 rpm. If the measured output voltage
is 45 V, calculate the shaft speed.
Solution:
Tachogenerator voltage constant is:

Tachogenerator output voltage is:

Shaft speed is:

4|Page
 By Bernard Chiaw

Thus,

2. A DC tachogenerator has an armature resistance (Ra) of 50 Ω and a voltage constant (Kg) of 0.1
V/rpm. It is connected to a load resistance (RL) of 950 Ω. Calculate the terminal voltage (V) when
the shaft rotates at 1000 rpm.
Solution:
Generated Voltage is:

Armatures Current is:

Terminal Voltage is:

Hence,

3. A DC tachogenerator produces an EMF of 100 V at 1000 rpm. Find the voltage generated when
the speed is 2500 rpm.
Solution:
Tachogenerator voltage constant is:

Calculating Eg2 at N2 = 2500 rpm:

Hence,

Exercise:
1. A DC tachogenerator produces 50 V when rotating at 200 RPM. Find its voltage constant, Kg and
the output voltage at 3500 RPM. (Hint: Example 3)
2. A 4-pole DC tachogenerator has a wave-wound armature (A=2) with 600 conductors. If the flux
per pole is 2mWb (or 0.002 Wb), calculate the output voltage at 1200 RPM. (Hint: Generated
EMF Equation).

AC Tachogenerators
AC tachogenerators are electromechanical sensors that measure rotational speed by producing an alternating
current (AC) output voltage directly proportional to the shaft's velocity. Commonly brushless with permanent
magnets or drag-cup designs, they provide reliable speed feedback for motor control, conveyors, and robotics.
They offer high durability and long life.

Key Aspects
 Working Principle: An AC tachogenerator consists of a permanent magnet or excited rotor spinning
inside a stator. As the rotor turns, it induces an AC electromotive force (voltage) in the stator windings.
 Output Characteristics: The voltage magnitude (e) and frequency (f) are proportional to the rotational
speed (N). The output is usually given as Vrms per 1,000 rpm.

5|Page
  Direction Sensing: While standard AC tachogenerators do not easily indicate rotation direction due to
the AC nature, using a phase-sensitive rectifier or analyzing the phase shift (180° difference in opposite
directions) allows for direction determination.
Types:
 Permanent Magnet (Synchronous Type): A rotating magnet induces voltage in a stationary winding.
 Drag-Cup (Induction Type): Utilizes an aluminum cup rotating in a magnetic field created by a
reference winding.
Key Advantages:
 Brushless: No commutators or brushes, leading to lower maintenance and longer life.
 Robustness: Suitable for harsh, high-power environments.
Applications: Used as feedback elements in servo motors, speedometers, inverters, and for controlling speed in
manufacturing automation.

Synchronous Tachogenerator
A synchronous tachogenerator is an AC device that measures rotational speed by producing an output voltage
and frequency directly proportional to the shaft's velocity. Using a permanent magnet rotor and non-collector
construction, it offers high reliability, low maintenance, and no sliding contacts, making it ideal for speed sensing
in industrial applications.

Construction

Main Components
 Stator (Field System): The stationary outer part, built with laminated silicon steel to reduce eddy
current losses. It contains slots that hold the armature windings, where the output voltage is induced.
 Rotor (Armature): The rotating part connected to the shaft whose speed is being measured. It consists
of a permanent magnet (most common in modern types) or an electromagnet that creates a constant
magnetic field.
 Frame: Supports the stator core and provides protection, often made of cast iron or welded steel.
 Output Circuit: The AC voltage produced in the stator is typically rectified and measured using a
PMMC voltmeter, which is calibrated to show speed (RPM).

Working Principle
 The permanent magnet rotor is coupled to the shaft whose speed needs to be measured.
 As the shaft rotates, the permanent magnets create a rotating magnetic field.
 This rotating magnetic field cuts the stationary armature windings on the stator, inducing an AC voltage
(EMF) in them.
 The amplitude and frequency of this induced AC voltage are proportional to the angular velocity (speed)
of the shaft.

