Electric drives utilities and need

Dr. Chitra A., SELECT, VIT University

 What are Electrical Drives?

Drives are systems employed for motion control

Require prime movers

Drives that employ electric motors as

prime movers are known as Electrical Drives

Dr. Chitra A., SELECT, VIT University

Introduction----Need for drive
• Most of the industrial drives are powered by IM of ratings upto 300KW.

15%
Pumps
8% Fans
14%
Process and Conveyors
Other Compressors
Air Compressors
8% 23%
Other

32%

Around 92% of the energy consumption is by electric drives

Basic functions of an electric drive

Starting
Speed control
Braking

Dr. Chitra A., SELECT, VIT University

Applications of electric drives

Domestic
Transport
Agricultural
Industrial
Aerospace

Dr. Chitra A., SELECT, VIT University

Applications of electric drives

1-TRANSPORTATION – EV/HV, SUBWAY,LOCOMOTIVES, ELEVATORS

2- HOME APPLIANCES – BLENDER, MIXER, DRILL, WASHING
MACHINE
3- PAPER AND TEXTILE MILLS
4- WIND POWER GENERATION
5- AIR CONDITIONERS AND HEAT PUMPS
6- ROLLING AND CEMENT MILLS
7- MACHINE TOOLS AND ROBOTICS
8- PUMPS AND COMPRESSORS
9- SHIP PROPULSION
10- COMPUTERS AND PERIPHERALS
11- SOLID STATE STARTER FOR MACHINES

Dr. Chitra A., SELECT, VIT University

Operations of electric drives

1. Milling
2. Grinding
3. Pressing
4. Punching
5. Drilling
6. Crushing
7. Lifting
8. Pumping

Dr. Chitra A., SELECT, VIT University

Advantages of electric drives

1. Feasible control characteristics

2. Available in wide range of speed torque and power
3. Higher efficiency
4. Lower noise
5. Cleaner operation
6. Low maintenance requirements
7. Electric energy is easy to transport

Dr. Chitra A., SELECT, VIT University

Disadvantages of electric drives

1. The dependence on a continuous power supply causes

problems with vehicle propulsion.
2. If no power rail or catenary is available, an electric
energy source must be carried on board, which is usually
bulky, heavy and expensive.
3. Due to the magnetic saturation of iron and cooling
problems, electric motors have a lower power to weight
ratio than high pressure hydraulic drives.

Dr. Chitra A., SELECT, VIT University

 Basic functional units of
electric drive

1/12/2024 Dr. Chitra A., SELECT, VIT University

Topics

➢ Difference between conventional and modern

electric drives
➢ Functional block diagram of a drive
➢ Functions of each block
➢ Motor and Load speed torque profiles
➢ Selection criteria for the drive

1/12/2024 Dr. Chitra A., SELECT, VIT University

 Example on VSD application

Constant speed Variable Speed Drives

valve

Supply Supply
motor pump motor
PEC pump

Power Power out

In Power Power out
In

Power loss
Power loss
Mainly in valve

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Dr. Chitra A., SELECT, VIT University
 Conventional electric drives (variable speed)

• Bulky
• Inefficient
• inflexible

1/12/2024 Dr. Chitra A., SELECT, VIT University

 Modern electric drives (With power electronic converters)

• Small
• Efficient
• Flexible

1/12/2024 Dr. Chitra A., SELECT, VIT University

Most of the production equipment in modern industrial
application consists of 3 main parts
➢ Prime mover
➢ Energy transmitting device
➢ Actual apparatus performing the desired job

Prime mover : Steam, Hydraulic, diesel engines…

Recently : Electric motors

Reason : Superior Performance, adjustable control characteristics

Speed, Torque, Acceleration, Deceleration can be controlled using Power

Electronics Controllers depending on the load

1/12/2024 Dr. Chitra A., SELECT, VIT University

Basic elements of an electric drive
• Electric motor along with power conditioning
and control circuit is an electric drive

