Explaining Static vs. Dynamic Sheave Balancing

by Don R. Sullivan

BALANCING

Before detailing the differences of static vs. dynamic, let’s first explore balance and its importance to sheaves and the overall drive. When an object like a sheave or even the wheel on a car rotates, centrifugal force causes the mass to naturally move away from the axis of rotation. If a sheave is not balanced, it will have an inherent uneven distribution of weight. This uneven weight distribution (even very minimal) magnifies vibration and noise when rotated and as speed of rotation increases. Unbalanced sheaves can also lead to premature life of other drive components due to the vibration and stresses placed on the components. In order to balance the sheave, we must remove small amounts of material (weight) so that the center of the sheave becomes optimally concentric with the axis of rotation.


STATIC BALANCE

The Mechanical Power Transmission Association (MPTA) is a body of manufacturers, including Browning, that defines criteria for the manufacture of power transmission products including sheaves. Static sheave balance is defined by MPTA as “one plane or static balance.” MPTA states, “A rotating body is said to be in static balance (sometimes called standing balance) when its center of gravity coincides with the axis upon which it revolves.” One plane balance is the recommended norm for most sheave products. As a result most sheaves, such as Browning’s, are statically balanced. The MPTA body corrects for static imbalance by removing weight (typically a drilled hole) from the heavy spot.

NOTE: MPTA one plane balancing guidelines are based on the allowable peripheral speed of cast iron (6,500 ft/min or 33 m/sec).


DYNAMIC BALANCE

With dynamic unbalance vibration also occurs when the part is rotated. MPTA states “dynamic unbalance is a condition where opposite radial centrifugal forces are acting on a sheave but not in the same radial plane. These centrifugal forces form an unbalanced ‘couple’ tending to cause vibration at each end of the sheave, but in opposite directions as shown below.”

Correcting this condition requires a machine that can balance each end independently of the other end. For critical applications or when the sheave is to be operated at a high rpm, a two plane dynamic balance is recommended.

Warning: MPTA and Browning stress — When belt speeds exceed 6,500 feet per minute, special materials must be used. Contact the manufacturer for assistance in selection.


SUMMARY

Static balance is the most common form of sheave balancing and most applications do not require dynamic balance. For those applications that do, manufacturers such as Browning can perform dynamic balancing for an added charge. However, it is best to speak with an application engineer to determine if the application is a candidate.

Explaining V-Belt Drive Misalignment

by Don R. Sullivan

V-belt drive misalignment exists when the driver and driven sheaves are not properly aligned. Misalignment can take either the form of angular or parallel (offset) misalignment, or a combination of both.


Figure 2. Parallel misalignment.
Angular misalignment occurs when the faces of the sheaves do not form a straight line. (See Figure 1.)

With parallel misalignment, the sheaves may be in angular alignment, but their position on the shaft creates a parallel offset. (See Figure 2.)

Ideally, you want to have both parallel and angular harmony. The objective is to have the shafts parallel and the center lines of the two sheaves in line with each other. (See Figure 3.)

IMPACTS OF V-BELT MISALIGNMENT

Figure 3. Desired alignment.
Excessive V-belt drive misalignment causes one or more of the following drive conditions:

1. Premature V-belt failure.

2. Uneven and premature sheave wear.

3. Higher V-belt operating temperature and energy consumption.

4. Uneven wear on belt sidewall.

5. V-belts rolling over in the sheave groove.

6. Transfer of load to one side of the V-belt, which can destroy the belt cords on that side.

7. Increased probability of vibration.

8. Drive instability.


BEST PRACTICES FOR V-BELT DRIVE ALIGNMENT

Acceptable V-belt misalignment for raw edge cogged V-belts is 1/2° or 1/10 inch per foot of center distance. Non-cogged V-belts can tolerate sheave misalignment of about 2° maximum.

The easiest way to quickly ensure sheave alignment is to use a straight edge or multi point contact string method.

Special Note: Sheave alignment should be checked before and after belt tensioning. Always adhere to strict safety and lock out and tag out procedures when performing maintenance on a V-belt drive.