Key Features & Design

6|Page
 By Bernard Chiaw

 Synchronous Operation: Because the magnetic field is generated by a permanent magnet on the rotor
and rotates at the same speed as the shaft, the output frequency is directly synchronized with the rotation
speed.
 No Brushes: Unlike DC tachogenerators, AC tachogenerators do not require commutators or brushes.
The rotor consists of a permanent magnet, while the stator contains the stationary output coils.
 Brushless Reliability: Because they lack brushes, they are highly reliable, have a long lifespan, and
require minimal maintenance, making them ideal for high-speed industrial applications.
 Signal Output: The generated EMF (voltage) is alternating current (AC). Both the amplitude and
frequency of this signal are proportional to the shaft speed.
 Construction: They often have a stationary armature (stator) and a rotating permanent magnet.

Dynamic Characteristics:
 Output Voltage vs. Speed (Linearity): The AC output voltage amplitude is directly proportional to
the rotational speed, offering a linear relationship over a wide speed range.
 Frequency Proportionality: The output frequency is directly related to the rotor speed and the number
of pole pairs (np, where n is speed and p is pairs).
 Dynamic Response: Because they lack brushes, they can operate reliably at very high speeds
(sometimes exceeding 10,000 rev/min) with low noise.
 Transient Behavior: In self-excited configurations, the voltage build-up depends on the magnetic
saturation of the machine and the connected excitation capacitor.
 Load Sensitivity: While designed for speed measurement, their output voltage can be affected by load
resistance, requiring high-impedance measurement circuits for accuracy.
 Directional Sensing: While a standard AC tachometer indicates speed via voltage amplitude,
specialized setups can detect direction.

Summary Table of Characteristics

Feature Characteristic

Maintenance Low (No brushes)

Construction Rugged, compact

Output AC (Proportional in amplitude/frequency)

Linearity High (but drops at very low/high speeds)

Ripple Very low (especially drag-cup type)

These generators are commonly used for speed feedback in servo-machine test benches and industrial motor
controls.

Advantages of Synchronous Tachogenerators

 Low Maintenance: Because they lack brushes and commutators, they have fewer mechanical parts to
wear out, resulting in a longer lifespan and less maintenance than DC counterparts.
 Rugged Construction: Generally designed with a permanent magnet rotor and a stationary stator, they
are durable and suitable for harsh industrial environments.
 High Accuracy and Reliability: They provide precise speed measurements, particularly when using a
drag cup design which offers high-resolution, ripple-free, and linear output voltage relative to speed.
 Reduced Friction: With no brushes to generate friction, there is less torque required for operation.
 Direction Detection: Certain AC tachogenerator types (like drag cup) allow for direction of rotation to
be determined by measuring the phase of the output voltage.

Disadvantages of Synchronous Tachogenerators

7|Page
  Non-Linearity at Low Speeds: At very low speeds, the output voltage might not be strictly proportional
to speed, and in some, the output voltage polarity is independent of direction (cannot determine direction
without additional circuitry).
 Rectification Needed: The output is an AC signal, which must be rectified and filtered into a DC
voltage for most industrial control systems, adding complexity.
 High-Frequency Non-Linearity: At very high speeds or frequencies, the relationship between input
speed and output voltage can become non-linear.
 Complex Calibration: It is sometimes difficult to calibrate the tachometer, especially the drag-cup
type.
 Voltage Drop Limitations: The output voltage can be affected by the load, and at very low speeds, the
output may be too low for accurate detection.

Applications of synchronous tachogenerators:

1. Speed Measurement and Indication
 Industrial Machinery: Used to monitor the precise operating speed of rotating equipment such as
motors, engines, turbines, conveyors, fans, and mixers.
 Machine Tools: Employed in CNC machines to monitor the speed of axes and spindles.
 Vehicles: Utilized in railway technology and automotive systems to monitor wheel speed, drive speed,
and traction, even in harsh environments (IP67 rating).
 Marine Applications: Used for monitoring the rotational speed of marine diesel engines and shipboard
equipment.

