TORQUE Control Technologies

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Copyright 2005 Rockwell Automation, Inc. All rights reserved

Power Diagram

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

What we Have at output to control 1) Voltage, 2) Torque Current IT, 3) Flux Current Iq and 4) Angle between voltage and Current. 5) Motor Thermal Condition

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Motor Control Technologies

Volts / Hertz Sensorless Vector

Flux Vector

Field Oriented

Speed Regulator

Speed Regulator

Speed Regulator

Torque Regulator Speed Regulator

Torque Regulator

Current Limit

Advanced Current Limit

Current Regulator based on Estimated Values

High Bandwidth Current Regulator

Conveyor

Mixer Extruder

Converting

Converting

Parameter Selectable (Application Based)

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Volts/Hertz Control

takes a speed reference and varies Voltage and Frequency

Current Limit monitors motor current and alters frequency command

Slip Compensation alters frequency reference during load changes

The drive monitors total current - no current resolver, Cannot distinguish between Id from Iq (Torque Capability limited)
Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Fan Pump Volts/Hertz Variable Torque

Maximum Voltage Motor NP Voltage

Voltage Run Boost 0 0 Motor NP Frequency Frequency Maximum Frequency

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Volts/Hertz Control

To increase starting torque, V/Hz Drives use Voltage Boost to over-flux the motor to increase starting torque
Output Voltage
460

Ratio @ 460VAC = 7.67 V/Hz +

248 138

% BOOST

Voltage Boost

15

30

60

90 Output

Hz

Base Frequency

Frequency

Voltage Boost over prolonged operating periods may result in overheating overheating of the motors insulation system and result in damage or premature failure.

CAUTION: Motor Insulation Life is decreased by 50% for every 10C above the insulations temperature capacity
Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Volts/Hertz Control

Notice that the ability of the drive to maintain high torque output
at low speeds drops off significantly below 3 Hz Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Volts/Hertz Control

Shock Load

Can not keep the shaft speed at desired level when subjected to shock loads. However Drives with slip compensation feature correct for extra load but the dynamics
are somewhat limited.
Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Volts/Hertz Control

There are a couple of key things to point out.

First, the ability of the drive to maintain high torque output at low speeds drops off significantly below 3 Hz. This is a normal characteristic of a Volts/Hertz drive and is one of the reasons that the operating speed range for Volts/Hertz drives is typically around 20:1.

Second, you can see as the load is increased, the motor speed drops off (due to slip). Using S Compensation can help. Thirdly, the maximum Torque that can be had is 150 to 160% only.

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Vector Definition ?

To know the direction as well as magnitude of a certain quantity

Vector Drive Definition

The ability to independently identify and control the flux and torque
producing components of current in a motor for the purpose of accurate torque and power control.

ITotal = (IReal) 2 + (IReactive) 2

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

DC Motor Model
DC
Load 2

DC

IaIa
Z Z

If

Load 1 Ia

Ia = Torque Producing Current (Armature Current) If = Flux Producing Current (Field Current)

If

T = K X X Ia X Sin (d) d = 900

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

= a*sin (d)

AC Motor Model
AC
Is
Z

AC
Load 2

Is

Iq Id
Z Z

Load 1 Is d Id

Iq Iq = Torque Producing Current Id = Flux Producing Current Is = Total Stator Current

T = K X X Ia X Sin (d) d = Varies

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

= K Id * Iq * sin(d)

Volts / Hertz Sensorless Vector

Flux Vector

Field Oriented

Speed Regulator

Speed Regulator

Speed Regulator

Torque Regulator Speed Regulator

Torque Regulator

Current Limit

Advanced Current Limit

Current Regulator based on Estimated Values

High Bandwidth Current Regulator

Conveyor

Mixer Extruder

Converting

Converting

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Sensorless Vector Control

Ability to sense the torque current and keep flux current constant through
out the operation. Produces Tmax /Amps of motor Current keeping Flux Current Constant
Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Sensorless Vector Control

The Torque Current Estimator block determines the percent of current that is in phase with the voltage, providing an approximate torque current. Improved control technique by providing both a magnitude and angle between the voltage and current. Current out of phase with voltage is flux current. Current in phase is torque producing current. V/Hz drives only control the magnitude. Vangle controls the amount of total motor current that goes into motor flux, enabled by the Torque Current Estimator. By controlling flux current, any additional current goes to producing torque, and we get better torque per amp (avoids underfluxing and overfluxing).

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Sensorless Vector Control

By controlling flux, low speed operation and torque control is improved over the standard V/Hz drive

High Starting (Maximum) Torque about 250%

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Sensorless Vector Control Shock Load

Better Dynamic Response to shock loads

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Volts / Hertz Sensorless Vector

Flux Vector

Field Oriented

Speed Regulator

Speed Regulator

Speed Regulator

Torque Regulator Speed Regulator

Torque Regulator Current Limit Advanced Current Limit Current Regulator based on Estimated Values High Bandwidth Current Regulator

Conveyor

Mixer Extruder

Converting

Converting

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Flux Vector Control w/ Feedback

Voltage Feedback

Uses Speed & Current Regulator , Has a Current Resolver that separates Torque and Flux Currents Auto - tuning is a must
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Flux Vector Control w/o Feedback

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Flux Vector Control w/ Feedback

Flux Vector Control Torque Vs Speed
2

Torque
1 12 5

10

20

30

40

50

60

Speed (Hz)

Much better response at low speeds 2Hz Torque is greater than 150%
Copyright 2007 Rockwell Automation, Inc. All rights reserved.