V-Belt Drive Video 

An informative V-belt drive sheave installation and tensioning instructional video

Circuit wiring

So far, we've been analyzing single-battery, single-resistor circuits with no regard for the connecting wires between the components, so long as a complete circuit is formed. Does the wire length or circuit "shape" matter to our calculations? Let's look at a couple of circuit configurations and find out:

When we draw wires connecting points in a circuit, we usually assume those wires have negligible resistance. As such, they contribute no appreciable effect to the overall resistance of the circuit, and so the only resistance we have to contend with is the resistance in the components. In the above circuits, the only resistance comes from the 5 Ω resistors, so that is all we will consider in our calculations. In real life, metal wires actually do have resistance (and so do power sources!), but those resistances are generally so much smaller than the resistance present in the other circuit components that they can be safely ignored. Exceptions to this rule exist in power system wiring, where even very small amounts of conductor resistance can create significant voltage drops given normal (high) levels of current.

If connecting wire resistance is very little or none, we can regard the connected points in a circuit as being electrically common. That is, points 1 and 2 in the above circuits may be physically joined close together or far apart, and it doesn't matter for any voltage or resistance measurements relative to those points. The same goes for points 3 and 4. It is as if the ends of the resistor were attached directly across the terminals of the battery, so far as our Ohm's Law calculations and voltage measurements are concerned. This is useful to know, because it means you can re-draw a circuit diagram or re-wire a circuit, shortening or lengthening the wires as desired without appreciably impacting the circuit's function. All that matters is that the components attach to each other in the same sequence.

It also means that voltage measurements between sets of "electrically common" points will be the same. That is, the voltage between points 1 and 4 (directly across the battery) will be the same as the voltage between points 2 and 3 (directly across the resistor). Take a close look at the following circuit, and try to determine which points are common to each other:

Here, we only have 2 components excluding the wires: the battery and the resistor. Though the connecting wires take a convoluted path in forming a complete circuit, there are several electrically common points in the electrons' path. Points 1, 2, and 3 are all common to each other, because they're directly connected together by wire. The same goes for points 4, 5, and 6.

The voltage between points 1 and 6 is 10 volts, coming straight from the battery. However, since points 5 and 4 are common to 6, and points 2 and 3 common to 1, that same 10 volts also exists between these other pairs of points:

Between points 1 and 4 = 10 volts                             
Between points 2 and 4 = 10 volts                               
Between points 3 and 4 = 10 volts (directly across the resistor) 
Between points 1 and 5 = 10 volts                              
Between points 2 and 5 = 10 volts                              
Between points 3 and 5 = 10 volts                               
Between points 1 and 6 = 10 volts (directly across the battery)  
Between points 2 and 6 = 10 volts                             
Between points 3 and 6 = 10 volts                      

Since electrically common points are connected together by (zero resistance) wire, there is no significant voltage drop between them regardless of the amount of current conducted from one to the next through that connecting wire. Thus, if we were to read voltages between common points, we should show (practically) zero:

Between points 1 and 2 = 0 volts    Points 1, 2, and 3 are  
Between points 2 and 3 = 0 volts     electrically common    
Between points 1 and 3 = 0 volts                          
                                                             
Between points 4 and 5 = 0 volts    Points 4, 5, and 6 are 
Between points 5 and 6 = 0 volts     electrically common   
Between points 4 and 6 = 0 volts                         

This makes sense mathematically, too. With a 10 volt battery and a 5 Ω resistor, the circuit current will be 2 amps. With wire resistance being zero, the voltage drop across any continuous stretch of wire can be determined through Ohm's Law as such:

It should be obvious that the calculated voltage drop across any uninterrupted length of wire in a circuit where wire is assumed to have zero resistance will always be zero, no matter what the magnitude of current, since zero multiplied by anything equals zero.

Because common points in a circuit will exhibit the same relative voltage and resistance measurements, wires connecting common points are often labeled with the same designation. This is not to say that the terminal connection points are labeled the same, just the connecting wires. Take this circuit as an example:

Points 1, 2, and 3 are all common to each other, so the wire connecting point 1 to 2 is labeled the same (wire 2) as the wire connecting point 2 to 3 (wire 2). In a real circuit, the wire stretching from point 1 to 2 may not even be the same color or size as the wire connecting point 2 to 3, but they should bear the exact same label. The same goes for the wires connecting points 6, 5, and 4.