2. Velocity Feedback in Control Systems

 Servomechanisms: Act as speed sensors in closed-loop servo systems to provide precise, real-time
speed feedback to controllers, improving system accuracy and stability.
 Motor Control: Used in variable frequency speed control systems to adjust the motor
voltage/frequency, ensuring optimal performance.
 Elevator Systems: Used for monitoring and Controlling the speed of lifting, ensuring smooth
acceleration, deceleration, and stopping.

3. Industrial and Process Control

 Automation Systems: Used in manufacturing, production lines, and robotic arms to provide, record,
and control speeds, particularly where high precision is required.
 Robotics: Used to detect the speed of joint movements.
 High-End Audio: Employed for precise control of turntable speeds.

4. Specialized Applications
 Aerospace: Used for measuring the rotational speed of aircraft engines and auxiliary power units.
 Research Equipment: Used in rate tables and centrifuges for precise speed monitoring during
experimentation.
 Medical Equipment: Used to track RPM in surgical drills and dental handpieces.

Calculations
 Fundamental Output Equation (Voltage and Speed)
The RMS generated voltage per phase (Eph) is given by:

Where:
 Kw = Winding factor (pitch x distribution factor)
 f = Frequency in Hz (PN/120)
 Φ= Flux per pole in Webers
 Tph = Turns per phase
 Linear Speed-Voltage Relationship
The output voltage VO (rectified or AC) is linear with respect to speed N:

8|Page
 By Bernard Chiaw

Where k is the constant of proportionality (e.g., 10 V/1000 RPM = 0.01 V/RPM).

 Load Regulation (Effect of Load Resistance)
Because the tachogenerator has internal synchronous reactance (XS) and resistance (Ra), the output
voltage drops as the load current increases.

 Frequency Calculation
The frequency is purely dependent on speed and poles:

Examples:
1. A 4-pole, 3-phase, permanent magnet synchronous tachogenerator has a flux per pole of 0.01 Wb.
The stator has 36 slots with 8 conductors per slot (double layer). The machine is driven at 1800
rpm. Assume Kw = 0.96 and all conductors per phase are in series. Calculate the phase voltage.
Solution:
Frequency is:

Total conductors are:

Conductors per phase,

Turns per phase are:

Generated Phase Voltage is:

Hence,

2. A synchronous tachogenerator has a calibration of 15 V per 1000 rpm. If the measured output
voltage (after rectification) is 45 V, what is the speed?
Solution:
Linear Speed-Voltage Relationship is:

But,

Hence Speed is:

3. A 3-phase tachogenerator has an open-circuit phase voltage of 100 V at 3000 rpm. It has a
synchronous reactance of 10 Ω and negligible resistance. If a 20 Ω resistor is connected per phase,
calculate the loaded terminal voltage.
Solution:
Armature Current per Phase is:

Load Terminal Voltage is:

Exercise:

9|Page
A 4-pole synchronous tachogenerator rotates at 1800 RPM. It has 120 turns per phase, a flux per pole of
0.02 Wb, and a winding factor of 0.95. Calculate the output frequency and phase voltage. (Hint: Find f
and Eph as in Example 1)

Induction Tachogenerator
An induction tachogenerator is an AC device that measures rotational speed by producing an output voltage
directly proportional to shaft speed, utilizing Faraday's law of induction. It typically features a stator with two
windings (field and output) and a conductive rotor (often a drag cup), providing a linear, ripple-free AC signal.

An induction tachogenerator (specifically the common Drag Cup variety) is an AC generator designed to
produce an output voltage proportional to the rotational speed of a shaft, operating essentially as a specialized
two-phase induction motor. It is characterized by high reliability, low noise, and the absence of brushes.

Key Aspects of Induction Tachogenerators

 Operating Principle: A constant AC voltage excites the input (field) winding, creating a magnetic flux.
The rotating conductor (drag cup) cuts this flux, inducing an AC voltage in the output winding
proportional to speed.
 Direction Sensing: While producing AC, the phase of the output voltage changes relative to the input
voltage when the direction of rotation reverses.
 Construction: Commonly designed with a "drag cup" rotor for low inertia, and simple, rugged
construction without brushes, requiring little maintenance.
 Linearity: The relationship between output voltage and speed is highly linear, particularly at higher
excitation frequencies (around 400 Hz).

