AND
ELECTRIC MOTORS
APPLICATIONS BULLETIN
BEARING
COOLING FAN
FITTED TO SHAFT
SHAFT
BEARING
4501-011 Rev B
FRAME ROTOR
2
APPLICATIONS BULLETIN
30 deg 30 deg
a b c
U1 U1
U1
W2 V2 W2 V2 W2 V2
V1 W1 V1 W1 V1 W1
U2 U2 U2
a b c 4501-016 Rev C
3
APPLICATIONS BULLETIN
4501-012 Rev B
Rotor
Torque
4501-044 Rev C
Figure 1.5(a): Induction of Rotor Current Figure 1.5(b): Interaction Between Rotor and Stator Fields
4
APPLICATIONS BULLETIN
150% 400%
Starting
torque
100% 300%
200%
50%
Full load 100%
slip
No-load
current
20% 40% 60% 80% 100% 20% 40% 60% 80% 100%
4501-018 Rev D Full load speed
MOTOR SPEED 4501-019 Rev D MOTOR SPEED
Figure 1.6(a): Motor Torque vs Speed Figure 1.6(b) Motor Current vs Speed
1.5 Motor Poles
Figure 1.2 shows the stator winding arrangement for a two pole motor, where each of the three phases has
two windings associated with it. Figure 1.7(a) depicts a four pole stator. In this stator, each winding has
four sections. Each section is displaced by 90 deg from the other. Thus when current is passed through
each winding, two magnetic fields are formed across the stator, at right angles from each other. Thus each
winding has four poles, i.e. the motor is referred to as a four pole machine. It can be shown that when the
windings are connected to a three-phase supply, the magnetic field rotates at half the frequency of the
supply. Hence for a 50 Hz supply, the field rotation speed is 25 rev/sec, i.e. 1500 r.p.m.
Similarly, a six pole stator field rotates at one third of the supply frequency, (1000 r.p.m. for 50 Hz) and an
eight pole stator field rotates at a quarter of the supply frequency (750 r.p.m. for 50 Hz). Refer to Figure
1.7(b) for a table of synchronous speeds versus number of stator poles, for a 50 Hz supply.
5
APPLICATIONS BULLETIN
STATOR POLES
U
W
4501-110 Rev A
Figure 1.7(a): 4-Pole Stator Windings Figure 1.7(b): Motor Speeds vs Number of Poles
1.6 Speed Control Of Squirrel Cage Motor
Inherently, the squirrel cage induction motor is a fixed-speed motor, whose speed is controlled by the
number of poles, and the frequency of the supply to which it is connected. A small speed change is
noticeable as the load on the motor changes, as a result of the slip.
The equation for motor speed is:
N = f x 120 - s
p
N = motor speed in revs per minute
f = frequency of supply to the motor in Hz
p = number of poles on the stator
s = slip of motor in revs per minute.
From this equation, it can be seen that the speed of an induction motor can be controlled in three ways:
(a) Change the number of poles.
This requires a rotor with two sets of windings, and a set of switchgear to enable energisation of either
winding.
Note that the speed is not continuously variable. For example, a 2 / 8 pole motor connected to 50Hz has two
synchronous speeds, i.e. 3000 and 750 r.p.m.
(b) Change the amount of slip.
This can be done by adjusting the voltage supplied to the motor. This causes the torque vs speed curve to
become less steep, thus causing more slip as the motor is loaded up. To work correctly, this method
requires a load with a rising torque vs speed characteristic. Any variation in load torque will cause a
variation in motor speed.
(c) Adjust the frequency of supply to the motor.
This is the method used by electronic speed controllers. It generates a whole family of Torque vs Speed
curves, each one with a synchronous speed corresponding to the frequency supplied to the motor at any
instant. Refer to Figure 1.8. This is best method of speed control, for the following reasons:
• High efficiency is maintained throughout speed range.
6
APPLICATIONS BULLETIN
• Continuously variable speed control is available. This can be controlled electronically, by (e.g.) 0 - 10V or
4 - 20 mA control signal. This makes a Variable Frequency Motor Controller ideal for process
automation.
• The torque available from the motor is maintained, even at low speeds. Thus it is suitable for use with
loads of any torque characteristic.