Knowing that electrically common points have zero voltage drop between them is a valuable troubleshooting principle. If I measure for voltage between points in a circuit that are supposed to be common to each other, I should read zero. If, however, I read substantial voltage between those two points, then I know with certainty that they cannot be directly connected together. If those points are supposed to be electrically common but they register otherwise, then I know that there is an "open failure" between those points.

One final note: for most practical purposes, wire conductors can be assumed to possess zero resistance from end to end. In reality, however, there will always be some small amount of resistance encountered along the length of a wire, unless its a superconducting wire. Knowing this, we need to bear in mind that the principles learned here about electrically common points are all valid to a large degree, but not to an absolute degree. That is, the rule that electrically common points are guaranteed to have zero voltage between them is more accurately stated as such: electrically common points will have very little voltage dropped between them. That small, virtually unavoidable trace of resistance found in any piece of connecting wire is bound to create a small voltage across the length of it as current is conducted through. So long as you understand that these rules are based upon ideal conditions, you won't be perplexed when you come across some condition appearing to be an exception to the rule. 

REVIEW:

• Connecting wires in a circuit are assumed to have zero resistance unless otherwise stated.
• Wires in a circuit can be shortened or lengthened without impacting the circuit's function -- all that matters is that the components are attached to one another in the same sequence.
• Points directly connected together in a circuit by zero resistance (wire) are considered to be electrically common.
• Electrically common points, with zero resistance between them, will have zero voltage dropped between them, regardless of the magnitude of current (ideally).
• The voltage or resistance readings referenced between sets of electrically common points will be the same.
• These rules apply to ideal conditions, where connecting wires are assumed to possess absolutely zero resistance. In real life this will probably not be the case, but wire resistances should be low enough so that the general principles stated here still hold.

Nonlinear conduction

Bernhard Haisch, Astrophysicist

Ohm's Law is a simple and powerful mathematical tool for helping us analyze electric circuits, but it has limitations, and we must understand these limitations in order to properly apply it to real circuits. For most conductors, resistance is a rather stable property, largely unaffected by voltage or current. For this reason we can regard the resistance of many circuit components as a constant, with voltage and current being directly related to each other.

For instance, our previous circuit example with the 3 Ω lamp, we calculated current through the circuit by dividing voltage by resistance (I=E/R). With an 18 volt battery, our circuit current was 6 amps. Doubling the battery voltage to 36 volts resulted in a doubled current of 12 amps. All of this makes sense, of course, so long as the lamp continues to provide exactly the same amount of friction (resistance) to the flow of electrons through it: 3 Ω.

However, reality is not always this simple. One of the phenomena explored in a later chapter is that of conductor resistance changing with temperature. In an incandescent lamp (the kind employing the principle of electric current heating a thin filament of wire to the point that it glows white-hot), the resistance of the filament wire will increase dramatically as it warms from room temperature to operating temperature. If we were to increase the supply voltage in a real lamp circuit, the resulting increase in current would cause the filament to increase temperature, which would in turn increase its resistance, thus preventing further increases in current without further increases in battery voltage. Consequently, voltage and current do not follow the simple equation "I=E/R" (with R assumed to be equal to 3 Ω) because an incandescent lamp's filament resistance does not remain stable for different currents.

The phenomenon of resistance changing with variations in temperature is one shared by almost all metals, of which most wires are made. For most applications, these changes in resistance are small enough to be ignored. In the application of metal lamp filaments, the change happens to be quite large.

This is just one example of "nonlinearity" in electric circuits. It is by no means the only example. A "linear" function in mathematics is one that tracks a straight line when plotted on a graph. The simplified version of the lamp circuit with a constant filament resistance of 3 Ω generates a plot like this:

The straight-line plot of current over voltage indicates that resistance is a stable, unchanging value for a wide range of circuit voltages and currents. In an "ideal" situation, this is the case. Resistors, which are manufactured to provide a definite, stable value of resistance, behave very much like the plot of values seen above. A mathematician would call their behavior "linear."

A more realistic analysis of a lamp circuit, however, over several different values of battery voltage would generate a plot of this shape:

The plot is no longer a straight line. It rises sharply on the left, as voltage increases from zero to a low level. As it progresses to the right we see the line flattening out, the circuit requiring greater and greater increases in voltage to achieve equal increases in current.