Construction

The construction of an induction tachogenerator consists of three main parts:

 Stator (Stationary Part): The stator contains two distinct sets of windings, usually made of laminated
steel, positioned at 90° to each other in space quadrature.
 Reference Winding (Input Winding): This winding is excited by a constant AC voltage source
(VrcosωCt).
 Quadrature Winding (Output Winding): This winding is positioned at 90° to the reference winding
and provides the output voltage (VO).
 Rotor (Rotating Part): The rotor is made with thin aluminium cup, and it is placed between the field
structure. Instead of a conventional wound rotor, the induction tachogenerator uses a hollow, thin
cylinder made of highly conductive material, typically aluminum (known as a "drag cup"). This cup is
placed in the air gap between the stator field structure. It has very low inertia, allowing it to respond
quickly to changes in speed without heavily loading the shaft.
 Shaft: The drag cup is mounted on the shaft whose rotational speed is being measured.

10 | P a g e
 By Bernard Chiaw

Working Principle
The induction tachogenerator operates through a combination of transformer action and rotational
electromagnetic induction:
 Excitation: The reference winding on the stator is fed with an AC supply, which creates a pulsating
magnetic field (Ɵr).
 Transformer Action (Stationary): When the rotor is stationary, the flux from the reference winding
does not link with the quadrature (output) winding because they are in quadrature (90° apart). Therefore,
the output voltage is zero.
 Rotation (Induced Voltage): When the shaft rotates, the drag cup rotates through the magnetic field of
the reference winding. This causes the flux to be "dragged" in the direction of rotation.
 Quadrature Flux & Output: Due to this, the flux links with the quadrature winding, inducing an
electromotive force (EMF) in it.
 Proportionality: The amplitude of this induced AC output voltage is directly proportional to the
rotational speed of the drag cup, while the phase of the output voltage determines the direction of
rotation.

Key Dynamic Characteristics

 Linear Speed-Voltage Relationship: The output AC voltage amplitude is directly proportional to the
rotational speed (angular velocity, ω) of the shaft, particularly at lower frequencies.
 Minimal Phase Shift: The output voltage is in phase with the excitation voltage, and for an ideal, well-
designed drag-cup induction tachogenerator, the phase shift is negligible.
 High Frequency Performance: To maintain linearity, the input frequency (excitation) is high, often
around 400 Hz or more. At very high speeds or frequencies, this relationship may become non-linear.
 Fast Response: Due to their low inertia (specifically drag-cup types), induction tachogenerators offer
a rapid transient response to changes in speed, making them suitable for high-performance
servomechanisms.
 Voltage Reversal: Reversing the direction of rotation reverses the phase of the output voltage (e.g.,
changes from in-phase to 180° out-of-phase with the excitation).

Performance Factors
 Temperature Dependence: While they are less affected by temperature than DC tachogenerators,
accurate, high-performance applications still require temperature compensation for the output voltage.
 Input Excitation Sensitivity: The output voltage is directly proportional to the magnitude of the input
excitation voltage; therefore, maintaining a strictly constant input excitation voltage is required to ensure
accuracy.
 Low Ripple: Being an AC machine without a commutator or brushes, the output is free from the ripples
associated with DC tachogenerators.
 Non-zero Residual Voltage: When the rotor is stationary, the output voltage is not perfectly zero; it
possesses a small, residual AC voltage.

Advantages
 Low Maintenance & High Reliability: Due to the absence of brushes and commutators, they are
rugged and have a long operational life.
 Low Friction & Inertia: The drag cup construction provides low inertia, which is ideal for precise,
high-speed, and low-friction applications.
 Ripple-Free Output: The output voltage is generally smooth and free of ripples.
 Direction Sensitivity: By analyzing the phase of the output signal relative to the excitation voltage, the
direction of rotation can be determined.
 Linearity: The output voltage is directly proportional to the rotational speed, providing a linear response
over a wide range.

