GREEN MOTOR CONTROL

Variable speed drives ace a green technology as the users can save energy

costs and reduce greenhouse-gas emissions by using variable-speed drives to

match motor output to process demands. A growing number of manufacturers

have recognized that replacing the various old-style motors and drives still used in

their facilities with modem technology can conserve a tremendous amount of

energy and money. Industry could reduce its electrical energy consumption by as

much as 18 percent if it replaced its motors with the latest high-efficiency motors

and appropriate variable-speed drives.

Energy is like any other commodity. If you are not thrifty with it, it will slip

through your fingers, so to speak. Almost 30% of all electrical energy is used in

industrial drive systems for pumps, blowers, compressors, conveyors, lifts etc.

Today the vast majority of these motors are three phase induction motor with an

aluminum rotor cage. While they are cheap to produce their energy efficiency is

rather poor ranging from around 77% for 1 kW motors up to some 94% for 100

kW motors. Savings more than pay for the higher price tags on these motors,

which can be 10 percent to 30 percent more than those on conventional motors,

depending on model and size. The reason is that electric motors are responsible for

about 63 percent of a manufacturing company's electric bills; over 97 percent of

the lifetime cost of a motor is its electricity consumption.

 Variable speed drive (VSD) describes equipment used to control the speed

of machinery. Many industrial processes such assembly line must operate at

different speeds for different products. Where process conditions demand

adjustment of flow from a pump or fan, varying the speed of the drive many save

energy compared with other techniques for flow control

TYPE OF VARIABLE SPEED DRIVES

Speed adjustment technique have been used in transmitting mechanical

power to machinery since the earliest use of powered machinery. Before electric

motor were invented, mechanical speed changers were used to control the

mechanical power provided by water wheels and steam engine when electric

motor came into use. Means of controlling their speed were developed almost

immediately .Today , various sod mechanical drives, hydraulic drives.

mechanixcal drives and electric drives complete with one another in the industrial

drives market.

MECHANICAL VARIABLE DRIVES

There are two types of mechanical drives , variable pitch drives and traction

drives.

Variable pitch drives are pulley and belt drives in which the pitch diameter

of one or both pulleys can be adjusted.

Tradition drive transmit power through metal rollers running against mating

metal rollers. The input/output speed ratio is adjusted by moving the rollers to
change the diameter of the contact path. Many different rollers shapes and

mechanical designs have been used.

HYDRAULIC VARIABLE SPEED DRIVES

There are three types of hydraulic drives, those are hydrostatic drives,

hydrodynamic drives and hydroviscous drives.

A hydrostatic drive consist of a hydraulic pump and a hydraulic motor.

Since positive displacement pumps and motor are used, one revolution of the

pump or motor correspondence to a set volume of fluid flow with s valve or by

changing the displacement of the pump or motor.

Hydrodynamic drives or fluid couplings use oil to transmit torque between

an impeller on the constant speed input shaft. The torque converter in the

automatic transmission of a car is a hydrodynamic drive.

A hydroviscous drive consists of one or more discs or connected to the input

shaft pressed against a similar disc or discs connected to the output shaft. Torque

is transmitted from the input shaft to the output shaft through an oil film between

the discs.
ELECTRIC VARIABLE – SPEED DRIVES

There are three general categories of electric drives : DC motor drives,

eddy current drives and AC motor drives. Each of these general types can be

further divided in to numerous variations. Electric drives generally include both an

electric motor and a speed control unit or system.

DC DRIVES

DC drives are DC motor speed control systems. Since the speed of a DC

motor is directly proportional to armature voltage and inversely proportional to

motor flux (which is a function of field current), either armature voltage or fiels

current can be used to control speed.

EDDY CURRENT DRIVES

An eddy current drive consist of a fixed speed motor and an eddy current

clutch. The clutch contains a fixed speed rotor and an adjustable speed rotor

separated by a small air gap. A direct current in a field coil produces a magnetic

field that determines the torque transmitted from the input rotor to the output rotor.

The controller provides closed loop speed regulation by varying clutch current,

only allowing the clutch desired speed. Speed feedback is typically provided via

an integral Ac tachometer
AC DRIVES

AC drives are AC motor speed control system

Slip controlled drives control the speed of an induction motor by increasing the

resistance of the rotor winding. Because they ate generally less efficient than other

types of drives, slip controlled drives have lost popularity and have recently been

used only in special situations.