If we try to apply Ohm's Law to find the resistance of this lamp circuit with the voltage and current values plotted above, we arrive at several different values. We could say that the resistance here is nonlinear, increasing with increasing current and voltage. The nonlinearity is caused by the effects of high temperature on the metal wire of the lamp filament.

Another example of nonlinear current conduction is through gases such as air. At standard temperatures and pressures, air is an effective insulator. However, if the voltage between two conductors separated by an air gap is increased greatly enough, the air molecules between the gap will become "ionized," having their electrons stripped off by the force of the high voltage between the wires. Once ionized, air (and other gases) become good conductors of electricity, allowing electron flow where none could exist prior to ionization. If we were to plot current over voltage on a graph as we did with the lamp circuit, the effect of ionization would be clearly seen as nonlinear:

The graph shown is approximate for a small air gap (less than one inch). A larger air gap would yield a higher ionization potential, but the shape of the I/E curve would be very similar: practically no current until the ionization potential was reached, then substantial conduction after that.

Incidentally, this is the reason lightning bolts exist as momentary surges rather than continuous flows of electrons. The voltage built up between the earth and clouds (or between different sets of clouds) must increase to the point where it overcomes the ionization potential of the air gap before the air ionizes enough to support a substantial flow of electrons. Once it does, the current will continue to conduct through the ionized air until the static charge between the two points depletes. Once the charge depletes enough so that the voltage falls below another threshold point, the air de-ionizes and returns to its normal state of extremely high resistance.

Many solid insulating materials exhibit similar resistance properties: extremely high resistance to electron flow below some critical threshold voltage, then a much lower resistance at voltages beyond that threshold. Once a solid insulating material has been compromised by high-voltage breakdown, as it is called, it often does not return to its former insulating state, unlike most gases. It may insulate once again at low voltages, but its breakdown threshold voltage will have been decreased to some lower level, which may allow breakdown to occur more easily in the future. This is a common mode of failure in high-voltage wiring: insulation damage due to breakdown. Such failures may be detected through the use of special resistance meters employing high voltage (1000 volts or more).

There are circuit components specifically engineered to provide nonlinear resistance curves, one of them being the varistor. Commonly manufactured from compounds such as zinc oxide or silicon carbide, these devices maintain high resistance across their terminals until a certain "firing" or "breakdown" voltage (equivalent to the "ionization potential" of an air gap) is reached, at which point their resistance decreases dramatically. Unlike the breakdown of an insulator, varistor breakdown is repeatable: that is, it is designed to withstand repeated breakdowns without failure. A picture of a varistor is shown here:

There are also special gas-filled tubes designed to do much the same thing, exploiting the very same principle at work in the ionization of air by a lightning bolt.

Other electrical components exhibit even stranger current/voltage curves than this. Some devices actually experience a decrease in current as the applied voltage increases. Because the slope of the current/voltage for this phenomenon is negative (angling down instead of up as it progresses from left to right), it is known as negative resistance.

Most notably, high-vacuum electron tubes known as tetrodes and semiconductor diodes known as Esaki or tunnel diodes exhibit negative resistance for certain ranges of applied voltage.

Ohm's Law is not very useful for analyzing the behavior of components like these where resistance varies with voltage and current. Some have even suggested that "Ohm's Law" should be demoted from the status of a "Law" because it is not universal. It might be more accurate to call the equation (R=E/I) a definition of resistance, befitting of a certain class of materials under a narrow range of conditions.

For the benefit of the student, however, we will assume that resistances specified in example circuits are stable over a wide range of conditions unless otherwise specified. I just wanted to expose you to a little bit of the complexity of the real world, lest I give you the false impression that the whole of electrical phenomena could be summarized in a few simple equations.