0.9

Flux Vector Control w/ Feedback Shock Loads

Sensorless FOC Load Removed V/Hz Load Applied Encoder FOC Load Removed

Per Unit Quantities

0.875

FOC, FV & SV Load applied

0.85

0.825 0 1 2 3 4 5

Time (seconds)

Shock load dynamic Response much faster

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

COMPARING AC DRIVE PERFORMANCE

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Control Selection
S tarting into rotating loads V /H z B etter S VC G ood FVC B est

FVC FVC operation operationis isbest bestsince sincethe theposition positionand andvelocity velocityof ofthe the rotor rotoris isknown knownand andrestarting restartingis isimmediate. immediate. V/Hz V/Hzbeing beinga asoft softspeed speedregulator regulatoris isvery veryforgiving forgivingfor for restarting restartinginto intoloads loadswith withhigh highinertia. inertia. SVC SVC may maybe bemore moredifficult difficultto toimplement implementdue dueto tolimitations limitationsby by manufacturer. manufacturer. Processor Processor& & algorithm algorithmdependent. dependent.
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Control Selection
Multi-motor Operation from one drive V/Hz SVC FVC

Best

Not Not Recommended Recommended

V/Hz V/Hzoperation operationinheriently inherientlycontrols controlsmultiple multiplemotors. motors. SVC SVCor orFVC FVCoperation operationwith withmultiple multiplemotors motorsis isonly onlypossible possible when whenmotor motorshafts shaftsare aremechanically mechanicallylocked lockedtogether togetherand and assumptions assumptionsare aremade madeabout abouttotal totalmotor motorcurrent currentvalues. values.
Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Control Selection
Constant Torque Range V/Hz Good SVC Better FVC Best

V/Hz V/Hzis istypically typicallygood goodfor forup upto to10:1 10:1Constant ConstantTorque. Torque. SVC SVC is istypically typicallygood goodfor forup upto to40:1 40:1Constant ConstantTorque. Torque. FVC FVC is istypically typicallygood goodfor forup upto to1,000:1 1,000:1which whichincludes includes continuous continuousoperation operationat atZero ZeroSpeed. Speed.
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Control Selection
Dynamic Response V/Hz SVC FVC

Good Better Best No Adjustable Adjustable tuning Gains for tuning Gains for tuning
V/Hz V/Hzhas hasno noquantifiable quantifiableresponse responsetime timeor orbandwidth. bandwidth. Typical TypicalSVC SVC specifications specificationsmay maystate state100 100Radians/second. Radians/second. Typical TypicalFVC FVCspecifications specificationsmay maystate state1,000 1,000Radian/second. Radian/second.
Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

What is

Force Technology is Allen-Bradleys version of Field ORiented Control Field Oriented Control is the First AC Motor Control Technology That Technology Can Truly Obtain DC Like Dynamic Performance Force has been developed over a 10 year period and is independent of the
hardware platform. In other words, as new hardware technologies are developed Force Technology will continue to improve.

Allen-Bradley has 9 patents on the basic technology and continues to be a leader in

Field Oriented Control technology.
Copyright 2007 Rockwell Automation, Inc. All rights reserved.

FORCE-FIELD ORIENTED CONTROL

Excellent Technology to produce as high as 400% Maximum torque Produces 100% torque at zero speed Key Inc. for Hoist Application Copyright 2007 Rockwell Automation, All rights reserved.

FORCE-FIELD ORIENTED CONTROL W/O Feedback

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FORCE-FIELD ORIENTED CONTROL

FORCE-FIELD ORIENTED CONTROL Torque Vs Speed

Excellent response at low speeds At 1Hz Torque is greater than 250%

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

FORCE - FIELD ORIENTED CONTROL

0.9
Sensorless FOC Load Removed V/Hz Load Applied Encoder FOC Load Removed

Per Unit Quantities

0.875

FOC, FV & SV Load applied

0.85

0.825 0 1 2 3 4 5

Time (seconds)

Shock load dynamic Response is Excellent

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Advantages of
Higher Bandwidth on Current Regulator Quicker Reaction to Shock Loads

Over DC

Reduced Motor Maintenance - AC Motor MTBF 5 Times Longer than DC- AC Motor Cost to Repair One Fourth of DC AC Motor Lower Rotor Inertia AC Motor Adaptable to Harsh Environments
Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Performance Comparison with Encoder

FORCE Technology Speed Control Speed Regulation Dynamic Response Speed Range Torque Control Regulation, No RTD Dynamic Response +/-0.001% 100 Rad 1000:1 Typical Vector +/-0.05% 15 Rad 100:1 Digital DC Drive +/-0.001% 100 Rad 1000:1

+/-2% 2500 Rad

+/-20% 300 Rad

+/-5% 950 Rad

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Performance & Benefits for

1000 to 1 Speed Range Full Torque at Zero Speed 0.001% Speed Regulation 2% Torque Regulation

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Applications For
Extruder High Starting Torque Up to 400% w/ Proper Sizing Material Handling Low Speed Performance Creep / Idle Speeds Metals Precise Speed Control Casters / Process Lines / Slitters Precise Torque Control Load Share / Tension Leveling Crane/Hoist Full Torque at Zero Speed Continuously Torque Proving Circuits Fast Response / Torque Switchable Speed / Torque Web Handling Precise Line Speed Control Precise Torque Control Draw / Load Share Tension Control Winder Control Dia Comp / Taper Tension

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Vector Vs Field Oriented Control

Vector Control
Acknowledges that motor current is the vector sum of the torque and flux currents and uses this information to provide better control of motor speed/torque.

Field Oriented Control

The ability to independently control the flux and torque in a motor for the purpose of accurate torque and power control.

Copyright 2007 Rockwell Automation, Inc. All rights reserved.

Copyright 2007 Rockwell Automation, Inc. All rights reserved.