Drive Basics

AC Drives Basics
28th June’2005 Copyright © 2005 Rockwell Automation, Inc. All rights reserved 1
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Basic Concept
How Does A Motor Work?
Basic Rules:
1. Current flowing through a Magnetic flux around the conductor
conductor
Polarity of the magnet
2. The direction of the current
flow
A voltage or current flow
3. Pass a conductor through a
magnetic field

Torque Generated in a motor
Elastic Nature of Magnetic
Rotor Field Created by Induced
Lines of Force Rotor
Current Flow in Rotor Conductors
N S
N S Stator Magnetic Field

Squirrel Cage Induction Motor
Workhorse of modern Industry

Found in virtually every phase of Manufacturing
One of the Most Common Forms of rotating power
in the World
•Consists of two sets of electromagnets – One set ,the stator,
housed in motor Frame and other rotor, free to rotate and
supported by bearings and motor end bells. End Rings
Rotor Bar Fan Blades
Stator Rotor
Perforated Lamination disks stacked together and through
careful die casting process Aluminum or Cu – Brass Alloy
is filled in the channels and then End rings are formed.
Operational Issues
1. To Change the speed
2. Starting Current - Very High
3. Power Factor - Poor at light load
4.Protection - additional Equipments Required

Frequency Drives

AC Technology
Current Source Inverter
Variable Voltage Inverter
PWM Inverters
– V/Hz Inverters
– High Performance Vector Drive – Preferred over CSI & VVI

• Diode rectifier converts AC line voltage to fixed voltage DC.
• DC voltage is filtered to reduce current ripple from rectification.
• Inverter changes fixed voltage DC to adjustable PWM AC voltage.
Actual Drive System
Encoder

PWM INVERTER
AC Input Fixed DC Bus
L + Inverter
C
Diode
Rectifier
Benefits Limitations
Constant input P.F. Extra hardware for regeneration to line
Wide speed range Motor noise (solved with IGBT’s)
High efficiency (97 - 98%) Possible Cable length limitations (with IGBT’s)
Ride through options
Open circuit protection
Common bus regeneration
Smooth low speed operation
Vector control performance (optional)

Rectifier Section - Conversion From AC to DC Positive Diodes
1 3 5
| |
3 phase AC input to
the converter | |
| |
| |
4 6 2
| |
| One 360°Cycle of Power |
6&1 2&3 4&5
| |
DC output
5&6 | 1&2 3&4 5&6 |
| |
| |
60°
Negative Diodes

Precharging Arrangement - in low Rated Drives
To Filter
Section

Precharging Arrangement - in High Rated Drives
Driver
Board
To Filter
Section

Filter Section - Smoothing of Rippled DC
DC Bus (+)
Rectified C Filtered
Input Output
DC Bus(-)
Rectified Filtered
Vdc
DC output DC output
OV OV
Vdc = 1.35VL- L
Idc =(1.1 X 746 X Drive HP)/ Vdc

Inverter Section – Conversion From DC to AC
Positive DC Bus Line
Filtered DC PWM Output

Input
Negative DC Bus Line
IGBT fired in a sequence to produce a PWM output

IGBT – Insulated or Isolated Gate Bipolar Transistor
IGBT combines the positive attributes of BJTs and MOSFETs.
BJTs have lower conduction losses in the on-state, especially in devices with
larger blocking voltages, but have longer switching times, especially at turn-off while.
MOSFETs can be turned on and off much faster, but their on-state conduction losses are
larger, especially in devices rated for higher blocking voltages.
IGBTs have lower on-state voltage drop with high blocking voltage capabilities in addition to
fast switching speeds.
NPN IGBT PNP IGBT

NPN IGBT PNP IGBT
(+) Collector (-) Collector
(+) Collector (-) Collector

(+) Base (-) Base
(+) Base (-) Base
(-) Emitter
(-) Emitter (+) Emitter (+) Emitter


IGBT – Insulated or Isolated Gate Bipolar Transistor
IGBT Advantages
• Higher Switching (Carrier) Frequencies than Bipolar Transistors
– Lower Motor Noise
– Lower Motor Heating
Bi-Polar
• Drive Size Reduction
• High Input Impedance