REVIEW:

• The resistance of most conductive materials is stable over a wide range of conditions, but this is not true of all materials.
• Any function that can be plotted on a graph as a straight line is called a linear function. For circuits with stable resistances, the plot of current over voltage is linear (I=E/R).
• In circuits where resistance varies with changes in either voltage or current, the plot of current over voltage will be nonlinear (not a straight line).
• A varistor is a component that changes resistance with the amount of voltage impressed across it. With little voltage across it, its resistance is high. Then, at a certain "breakdown" or "firing" voltage, its resistance decreases dramatically.
• Negative resistance is where the current through a component actually decreases as the applied voltage across it is increased. Some electron tubes and semiconductor diodes (most notably, the tetrode tube and the Esaki, or tunnel diode, respectively) exhibit negative resistance over a certain range of voltages.

Resistors

Because the relationship between voltage, current, and resistance in any circuit is so regular, we can reliably control any variable in a circuit simply by controlling the other two. Perhaps the easiest variable in any circuit to control is its resistance. This can be done by changing the material, size, and shape of its conductive components (remember how the thin metal filament of a lamp created more electrical resistance than a thick wire?).
Special components called resistors are made for the express purpose of creating a precise quantity of resistance for insertion into a circuit. They are typically constructed of metal wire or carbon, and engineered to maintain a stable resistance value over a wide range of environmental conditions. Unlike lamps, they do not produce light, but they do produce heat as electric power is dissipated by them in a working circuit. Typically, though, the purpose of a resistor is not to produce usable heat, but simply to provide a precise quantity of electrical resistance.
The most common schematic symbol for a resistor is a zig-zag line:

Resistor values in ohms are usually shown as an adjacent number, and if several resistors are present in a circuit, they will be labeled with a unique identifier number such as R₁, R₂, R₃, etc. As you can see, resistor symbols can be shown either horizontally or vertically:

Real resistors look nothing like the zig-zag symbol. Instead, they look like small tubes or cylinders with two wires protruding for connection to a circuit. Here is a sampling of different kinds and sizes of resistors:

In keeping more with their physical appearance, an alternative schematic symbol for a resistor looks like a small, rectangular box:

Resistors can also be shown to have varying rather than fixed resistances. This might be for the purpose of describing an actual physical device designed for the purpose of providing an adjustable resistance, or it could be to show some component that just happens to have an unstable resistance:

In fact, any time you see a component symbol drawn with a diagonal arrow through it, that component has a variable rather than a fixed value. This symbol "modifier" (the diagonal arrow) is standard electronic symbol convention.
Variable resistors must have some physical means of adjustment, either a rotating shaft or lever that can be moved to vary the amount of electrical resistance. Here is a photograph showing some devices called potentiometers, which can be used as variable resistors:

Because resistors dissipate heat energy as the electric currents through them overcome the "friction" of their resistance, resistors are also rated in terms of how much heat energy they can dissipate without overheating and sustaining damage. Naturally, this power rating is specified in the physical unit of "watts." Most resistors found in small electronic devices such as portable radios are rated at 1/4 (0.25) watt or less. The power rating of any resistor is roughly proportional to its physical size. Note in the first resistor photograph how the power ratings relate with size: the bigger the resistor, the higher its power dissipation rating. Also note how resistances (in ohms) have nothing to do with size!
Although it may seem pointless now to have a device doing nothing but resisting electric current, resistors are extremely useful devices in circuits. Because they are simple and so commonly used throughout the world of electricity and electronics, we'll spend a considerable amount of time analyzing circuits composed of nothing but resistors and batteries.
For a practical illustration of resistors' usefulness, examine the photograph below. It is a picture of a printed circuit board, or PCB: an assembly made of sandwiched layers of insulating phenolic fiber-board and conductive copper strips, into which components may be inserted and secured by a low-temperature welding process called "soldering." The various components on this circuit board are identified by printed labels. Resistors are denoted by any label beginning with the letter "R".

This particular circuit board is a computer accessory called a "modem," which allows digital information transfer over telephone lines. There are at least a dozen resistors (all rated at 1/4 watt power dissipation) that can be seen on this modem's board. Every one of the black rectangles (called "integrated circuits" or "chips") contain their own array of resistors for their internal functions, as well.
Another circuit board example shows resistors packaged in even smaller units, called "surface mount devices." This particular circuit board is the underside of a personal computer hard disk drive, and once again the resistors soldered onto it are designated with labels beginning with the letter "R":

