Practical Presentation SS 2022

Electric Drive Systems

AC Machine (DC Sinamics)

Prepared By:
Fahad Jamshaid

A K MD Bodiuzzaman

Syed Khizar Hayat

Accompanying Course Information 1

 Contents

Goal / Tasks

Introduction

Parts & Components

Circuit & Operation

Safety Measures

Commissioning

Accompanying Course Information 2

 Goal / Tasks

❑ Operate Three Phase AC fan.

❑ Operate Three Phase AC Machine.
(Make sure Machine will run only when Fan is operating).
❑ Measure Rotational Speed of Machine.
❑ Control Speed using Frequency Converter.
❑ Rotation of Motor in both directions.
(Clock-wise and Anti clock wise direction).
❑ Stop Machine in case of Emergency.

Accompanying Course Information 3

 Introduction

AC Machine with DC Sinamics

❑ Three Phase AC Machine

❑ DC Input
❑ AC Output (Three Phase with 50Hz Frequency)

Three Phase AC Supply

DC Supply
3 Phase Inverter, Control
Unit, Electric Components,
Speed Control Unit etc.

Accompanying Course Information 4

 Parts & Components
AC Machine with DC Sinamics

❑ Rectifier
❑ Inverter
❑ Three Phase AC Motor
❑ Tachogenerator
❑ Temperature sensor
❑ Potentiometer
❑ Circuit Breakers
❑ Push Buttons, Switches
❑ Relays
❑ Fuses
❑ Control Unit

Accompanying Course Information 5

 DC Supply via Rectifier

Grid is supplying with AC power and no DC source.

3 phase Rectifier is used to convert 3 phase AC Supply into DC to feed

the DC Sinamics.

Smoothing Capacitor (Filter) can be used to Three Phase Rectifier

remove the ripples from rectifier output.

Accompanying Course Information 6

 Frequency Inverter
❑ Inverter is used to convert DC voltage from rectifier to three phase AC
voltage to run the 3 Phase AC motor.

❑ Harmonics such as 3rd, 5th and so on…

❑ Specially designed filter used to remove the harmonics.

Three Phase Inverter

Accompanying Course Information 7

3 Phase AC Motor
Parts of AC Motor
Three Phase Motor has mainly two parts:

❑ Stator Windings
❑ Stationary part placed in stator of
motor.
❑ Stator Frame, outer part (covering, Stator of 3 Phase AC Motor

protection and mechanical strength)

❑ Stator core (reduce eddy current &
Hysteresis loss)
❑ Stator or field windings (3 windings,
120 degree apart, wound on the stator
of AC machine. Produces three phase
magnetic field.
Accompanying Course Information 8
3 Phase AC Motor

❑ Rotor

❑ Rotating Part of Motor.

❑ Contains conductors in the form of Aluminum or copper bars connected

to form a circuit.

❑ The rotor surrounds the motor shaft and is the motor component that
rotates to produce the mechanical energy output of the motor.

❑ The spinning fan draws ambient air from outside across the stator and
rotor for cooling.

Rotor of 3 phase AC Machine

Accompanying Course Information 9
Operation of 3 Phase AC Motor

Accompanying Course Information 10

Operation of 3 Phase AC Motor

❑ Three Phase AC Supply in given to the Stator windings.

❑ AC currents are phase-shifted by 120o, the magnetic polarity of the

three coils are not all identical at the same instant of time.

❑ Produces three phase changing magnetic field, known as Rotating

Magnetic field.

❑ Changing magnetic field from the stator induces a current in the

rotor coils by EMF (Faraday’s Law).

❑ Rotor induced current results in opposing magnetic field by rotor.

(Lenz’s Law)

❑ The rotor seeks to align its polarity against that of the stator field,
the result being a net torque is applied to the shaft

Accompanying Course Information 11

Components

Tachogenerator

❑ Electrical generator used to detect the speed of electrical machines or

other drives.