IGBT
– Reduces Base Driver Power Consumption
– Reduces Base Driver Board Size

PWM WAVEFORMS
Voltage
0
(Line to Neutral)
Current
0
(Line)
The PWM waveform actually is a Square wave DC voltage. This voltage is

applied directly to the AC motor terminals.
Remember, even though we have DC voltage applied to the motor, the current
waveform resembles an AC sine wave. and is used to control speed of the AC
squirrel cage induction motor.
Generation of PWM WAVEFORMS
Triangle
Generator
Modulation
Generator

Sine Weighted PWM Pulses
The pulses are then inverted and are applied to the base of the transistor used to fire “gate”
or turn on the power transistors to create the actual PWM output.

Sine Weighted PWM

Powering the Motor

1 3 5

Phase A

Phase B

Phase C
4 6 2

1,5 and 6 Conducting

Powering the Motor

1 3 5

Phase A

Phase B

Phase C

4 6 2


Powering the Motor

1 3 5

Phase A

Phase B

Phase C
4 6 2


Powering the Motor

1 3 5

Phase A

Phase B

Phase C

4 6 2


Powering the Motor

1 3 5

Phase A

Phase B

Phase C

4 6 2


Powering the Motor

1 3 5

Phase A

Phase B

Phase C

4 6 2


Powering the Motor

1 3 5

Phase A

Phase B

Phase C

4 6 2


Transistor Conduction Order
In summary, fill in the chart below using the diagrams provided. “T1 through T8” represent frozen moments
in time, look at the phases along each time to see which one is most positive and negative. Then apply
what you know about the phases to the IGBT bridge and figure out which transistors are conducting.
Positive DC Buss Line
1 3 5
Phase A
Phase B
Phase C
4 6 2
Negative DC Buss Line
Time Most Positve Phase Most Negative Phase "+" IGBT Conducting "-" IGBT Conducting Turn "On" Order
T1 A&C B 1&5 6 Skip
T2 A B&C 1 6&2 2
T3 A&B C 1&3 2 3
T4 B C&A 3 2&4 4
T5 B&C A 3&5 4 5
T6 C A&B 5 4&6 6
T7 C&A B 5&1 6 1
T8 A B&C 1 6&2 2

How To Change SPEED ??
AC Motor
1. By Changing Number of Poles – Very Complicated and costly method,

Linear Speed Change not Possible
2. By Changing Frequency of Input supply

How To Change SPEED ??
120 x Applied Frequency
RPM =
Number of Poles per Phase
I Want to Control speed I need high speed machine operation

and Save energy ? to increase my production ?
e.g for a 4 POLE & 50 Hz FREQUENCY e.g for a 4 POLE & 60 Hz FREQUENCY
120 X 50 120 X 60
RPM = ----------- = 1500 RPM = ----------- = 1800
4 4
e.g for a 4 POLE & 30 Hz FREQUENCY e.g for a 4 POLE & 70 Hz FREQUENCY
120 X 30 120 X 70
RPM = ----------- = 900 RPM = ----------- = 2100
4 4

Slip
60 RPM
Slip
0 750 1440 1500

Base Sync
Speed Speed
Rotor Speed = Synchronous Speed - Slip Speed

TORQUE Control
In an AC motor, torque varies by:
V 2
T = K x x I
Line
F
Where : V/F proportional to Motor Flux

I is current drawn by the motor
PLAY WITH V/F RATIO TO GET HIGHER STARTING TORQUE

Why Voltage varies as frequency is changed
1). V/F proportional ФRated (Motor Rated Flux)
If Ф > ФRated (What Happens?)
If Ф < ФRated (What Happens?)
2 2
2). Impedance/Reactance Issue Z = R + X
s L S
X L = 2 π fL • XL is dominant above 3-5

hertz
• Since I =V/Z; If we increase or decrease the applied frequency we must also
increase or decrease the applied voltage accordingly.
3). To keep the torque Constant as T α V/F Ratio

Motor Operating Characteristics
600
Starting Current Cu
rre
n t Break down torque
(peak Torque)
Starting torque
400 (Break over Torque)
Rated Torque
% Current at rated FLA.
and Pull UP torque
(DIP Torque) No Load
% Torque
Synchronous
200
speed
Torque
100
0
500 900 1800RPM Base
1725 speed
Speed (RPM) 1750