Disadvantages
 Requires AC Excitation: They require an external AC power supply for the reference winding, making
them unsuitable for passive, standalone, or DC-only systems.
 Low-Speed Nonlinearity: At very low speeds, the output voltage frequency is low, which can result in
non-linear or inaccurate readings.
11 | P a g e
  Sensitivity to Excitation Voltage: The output is dependent on maintaining a perfectly constant
excitation voltage and frequency.
 Phase Shift & High Impedance: At high operating speeds (often >400 Hz), the impedance of the coils
increases, which can cause non-linearity in the output.
 Temperature Sensitivity: The output voltage can be affected by temperature changes, as they can
impact the resistance of the drag cup.

Summary Table
Feature Advantage Disadvantage

Maintenance Low (no brushes) N/A

Output Smooth, Linear Low voltage at low speed

Construction Rugged, Low inertia Requires AC excitation

Accuracy Good at high speed Sensitive to frequency changes

The drag cup AC tachogenerator is considered a high-quality sensor for industrial control systems, but it requires
careful calibration and AC power, unlike the simpler but more maintenance-heavy DC tachogenerator.

Applications of Induction Tachogenerators:

1. Motor Speed Control and Feedback
 Variable Frequency Drives (VFDs): They provide precise speed feedback to inverters in closed-loop
AC motor control systems.
 Servo Drives: Used to monitor the angular velocity of motors in servo mechanisms, especially where
high reliability is needed.
 DC Drive Systems: Although AC-based, they are often used in older or specialized DC drive systems
to monitor motor speed.
2. Industrial Automation and Machinery
 Conveyor Systems: They ensure proper synchronization of speed between different segments of
production lines.
 Machine Tools: They monitor the rotational speed of cutting tools, spindles, lathes, and mills.
 Process Machinery: Used in industrial mixers, pumps, and blowers to maintain optimal operational
speeds.
3. Transportation and Heavy Equipment
 Elevator Systems: They provide critical speed, acceleration, and deceleration data to the control system
to ensure smooth operation and precise floor stopping.
 Rail Transit Vehicles: They are used to monitor wheel speed, providing data for automatic train control
systems and traction monitoring.
 Marine and Shipbuilding: Used for measuring the rotational speed of propellers and ship engine
components.
 Automotive/Mining: Used in traction monitoring and in heavy machinery like mining drills.
4. Precision Control Systems
 CNC Machines: Used for continuous monitoring of the speed of axes and spindles.
 Robotics: Used to measure the velocity of robotic joints.
 Rate Tables and Centrifuges: They provide precise speed data for calibration and experimental
conditions.
5. Specialized Applications
 High-End Audio Turntables: Used to accurately control the playback speed of records.
 Energy Harvesting: Some advanced tachogenerators can convert rotating energy into electrical power,
and in some applications, feed it back to the grid, or use it for powering low-energy devices.

12 | P a g e
 By Bernard Chiaw

Calculations
 Output Voltage: Proportional to speed is:

Where K is the tachogenerator constant (V/rad/s or V/RPM) and ω is angular velocity.

 Frequency: For pulse-type induction tachogenerators is:

Where f = frequency (Hz), N = speed (RPM), and P = number of magnetic poles/slots.

 Speed (RPM) from Frequency:

Examples:
1. An AC induction tachogenerator has a sensitivity constant of 0.05 V/(rads/s). Calculate the output
voltage when the shaft rotates at 1000 rpm.
Solution:
Angular velocity in rad/s is:

Thus,

Output Voltage is:

Hence,

Thus,

2. An inductive pulse tachogenerator has 60 teeth (P = 60) and produces an output frequency of 400
Hz. What is the shaft speed in RPM?
Solution:
Speed is:

Hence,

Thus,

3. A drag-cup AC tachogenerator has a linear range up to 5000 rpm. If it produces 10 V at 200 rpm,
calculate the expected voltage at 4000 rpm.
Solution:
The Tahogenerator Voltage Sensitivity is:

Voltage at New Speed is:

Hence,

Thus,

13 | P a g e