❑ Develops DC voltage proportional to the speed of the connected motor.

Temperature Sensor

❑ Used to measure the temperature of motor in order to prevent it from

over heating and to keep the motor within extreme limits.

Potentiometer

❑ It is used to control the speed of motor.

❑ It has three terminal, one with maximum, one with minimum value and
other is sliding terminal.

Accompanying Course Information 12

Components

Relay

❑ The Relay is a switching device which gives a signal to the circuit breaker
as soon as the fault occurs in the power system.

Circuit Breaker

❑ Electrical safety device

❑ Received signal from the relay.
❑ Protect an electrical circuit from damage caused by an overcurrent or
short circuit.

Example:
Motor has installed a relay of 30A.
Current increased from 30A.
Relay give signal to circuit breaker
Circuit breaker interrupts the current.

Accompanying Course Information 13

 Industrial Motor Controls

Figure: control unit [9]

• Power Management control: short circuit protection ,Overvoltage protection
• Speed Control for efficient use of the motor
• Temperature Control : overheating
• Emergency safety control

Accompanying Course Information 14

 Consideration for circuit development
soft-start

▪ Induction motors can have inrush currents seven to ten times that of the
operational current. Starting torques can be 3 times higher to overcome
the starting conditions, causing mechanical stress on the components in
the motor.
▪ Reduce the load on the self-starting motor and the current surge of the
motor during start-up.
▪ This reduces the mechanical stress on the motor and shaft, as well as the
electrodynamics' stresses on the attached power cables and electrical
distribution network, extending the lifespan of the system.

Parameter to monitor:

A digital soft-starter controller continuously monitors the voltage during

start-up, adjusting to the load of the motor to provide a smooth
acceleration and the speed control.
Accompanying Course Information 15
 Speed monitor :

The synchronous speed ns of the motor is calculated by:

120∗𝑓𝑠
ns = [rpm]
𝑃
where ,fs is the synchronous stator frequency in Hz, p is the number of stator poles.

The load torque is produced by slip frequency. The motor speed is characterized by a slip sr

(ns −nr ) nsl

Sr = =
ns ns
Where, nr is the rotor mechanical speed and nsl is the slip speed, both in rpm.

The motor speed is controlled by variation of a stator frequency with the influence of the
load torque.

Accompanying Course Information 16

 Figure: Torque-Speed Characteristic at Constant Voltage and Frequency [9]

Accompanying Course Information 17

 Speed Closed-Loop System

Figure: Closed Loop Control System [9]

To improve system performance, a closed-loop Volts per Hertz control was

introduced. In this method, a speed sensor measures the actual motor
speed and the system takes this input into consideration.

Accompanying Course Information 18

 Connecting the fan
▪ The motor has to be operated with fan
▪ If the motor is operated without fan it will overheat because the heat
that is generated cannot be dissipated.
▪ Destruction of the motor is the consequence.

▪ Provide a protective circuit that prevents the main motor from being
switched on when the fan unit is not in operation.

Parameter to Monitor: Temperature

Accompanying Course Information 19

 Stopping
▪ There are three forms of stopping: coasting, braking or a deceleration ramp.

▪ When power is removed from a motor, it begins to coast to a stop and is time dependent
upon the inertia and the load. Coasting is impractical in some applications because the
motor
would take too long to stop.

▪ Brake can be used to stop the motor quickly. Mechanical brake: magnetic clutch
▪ Electric brake : Dynamic DC braking and regenerative brakes

self-holding

When the relay is triggered, the state is retained by a function called a self-
holding circuit. A self-holding circuit enables a control range to be set and
also prevents the relay from switching rapidly due to ripples of power supply.

Accompanying Course Information 20

 Overview of electrical faults

Figure: Electrical faults[10]

Accompanying Course Information 21

 Wiring diagram

Figure: Wiring diagram

Accompanying Course Information 22

 Safety Measures

1. Personal Health Safety

❑ Avoid working alone in the lab. Perform the lab in the presence of instructor
because the procedures being conducted are hazardous.