POWER CONTROL ELECTRIC MECHANICAL

SUPPLY EQUIPME MOTOR LOAD
NT

Dr. Chitra A., SELECT, VIT University

 Electric Drive
Electric Drive

Energy
Transfer
Power Electronic Mechanical
Source Converter Motor Load
(Power
Modulator)

Ref
Controller Sensing unit

1/12/2024
Dr. Chitra A., SELECT, VIT University
 Parts of Electrical Drives

▪ Source ,
▪ power modulator,
▪ Motor,
▪ control unit,
▪ Load

1/12/2024 Dr. Chitra A., SELECT, VIT University

1/12/2024 Dr. Chitra A., SELECT, VIT University
 SOURCES

• AC: 1-ph, 3-ph, Low or medium power:

400V, High power: 3.3kV, 6.6kV, 11kV.

• DC: Main traction 25kV, 50Hz;

Underground traction: 500 to 1500V DC

1/12/2024 Dr. Chitra A., SELECT, VIT University

 SOURCES

• Low power drives – Single Phase

• High Power Drives – Three Phase
• Traction – high power – Single Phase
• Fed from 50 Hz, max speed of IM and Sync motor is approx
3000rpm
• For higher speed – conversion of frequency
• Space and aircraft applications – 400 Hz AC
• Some drives fed from battery
• Low voltage drives – solar powered – space applications

1/12/2024 Dr. Chitra A., SELECT, VIT University

Functions of Power Modulator
➢ Modulates the power flow as required( by the load)
➢During Transient operation ( starting, braking...)limits the
current drawn
➢Converts Electrical Energy as required ( dc-dc, dc- ac, ac-ac…)
➢Determines the modes of operation ( motoring or braking)

1/12/2024 Dr. Chitra A., SELECT, VIT University

 Power Modulators

• Converters
➢ AC – DC converters ( Rectifier)

➢ DC – DC converters ( Chopper)

➢ DC- AC converters (Inverter)

➢ AC- AC converters (AC voltage regulator, Cycloconverter)

1/12/2024 Dr. Chitra A., SELECT, VIT University

 AC-DC converters
Fixed Fixed
AC DC
Diode Rectifier

Fixed Variable
AC Half Controlled DC
Thyristor Converter

Fixed Variable
AC Fully Controlled DC
Thyristor Converter

Variable
Fixed AC Variable
AC Transformer With DC
Taps Diode Rectifier

Fixed Fixed
DC Variable
AC DC
Diode Rectifier
Chopper

1/12/2024 Dr. Chitra A., SELECT, VIT University

 DC-DC converters

Fixed Variable
DC DC
Chopper
Step UP/Step Down

1/12/2024 Dr. Chitra A., SELECT, VIT University

 DC- AC converters
Variable Frequency,
Dc Voltage Variable Voltage AC
PWM Inverters

Variable Frequency,
Dc Voltage Variable Voltage AC
SPWM Inverters

Variable Frequency,
Dc Voltage fixed Voltage AC
Stepped wave
Inverters

1/12/2024 Dr. Chitra A., SELECT, VIT University

 AC – AC Converters
Fixed Variable
AC AC
Transformer with Taps

Fixed Variable
AC AC
Autotransformer

Fixed Variable
AC AC
Thyristor Voltage
Controllers

Fixed Variable
AC AC voltage and frequency
Cycloconverter

1/12/2024 Dr. Chitra A., SELECT, VIT University

 Motors

▪ Motor:

DC Motor AC / Induction Others

Motors
Shunt, series, Cage, Wound Brushless DC
Compound, Permanent rotor, Linear IM, motors, Stepper
magnet Synchronous motors,
motors Switched
Reluctance
Motors
DC motors : Presence of commutator and brushes, high cost, weight,
need frequent maintenance , unsuitable for explosive
environments, restriction on voltage, speed and power ratings

1/12/2024 Dr. Chitra A., SELECT, VIT University

 MotorS
Induction Motors : Costs 1/3 of DC motor of same rating, less
maintenance, can be built for higher power, speed
and voltage ratings

Synchronous motors : High efficiency and better power factor compared

to IM

PMSM: All advantages of IM, available in low ratings

Brushless DC motors : Low cost, simpler – low power applications

Stepper Motor: Position control

SRM : Speed Control

AC drives replaces DC drives in number of applications

1/12/2024
Dr. Chitra A., SELECT, VIT University
 CONTROL UNIT

➢ Controls the power modulator

➢ Connected with a sensing circuits

Speed sensing , Current Sensing

➢ eg. Hall effect sensor.