Variable Frequency drives control the speed of either an induction motor or

a synchronous motor by adjusting the frequency of the power supplied to the

motor. Variable frequency drives are also known as adjustable frequency drives.

AC & DC VARIABLE SPEED DRIVES

The AC and DC drives is booming, however the sales predicts of high

power AC drives will grow 13.3% in Indian over the next five years. Combined

with continuing advances in power electronics, microprocessor, DSP and VLSI

technology, this allows AC variable speed drives designers to incorporate grater

control, greater power handling capability and to reduce switching losses. As a

result the following changes have occurred

 Increased drive efficiency (typically 97-98%)

 Reduce volume and weight

 Lower price

 Reduce audible noise level

  Improved power factor

 Reduce harmonic distortion to supply

 Improve reliability

 Large voltage and current rating

 High switching speeds and lower losses

VARIABLE SPEED DRIVES CASE STUDY

Controlling motor speed makes matching process demand and machine

output possible. Control of a pumping system provides a good example. Rather

than controlling flow in the normal way via a throttle valve, a variable speed drive

can be more efficient. Suppose the flow rate is to be half maximum, reducing the

speed reducing the motor speed reduces energy consumption by a factor of eight.

The throttle valve, which reduces flow by introducing impedance, actually

increases the motor's load, increasing energy use. Pump operation provides an

example of another way to save energy with variable-speed drives

In water purification plant the objective is to keep a constant

pressure in the process despite, large variation in demands during the day

and night. To fulfill these variations, the pumps have to be controlled in

order to work efficiently at all times. It is also important to protect the

equipment from water hammer by ensuring soft starts drive and four

soft starters has resulted in a very cost-efficient solution. The variable

speed drive controls all five pumps without external PLCs. It works as the

master and gives feedback of measured pressure to the internal PID

regulator. When the master pump reaches its capacity limit, the drive sends

a signal to soft starter to smoothly start the next pump. By keeping track of

how long each. pump has been running, the drive gives them all an equal

running time and thereby simplifies servicing. The drive continuously

adjusts the pressure. and minimizes energy consumption. When the

demands decrease, the pumps are stopped smoothly without any water

hammer. The one stopped first is the one with the longest running time. If

there is a problem with a pump or motor the system automatically switches

over to next pump in turn, avoiding unnecessary downtime.

 A hotel has a large number of units supplying air conditioning to the

guest rooms. As more rooms are occupied, more air is needed to maintain a

comfortable temperature in each room. As a result, the fans supplying the

air need to vary their output, based on the number, of occupied rooms at

any given time. The initial installation had throttling dampers installed in

the supply air ductwork. As the requirement for airflow decreased, these

dampers closed to reduce airflow to the rooms. Not only was this method

o f flow control inefficient in terms of energy use, it was noisy and required

regular maintenance.

The hotel determined that installing VSDs on the fans would save

energy, improve system performance and lower! maintenance costs. After a

trial run, the hotel installed VSDs on each of the guests'' rooms supply air

fans. The work included disconnecting the existing supply air dampers,
upgrading the air conditioning control systems and installing the n e w ,

VSDs. Savings achieved were around 40% of fan energy costs.

CONCLUSION

Today is the day of energy efficiency. In good old days, when

electrical power was a cheap commodity, none was giving due importance

to the efficient use of power. However, there is a sea change in the

situation now. Power is no cheaper and for most of the industries, electrical

energy has become almost a raw material. Most of our traditional industries

like sugar, textiles etc. are dying down. One of the main reasons is the

inefficiency in operation and the comparatively high operating cost, which

makes the product incompetent in the current global market: The recent

initiatives taken by the government by way of enacting the energy

conservation act 2001 and electricity act 2003 are to help the industries

in coping with the efficiency crisis and to make them energy efficient,

thereby leading them to become competitive. If we analyze the Indian

power scenario, it is being reported that of the transmission and

distribution losses is about 25-30% or even more. At the same time, a

critical analysis of the performance of electrical motors reveals that the

power I loss due to inefficient electrical motors is also as high as 25-30%

GREEN MOTOR CONTROL

Submitted By

Sherin Annie Eappen

S7,EEE

Roll No : 58