• Speeds above the 50 Hz "base speed" can be achieved, although at the cost of a reduction in the
maximum torque available.
200 %
100 %
100 Hz
10 Hz
20 Hz
30 Hz
40 Hz
50 Hz
60 Hz
70 Hz
80 Hz
90 Hz
4501-023 Rev D
Figure 1.8: Torque vs Speed Curves for Motor Under Variable Frequency Control
7
APPLICATIONS BULLETIN
Rs
RL
IM 1 - S Rr IM
LM S LM
Vs Vs Load resistance:
Load resistance: reduces with
Magnetising reduces with Magnetising increasing slip
inductance increasing slip inductance
4501-024 Rev D
nt
rre
current they generate the rotating magnetic field(s) tal IT
Cu
essential to the operation of the motor. The IR
nt
rre
To
al IT
magnetising current is reactive, that is, it lags behind
Cu
O
the applied voltage by 90 . M
t
To
M
Load path: This current path transforms from
the stator to the rotor by transformer action, and
flows through the rotor bars. The more load on the IM IM
motor, the higher the slip, and the higher the load Imaginary Imaginary
current is. Load current is real, i.e., it is in phase (Magnetising) Current (Magnetising) Current
4501-025 Rev D
with the applied voltage.
(a) Full Load (b) Half Load
Total current: The total current in each
winding of a motor is the vector sum of the load Figure 1.10: Components of Current
current and the magnetising current, as shown in in Induction Motor
Figure 1.10. Generally the magnetising component
is constant and does not change with load. It
ensures that the motor always runs at a lagging
power factor.
8
APPLICATIONS BULLETIN
100%
Field Weakening Region
OUTPUT VOLTAGE
Amount
of Boost
50 Hz
4501-027 Rev D OUTPUT FREQUENCY
Figure 1.11: Variable Speed Drive Output Voltage vs Frequency
From the above figure, it can be seen that for increasing output frequency, the V/Hz ratio remains constant
until the motor voltage reaches 100% of the (Drive input) voltage. For higher Drive frequency, the voltage to
the motor cannot increase, and magnetic field weakening happens. Thus when the motor is oversped past
its nominal operating frequency, its output torque capability reduces.
We can improve low speed motor torque by applying BOOST. This is done by increasing output voltage at
low speed, as shown in Figure 1.11. Boosting overcomes the voltage drop caused by the stator winding
resistance, RS in Figure 1.9. This in turn causes torque loss at low speeds.
9
APPLICATIONS BULLETIN
400VAC 565VDC
3 PHASE
50Hz
AC Diode
input Load
v AC input voltage
v voltage to load
Referring to Figure 2.2, on a positive half cycle of the mains, that is, when the top input is more positive than
the bottom input, the diode is forward biased and will conduct current through the load. On a negative half
cycle, when the top input is more negative than the bottom input, the diode is reverse biased and will block
current from conducting. Thus in the circuit of Figure 2.2, the load will have half of the mains voltage across
it. Thus if it was a lamp, it would glow with half brightness.
Figure 2.3 shows a full wave three phase rectifier, where six diodes are used to convert AC into DC.
DC CHOKE
POS
L1 DC BUS DC BUS
3-PHASE CAPACITORS 565 VDC
INPUT L2 VR
MAINS
(400VAC) L3
NEG
3-PHASE SOFT CHARGE
BRIDGE RESISTOR &
RECTIFIER CONTACTOR
DC CHOKE
Vin
V 12 V 23 V 31
MAINS INPUT
VR ripple
VDC = 560Vdc
t
RECTIFIER OUTPUT
4501-112 Rev A
11
APPLICATIONS BULLETIN
WARNING: The capacitors can hold a lethal charge for some minutes after power
has been turned off.
12
APPLICATIONS BULLETIN
LAMP LAMP
LOAD LOAD
COLLECTOR
10Vdc + + RELAY
COIL
EMITTER - -
-DC bus
(a) IGBT Symbol and Terminals (b) IGBT as a Power Switch (c) Relay Equivalent of IGBT Switch
SATURATION VOLTAGE
VSAT
t
W
TURN-ON TURN-OFF
TIME TIME
TURN-ON
LOSS TURN-OFF
LOSS
CONDUCTION LOSS
t
4501-033 Rev D
13
APPLICATIONS BULLETIN
A B C
VBC
t
M VCA
t
Motor
Current
IAB
4501-114 Rev A t
14
APPLICATIONS BULLETIN
inserted in the cycle. In a practical drive, the number of chops may be 80 per cycle, giving an even
smoother motor current waveform.