There are over one hundred surface-mount resistors on this circuit board, and this count of course does not include the number of resistors internal to the black "chips." These two photographs should convince anyone that resistors -- devices that "merely" oppose the flow of electrons -- are very important components in the realm of electronics!
In schematic diagrams, resistor symbols are sometimes used to illustrate any general type of device in a circuit doing something useful with electrical energy. Any non-specific electrical device is generally called a load, so if you see a schematic diagram showing a resistor symbol labeled "load," especially in a tutorial circuit diagram explaining some concept unrelated to the actual use of electrical power, that symbol may just be a kind of shorthand representation of something else more practical than a resistor.
To summarize what we've learned in this lesson, let's analyze the following circuit, determining all that we can from the information given:

All we've been given here to start with is the battery voltage (10 volts) and the circuit current (2 amps). We don't know the resistor's resistance in ohms or the power dissipated by it in watts. Surveying our array of Ohm's Law equations, we find two equations that give us answers from known quantities of voltage and current:

Inserting the known quantities of voltage (E) and current (I) into these two equations, we can determine circuit resistance (R) and power dissipation (P):

For the circuit conditions of 10 volts and 2 amps, the resistor's resistance must be 5 Ω. If we were designing a circuit to operate at these values, we would have to specify a resistor with a minimum power rating of 20 watts, or else it would overheat and fail.

• REVIEW:
• Devices called resistors are built to provide precise amounts of resistance in electric circuits. Resistors are rated both in terms of their resistance (ohms) and their ability to dissipate heat energy (watts).
• Resistor resistance ratings cannot be determined from the physical size of the resistor(s) in question, although approximate power ratings can. The larger the resistor is, the more power it can safely dissipate without suffering damage.
• Any device that performs some useful task with electric power is generally known as a load. Sometimes resistor symbols are used in schematic diagrams to designate a non-specific load, rather than an actual resistor.

Calculating electric power

We've seen the formula for determining the power in an electric circuit: by multiplying the voltage in "volts" by the current in "amps" we arrive at an answer in "watts." Let's apply this to a circuit example:

In the above circuit, we know we have a battery voltage of 18 volts and a lamp resistance of 3 Ω. Using Ohm's Law to determine current, we get:

Now that we know the current, we can take that value and multiply it by the voltage to determine power:

Answer: the lamp is dissipating (releasing) 108 watts of power, most likely in the form of both light and heat.
Let's try taking that same circuit and increasing the battery voltage to see what happens. Intuition should tell us that the circuit current will increase as the voltage increases and the lamp resistance stays the same. Likewise, the power will increase as well:

Now, the battery voltage is 36 volts instead of 18 volts. The lamp is still providing 3 Ω of electrical resistance to the flow of electrons. The current is now:

This stands to reason: if I = E/R, and we double E while R stays the same, the current should double. Indeed, it has: we now have 12 amps of current instead of 6. Now, what about power?

Notice that the power has increased just as we might have suspected, but it increased quite a bit more than the current. Why is this? Because power is a function of voltage multiplied by current, and both voltage and current doubled from their previous values, the power will increase by a factor of 2 x 2, or 4. You can check this by dividing 432 watts by 108 watts and seeing that the ratio between them is indeed 4.
Using algebra again to manipulate the formulae, we can take our original power formula and modify it for applications where we don't know both voltage and current:
If we only know voltage (E) and resistance (R):

If we only know current (I) and resistance (R):

An historical note: it was James Prescott Joule, not Georg Simon Ohm, who first discovered the mathematical relationship between power dissipation and current through a resistance. This discovery, published in 1841, followed the form of the last equation (P = I²R), and is properly known as Joule's Law. However, these power equations are so commonly associated with the Ohm's Law equations relating voltage, current, and resistance (E=IR ; I=E/R ; and R=E/I) that they are frequently credited to Ohm.
 
REVIEW:

• Power measured in watts, symbolized by the letter "W".
• Joule's Law: P = I²R ; P = IE ; P = E²/R

Power in electric circuits

In addition to voltage and current, there is another measure of free electron activity in a circuit: power. First, we need to understand just what power is before we analyze it in any circuits.

Power is a measure of how much work can be performed in a given amount of time. Work is generally defined in terms of the lifting of a weight against the pull of gravity. The heavier the weight and/or the higher it is lifted, the more work has been done. Power is a measure of how rapidly a standard amount of work is done.