Torque & Speed Curve without Drive
Breakdown Torque
400
Operating Range
Percent Torque
of Variable Frequency
300 Drives
200
100
0
0 20 40 60 80 100
Percent Synchronous Speed
Torque / Speed with drive applied
Break down torque

(peak Torque)
Torque
200
% Current
and
% Torque Current Rated Torque
100
at rated FLA.
500 900
1800RPM
1725
Speed (RPM)
75RPM Slip
75RPM Slip

0 to Twice Base Speed Operation
Torque
CT range CHP
Peak
1
.64 Tpeak = 2
N
Rated .44
.33
.25
Base 1.25 1.5 1.75 2

Speed (Multiple of Base)

Benefits from Drives
Energy Saving Concept

How How
Drives Can Help
Drives Can Help
Save substantial energy costs (due to direct speed control)
Improves Process by smooth speed control
Save Energy costs by reducing maximum utility demand charges
Increase Life of mechanical equipment (due to ‘soft starting’)
Reduce Motor stress (lower heat, vibration, and transient torques)
Lower chances of System disruptions (by lowering current inrush

from 600% to 100-150%)
Substantially brings down – Down time & Maintenance costs

Benefits of VFD
Flexibility in Starting Current
275 150%-260%
180% 180%
150
% 115%
Torque C
75
B
A
0
AC Full Voltage Reduced Solid State*
Drive Starter Voltage Starter (SMC)
0
120
A
150%
240
%
B
Current 360
C
480
480%
600
600% 600%
* maximum shown,
adjustable via digital switches
Lower Investment in DG sets

No Penalty From Electricity Board
Benefits of VFD
ACCELERATION RANGE
Seconds
0 15 60 30 300 600
AC Drive (Adjustable)
Solid State (Load Dependent) WK 2 x hN

Acceleration Time =
308 x T
Reduced Voltage Where:
WK 2 = Moment of inertia (lb-ft 2)
Full Voltage (Not Adjustable) hN = Change in motor RPM
T = Torque required
308 = Constant
Smooth Start and perfect Control

Benefits of VFD
STOPPING CHOICES
Coast Soft Ramp D.B. DC Inj.
AC Drive X X X X X
Solid State X X
R.V. X
F.V. X
Speed
Time Dynamic DC Ramp Soft Coast

Braking Injection Stop

Benefits of VFD
Complete Motor Protection
Complete Protection for motor

Against Over voltage
Overload
Motor Stalling
Short Circuit
Transients
Phase Loss
I2t Protection to Motor
& so on ……….Just Name….

Drives Save Energy ?

Energy Saving Concepts
Real & Reactive

Phase A
motor current
Real Current Only
Phase B
Phase C
AC Input AC Output
Power PWM VFD Power
• Input Current is less than Output since Source Voltage is Constant
• Lower demand on distribution system

• Power Consumption is proportional to motor speed

Auto-Economizer - Extra Saving
“Idle Mode” Energy Saver
Reduced Load
Automatically fold back Voltage to reduce motor flux

A key in Press Applications - 3-5% Saving

Energy Savings
High Efficiency (>97% )

Improves Power Factor to 0.98
Payback within 12 to 24 months for reduced energy consumption
An investment which pays back

immediately !

Types of Loads & Energy Savings
Variable Torque (VT)
Constant Torque (CT)
Constant Power (CHP)
Non-Motor Applications (NMA)

Variable Torque
Power α (Speed)3
Torque α (Speed)2
HP PRESSURE * FLOW
PRESSURE SPEED2
FLOW
AFFINITY LAW SPEED
HP SPEED3

Some Applications
– FANS – – PUMPS –
• ID / FD Fans • Chilled water pumps
• Primary Air fans • Pressure boosting pumps
• Return fans
• Cooling tower pumps
• Cooling tower fans
• Wastewater pumps
• Ventilation fans
• Dryer fans • Syrup pumps
20 % REDUCTION IN SPEED REDUCES 45 % ENERGY CONSUMPTION

Variable Torque
P2 = P1 X (N2 / N1)3
P2 = 100HP X (1200 / 1440)3
P2 = 58HP
Power Saved = P1 – P2 = 100-58
= 42HP
Multiply this quantity (42HP) by Time of operation and Cost/HP
and get the energy saving on a variable torque applications
Instantly.