❑ High voltages dangerous for health

❑ Avoid using loose dress, or tie while operating the machine

❑ Don’t make changes to the pin configuration (add/remove the pins) while the
machine operating

❑ Know the Emergency Exit routes, first Aid box (1st floor), fire extinguisher and
Emergency contact (I.C.E Call 999,0112)

Accompanying Course Information 23

 Safety Measures

2. Safety for Machinery/Circuit

❑ Emergency Stop Button : The red round button placed in the panel is
Emergency Stop button. Press the button in case of emergency to avoid any bad
things.

Fig : Emergency Stop Button

❑ Wires: Place correct wires at correct positions.
❑ Fuse: The fuse is used to protect the controller in case of over current. we use
F11 here in the circuit. The fuse cannot be repaired once damaged.
❑ Circuit Breaker: The circuit breaker is used to protect the Fan. we use Q1 in the
circuit. The circuit braker is tripped but not damaged.

Accompanying Course Information 24

 Safety Measure

❑ Here in this circuit, for the safety we introduce a topology that when the motor
rotates (as explained previously) it produce heat losses. The heat losses is
proportional to the square of the current.

❑ To counter this effect, a cooling system (Fan) needs to be operate in parallel

with the motor operation all the time.

❑ For further safety, the motor will works only when the Fan is working properly.

❑ For inverter safety, it is necessary to ensure that same leg switches will conduct
in the same time, otherwise it produce the short circuit between the input
supply.

Accompanying Course Information 25

 Wires Color Coding
❑ Black Wire : Used for Live phase
❑ Blue Wire: Used for Neutral

Black and Blue wires are used for single phase AC Supply (220 V)

❑ Red Wire: Used for positive DC

❑ Blue Wire: Used for negative DC / Gnd

❑ Red and Blue wires are used for DC supply

❑ Black, Grey, Brown is used for three phase AC supply

❑ Yellow: used for potential Earth

Accompanying Course Information 26

 Commissioning

▪ Hardware
– Three Phase Rectifiers
– Circuit Breaker
– Fuses
– Relay
– Switches
– Wires

▪ Software
– PWM Generation for inverter switches
– Speed control
– Position control

Accompanying Course Information 27

 Thank You for the Attention ☺

Accompanying Course Information 28

 References
[1] https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.electronics-tutorials.ws%2Fpower%2Fthree-phase-
rectification.html&psig=AOvVaw2F8GxsDQN-
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[2] https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.electricalvolt.com%2F2019%2F06%2Frotating-magnetic-field-in-
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4Ib7qPcCFQAAAAAdAAAAABBD

[3] Construction of Three Phase Induction Motor _ Electrical4U

[4] https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.flaktgroup.com%2Fen%2Fnews%2Fnews-
archive%2F2020%2Fjuly%2Fbasic-principles-of-ac-induction-
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[5] What is a 3-Phase Motor and How Does it Work_

[6] 3 Phase Induction Motor Definition And Working Principle

[7] https://www.allaboutcircuits.com/uploads/articles/ezgif.com-gif-maker_(1)_.gif

[8] https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.researchgate.net%2Ffigure%2Fthree-phase-inverter-output-
voltage-and-current-waveforms-cut-diode-7-The-
difference_fig5_303331885&psig=AOvVaw0JPblOYnbEC8RSM6TEzLLi&ust=1650899162113000&source=images&cd=vfe&ved=0CAw
QjRxqFwoTCOi-3OL8rPcCFQAAAAAdAAAAABAb
[9]. 3-Phase AC Motor Control with V/Hz Speed Closed Loop Using the 56F800/E
https://www.nxp.com/docs/en/application-note/AN1958.pdf
[10].https://cache.industry.siemens.com/dl/files/231/34682231/att_80493/v1/1PL628_BE_0308_en.pdf

Accompanying Course Information 29