➢ For closed loop control

➢ Control unit – Firing circuits, transistors, Microprocessor, Microcontroller,

DSP, FPGA…

1/12/2024 Dr. Chitra A., SELECT, VIT University

 Load

Load Torque Characteristics

• Constant
• Linear
• Square
• Inverse

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Dr. Chitra A., SELECT, VIT University
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Dr. Chitra A., SELECT, VIT University
1/12/2024
Dr. Chitra A., SELECT, VIT University
T-N characteristics of motors

Loads will have their own T- characteristics.

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Dr. Chitra A., SELECT, VIT University
 Classes of motor duty

➢ Continuous duty
➢ Short time duty
➢ Intermittent periodic duty
➢ Intermittent periodic duty with starting
➢ Intermittent periodic duty with starting and braking
➢ Continuous duty with intermittent periodic loading
➢ Continuous duty with starting and braking
➢ Continuous duty with periodic speed changes

1/12/2024 Dr. Chitra A., SELECT, VIT University

 Contd
➢ Continuous duty
Motor operation at a constant load torque for long time

➢ Short time duty

Machine can be loaded until at the end of loading time reaches the permissible limit.

1/12/2024 Dr. Chitra A., SELECT, VIT University

 Contd

➢ Intermittent periodic duty

periodic duty cycles – period of running at constant load and rest time
temperature will raise to steady state value or cool down to ambient temperature
Ex. Cutting
Drilling
Pressing

➢ Intermittent periodic duty with starting

Period of starting, period of operation at constant load and rest period
Ex. Fork lift torque, Marine hoist

1/12/2024 Dr. Chitra A., SELECT, VIT University

 Contd
➢ Intermittent periodic duty with starting and braking
Period of starting, period of operation at constant load, electrical braking period and rest
period. Ex. Electric suburban trains

➢ Continuous duty with intermittent periodic loading

Period of running with constant load, and period of running in no load
Ex. Cutting, Drilling, Pressing

➢ Continuous duty with starting and braking

Period of starting, period of operation at constant load and electrical braking period. Ex.
Blooming mills

➢ Continuous duty with periodic speed changes

Period of running at one load and speed, running in different speed and load

Ex. Electric vehicle

1/12/2024 Dr. Chitra A., SELECT, VIT University

TYPES OF ELECTRICAL DRIVES

1. GROUP DRIVE

2. INDIVIDUAL DRIVE

3. MULTIMOTOR DRIVE

Dr. Chitra A., SELECT, VIT University

GROUP DRIVE

If several group of mechanisms or machines are organized on one

shaft and driven or actuated by one motor, the system is called a
group drive or shaft drive.
Drive consists of only one electric motor which drives several
machines
➢Single motor
➢Actuates several mechanisms by means of shafts
➢Called as line shaft drive
➢Multistep pulleys depending on speed

Dr. Chitra A., SELECT, VIT University

GROUP DRIVE

Advantage
• Most Economical
Disadvantage
• Any Fault that occurs in the driving motor renders all the driving
equipment idle.

• Efficiency low because of losses occurring in the energy

transmitting mechanisms (Power loss)

• Not safe to operate.

• Noise level at the working spot is high.

Dr. Chitra A., SELECT, VIT University
GROUP DRIVE

Dr. Chitra A., SELECT, VIT University

 INDIVIDUAL DRIVE

If a single motor is used to drive or actuate a given

mechanism and it does all the jobs connected with this load ,
the drive is called individual drive.
• All the operations connected with operating a lathe may
be performed by a single motor.
• Each motor is driven by its own separated motor with the
help of gears , pulleys etc.
Disadvantage
Due to power loss ,the efficiency of such drive is also poor
Dr. Chitra A., SELECT, VIT University
INDIVIDUAL DRIVE

electric saws,
drills, fans,
washers, blenders,
disk-drives,
electric cars.