For American automobiles, engine power is rated in a unit called "horsepower," invented initially as a way for steam engine manufacturers to quantify the working ability of their machines in terms of the most common power source of their day: horses. One horsepower is defined in British units as 550 ft-lbs of work per second of time. The power of a car's engine won't indicate how tall of a hill it can climb or how much weight it can tow, but it will indicate how fast it can climb a specific hill or tow a specific weight.

The power of a mechanical engine is a function of both the engine's speed and its torque provided at the output shaft. Speed of an engine's output shaft is measured in revolutions per minute, or RPM. Torque is the amount of twisting force produced by the engine, and it is usually measured in pound-feet, or lb-ft (not to be confused with foot-pounds or ft-lbs, which is the unit for work). Neither speed nor torque alone is a measure of an engine's power.

A 100 horsepower diesel tractor engine will turn relatively slowly, but provide great amounts of torque. A 100 horsepower motorcycle engine will turn very fast, but provide relatively little torque. Both will produce 100 horsepower, but at different speeds and different torques. The equation for shaft horsepower is simple:

Notice how there are only two variable terms on the right-hand side of the equation, S and T. All the other terms on that side are constant: 2, pi, and 33,000 are all constants (they do not change in value). The horsepower varies only with changes in speed and torque, nothing else. We can re-write the equation to show this relationship:

Because the unit of the "horsepower" doesn't coincide exactly with speed in revolutions per minute multiplied by torque in pound-feet, we can't say that horsepower equals ST. However, they are proportional to one another. As the mathematical product of ST changes, the value for horsepower will change by the same proportion.

In electric circuits, power is a function of both voltage and current. Not surprisingly, this relationship bears striking resemblance to the "proportional" horsepower formula above:

In this case, however, power (P) is exactly equal to current (I) multiplied by voltage (E), rather than merely being proportional to IE. When using this formula, the unit of measurement for power is the watt, abbreviated with the letter "W."

It must be understood that neither voltage nor current by themselves constitute power. Rather, power is the combination of both voltage and current in a circuit. Remember that voltage is the specific work (or potential energy) per unit charge, while current is the rate at which electric charges move through a conductor. Voltage (specific work) is analogous to the work done in lifting a weight against the pull of gravity. Current (rate) is analogous to the speed at which that weight is lifted. Together as a product (multiplication), voltage (work) and current (rate) constitute power.

Just as in the case of the diesel tractor engine and the motorcycle engine, a circuit with high voltage and low current may be dissipating the same amount of power as a circuit with low voltage and high current. Neither the amount of voltage alone nor the amount of current alone indicates the amount of power in an electric circuit.

In an open circuit, where voltage is present between the terminals of the source and there is zero current, there is zero power dissipated, no matter how great that voltage may be. Since P=IE and I=0 and anything multiplied by zero is zero, the power dissipated in any open circuit must be zero. Likewise, if we were to have a short circuit constructed of a loop of superconducting wire (absolutely zero resistance), we could have a condition of current in the loop with zero voltage, and likewise no power would be dissipated. Since P=IE and E=0 and anything multiplied by zero is zero, the power dissipated in a superconducting loop must be zero. (We'll be exploring the topic of superconductivity in a later chapter).

Whether we measure power in the unit of "horsepower" or the unit of "watt," we're still talking about the same thing: how much work can be done in a given amount of time. The two units are not numerically equal, but they express the same kind of thing. In fact, European automobile manufacturers typically advertise their engine power in terms of kilowatts (kW), or thousands of watts, instead of horsepower! These two units of power are related to each other by a simple conversion formula:

So, our 100 horsepower diesel and motorcycle engines could also be rated as "74570 watt" engines, or more properly, as "74.57 kilowatt" engines. In European engineering specifications, this rating would be the norm rather than the exception.

REVIEW:

• Power is the measure of how much work can be done in a given amount of time.
• Mechanical power is commonly measured (in America) in "horsepower."
• Electrical power is almost always measured in "watts," and it can be calculated by the formula P = IE.
• Electrical power is a product of both voltage and current, not either one separately.
• Horsepower and watts are merely two different units for describing the same kind of physical measurement, with 1 horsepower equaling 745.7 watts.