Would this application warrant the use of a custom wound motor?
Jon
For this particular case, no I can’t get a custom motor, but for the next time, absolutely!
If the motor selection has not already been made, it seems to me that a 2-speed "constant-torque" single winding motor could offer some advantages in this application. With such a motor, before nearing the stop at the end of travel, the high inertia load could be decelerated to 1/2 speed by having contactors select the "low speed" mode. At 1/2 speed the kinetic energy of the load will be reduced by 75% and the momentum by 50%. This should reduce the likelihood of a significant rebound from the stop. When the low speed is selected, the motor will provide regenerative braking and deliver current into its power source until the motor gets close to its synchronous RPM in 1/2 speed mode.
An alternative to reduce the motor volts-per-turn and heating:
If a custom motor was an option, a 9-lead connection to a 2-speed motor would allow the addition of the low speed configuration used in 2-speed "variable torque" motors. This consists of a wye connection of the three pairs of series connected windings which are configured in a delta in the low speed mode of a "constant torque" motor. When this additional connection is selected by contactors, it will reduce the volts-per-turn on the windings down to 58% of that in the "constant torque" low speed configuration, with a consequent reduction in current and heating. This second low-speed mode will have a reduced torque and might be selected after any possibility of a rebound is over, or before that if the rebound is sufficiently controlled using this lower torque level. Of course, this current reduction could also be done with a standard 2-speed "constant torque" motor by using external means such as an autotransformer, series impedances, etc.