Variable Torque
Variable Inlet Vane ID Fan application
To reduce the flow from 100% to

60% , input power requirements
are reduced from
100Saves
% to38%62 %

Variable Torque
Outlet Damper ID Fan application
To reduce the flow from 100% to

60% , input power requirements
are reduced only from
100 % to 86 %
Saves 14%

Variable Torque
Variable Speed Drive ID Fan application

Reduction of flow from 100% to Energy
60% , results into Input power Saved
requirements reduction from
100% to 22%
Saves 78% of Energy

Constant Torque
Power α (Speed)
P=2XΠXNXT
Torque is Constant

Some Applications
Wagon Tippler
Food processing equipment
Screw Feeder
Machine tools
Press and stamping
Conveyor equipment
Crane/Hoists - Drive needs
Packaging machinery a special software
Wood working machinery Lifts
Press and stamping Compressors
Winder Etc…….

Constant Torque
P2 = P1 X (N2 / N1)
P2 = 100HP X (1200 / 1440)
P2 = 84HP
Power Saved = P1 – P2 = 100-84
= 16HP
Multiply this quantity (16HP) by Time of operation and Cost/HP
and get the energy saving on a Constant torque applications
Instantly.
20 % SPEED REDUCTION
Copyright ©SAVES 20 Inc.%All rights
2007 Rockwell Automation, ENERGY
reserved.
Constant Power
P Constant Power
Zone
Example:
Blower
Spindle
P=2XΠXNXT
Mixer etc..
NO Energy Saving
Non-Motor Application
• Electromagnetic Stirring
• Vibration Welding
• Vibratory Conveying
• Induction Heating
• Power Supplies
• Linear Motors
• Resistive Loads
Voltage : Separately Controlled

Frequency : Separately Controlled
Voltage and Frequency Parameters are independent now.
No need to keep V/F ratio constant
It starts with a philosophy

What makes Drives More Reliable
Ambient Temperature of 50 Degree C.
Flexible performance with ForceTM Like Technology.
Seamless Integration
Built in DC Chokes to abate input Current Harmonics (Obeys IEEE 519 -1992 Standards) with
97.5% Efficiency
Power Devices having PIV of 1700V and Transient Protection of 6KV
Built in Software to control the effect of reflected wave
Built in EMC Filters and common mode core to address noise related issues. Conformity to EMC
directives and european Standards.
Excellent Feature of Zero Stacking
PTC input to the Drive
Internal family of communications and HIM modules
7th IGBT – Chopper is internally Provided
Over Load Capacity as per Application.
Complete Output Short Circuit Protection
Compact Size


Drive Basics

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Drive Basics

Uploaded by

Copyright:

Available Formats

AC Drives Basics

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

N S Stator Magnetic Field

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Workhorse of modern Industry

2. Starting Current - Very High

3. Power Factor - Poor at light load

4.Protection - additional Equipments Required

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Current Source Inverter

Variable Voltage Inverter

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Idc =(1.1 X 746 X Drive HP)/ Vdc

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Filtered DC PWM Output

Negative DC Bus Line

IGBT fired in a sequence to produce a PWM output

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

NPN IGBT PNP IGBT

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

• Drive Size Reduction

• High Input Impedance

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

The PWM waveform actually is a Square wave DC voltage. This voltage is

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

1,5 and 6 Conducting

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

1,2 and 6 Conducting

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

1,2 and 3 Conducting

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

2,3 and 4 Conducting

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

3,4 and 5 Conducting

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

4,5 and 6 Conducting

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

1,5 and 6 Conducting

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Positive DC Buss Line

Negative DC Buss Line

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

1. By Changing Number of Poles – Very Complicated and costly method,

2. By Changing Frequency of Input supply

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

I Want to Control speed I need high speed machine operation

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

0 750 1440 1500

Rotor Speed = Synchronous Speed - Slip Speed

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Where : V/F proportional to Motor Flux

PLAY WITH V/F RATIO TO GET HIGHER STARTING TORQUE

X L = 2 π fL • XL is dominant above 3-5

3). To keep the torque Constant as T α V/F Ratio

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.