Dr. Chitra A., SELECT, VIT University

 MULTIMOTOR DRIVE

Each operation of the mechanism is taken care of by a

separate drive motor.

The System contains several individual drives each of which

is used to operate its own mechanism.

Separate motors are provided for actuating different parts of

the driven mechanism.

Example Cranes
Hoisting, long travel, cross travel – different motors
Dr. Chitra A., SELECT, VIT University
 MULTIMOTOR DRIVE
Advantages
• Increase the overall productivity
• Each Machine is driven by a separated motor it can be run and
stopped as desired.
• Machines not required can be shut down and also replaced with a
minimum of dislocation.
• There is a flexibility in the installation of different machine’s.
• In the case of motor fault, only its connected machine will stop
where as others will continue working undisturbed.
• Safe operation is possible
• Automation is possible
Dr. Chitra A., SELECT, VIT University
MULTIMOTOR DRIVE
Disadvantage
• Initial cost involved is high

paper making machines, robotics, airplanes.

Dr. Chitra A., SELECT, VIT University

MULTIMOTOR DRIVE

Dr. Chitra A., SELECT, VIT University

Food and Packaging

Dr. Chitra A., SELECT, VIT University

 Food and Packaging

Automatic thermoforming vacuum food packing machine continuous stretch film vacuum sealer
equipment
Dr. Chitra A., SELECT, VIT University
Printing and Converting

Shaftless drives in the printing sector

Dr. Chitra A., SELECT, VIT University

 Automation and Handling

The BASF workerless warehouse in France (Photo courtesy of Egemin Automation)

Dr. Chitra A., SELECT, VIT University
1/12/2024
Dr. Chitra A., SELECT, VIT University
 COMPARISON BETWEEN AC AND DC
DRIVE
S.NO D.C.DRIVE A.C DRIVE

1 SPEED TORQUE CAN BE ACHIEVED EASILY IT IS NOT EASTY TO ADJUST

SPEED TORQUE CURVES

2 SELF STARTING NOT SELF STARTING

3 FREQUENT MAINTENANCE IS REQUIRED LESS MAINTENANCE

4 COSTLY CHEAPER

5 RECTIFYING CIRCUIT IS NECESSARY NO NEED

Dr. Chitra A., SELECT, VIT University

1/12/2024
Dr. Chitra A., SELECT, VIT University
 Selection of motor power rating
➢Power rating of a motor for a specific application must be carefully chosen to achieve
economy and reliability

➢Insufficient rating – Fails to drive the load , lowers productivity and reliability

➢Liberal rating – Extra initial cost, more loss, uneconomical , synchronous and induction
motors runs at low power factor when operated below rated power

➢When motor operates – heat produced due to loss

➢When temperature increases beyond the ambient temperature – heat flows out to the
surrounding medium

➢Steady state temperature depends on loss – which depends on output power of the
machine

1/12/2024 Dr. Chitra A., SELECT, VIT University

 Contd
➢ Temperature rise – direct relationship with output power – it is termed as
thermal loading on the machine.

➢ Steady state temperature is not same in all parts of machine – highest in the
windings

➢ Insulation has lowest temperature limit

➢ While selecting a motor- Ensure that the insulation temperature never exceeds
the prescribed limit

1/12/2024 Dr. Chitra A., SELECT, VIT University

 FOUR QUADRANT OPERATION
QUADRANT POLARITY POLARITY OF NATURE OF OPERATION
OF VOLTAGE CURRENT

I POSITIVE POSITIVE FORWARD MOTORING

II POSITIVE NEGATIVE FORWARD REGENERATION

III NEGATIVE NEGATIVE REVERSE MOTORING

IV NEGATIVE POSITIVE REVERSE REGENERATION

Dr. Chitra A., SELECT, VIT University