15
APPLICATIONS BULLETIN
PWM LINE-TO-LINE
OUTPUT VOLTAGE
MOTOR
CURRENT
4501-115 Rev A
• Generates modulated waveforms, to drive the inverter switches to provide the correct output voltage and
frequency to run the motor at the desired speed.
• Monitors motor current to provide motor and controller with protection against overloads.
• Provides status outputs, e.g. motor current, drive frequency, start, run, overload, fault indication.
User Controls
In later model AC Motor Controllers, the function of the user input control switches can be customised in the
software. This can eliminate the need for external logic control functions. Examples may be to provide a
software motorised potentiometer, with one input switch to increase the reference, and one to decrease the
reference.
Similarly, analogue inputs can be configured as to type (0 to 10Vdc, 4 to 20mA, +/-10Vdc etc.) and function
to suit what the control system has available.
Output relays can be configured as to the status that they indicate, and analogue output(s) can have their
type and function configured.
Some controllers have a software process control loop available to enable closed loop applications such as
constant pressure pumping, level control, load control, etc.
Motor Current Monitoring
The AC Motor Speed Controller output current is continuously monitored, to enable Controller, motor
overload and load protection. Use of Hall Effect DC current transformer devices enable measurement and
control of motor currents at low frequency and DC levels. Motor current imbalance and earth leakage can be
monitored and protected against.
16
APPLICATIONS BULLETIN
17
APPLICATIONS BULLETIN
23
40
0V
0V
23
0V
40
V2
W2
U2
U1 V2
W1
W2 W1 U1
230V U 400V W
U W
230V motor winding connections 400V motor winding connections
W2 U2 V2
4501-037 Rev E W2 U2 V2
U1 V1 W1 U1 V1 W1
18
CHAPTER 3: PRINCIPLES OF FLUX VECTOR CONTROLLERS
3.1 Difference Between Scalar And Vector Control
As discussed in Section 1, the operation of the three phase induction motor is due to the interaction of the
(excited) stator magnetic field with the (induced) rotor magnetic field. The stator excitation produces a
magnetic field, which rotates at synchronous speed in the air gap between stator and rotor. This field
induces currents in the rotor bars, so giving rise to another rotating magnetic field. These fields want to line
up with each other, so the rotor experiences a torque, and tends to be dragged along with the stator field.
As the rotor speed approaches that of the rotating stator field, the rotor bar currents will reduce. This
reduces the rotor torque, until when rotating at synchronous speed, the rotor torque is zero. Under normal
motoring conditions, the rotor will rotate at a speed slightly slower than that of the stator field. This speed
difference is termed the slip, and the more slip, the more torque the motor will deliver to the load.
By applying a variable voltage variable frequency (VVVF) controller, as discussed in Section 2, the stator
field rotation speed can be changed, thus the rotor speed changes. This is done. For most motor speed
control applications, e.g. pumps, fans, conveyors, etc., this is a satisfactory method of speed control.
However there are some types of load where the performance of a VVVF controller is not good enough for
operating the induction motor. One such application area is where very fast speed response is needed, e.g.
in position control systems and flying shears. Under such highly dynamic conditions, the operation of a
VVVF controller will be underdamped or even unstable. Another area where a VVVF controller is not
particularly suitable is in torque control applications, e.g. rewinders, torque boosters, etc. Also the standstill
torque and low speed torque capabilities of a VVVF controller on an induction motor are not very good,
making it unsuitable for use on hoists and elevators.
For high performance operation, closed loop torque control is required. This requires that the torque
producing and magnetising components of stator current must be accurately and separately controlled as
vectors, i.e. they are controlled in both magnitude and spatial position. The two components are kept in
quadrature, i.e. 90O electrical apart. This class of induction motor controller is referred to as a Field
Orientated Flux Vector Controller, or simply Vector Controller, as represented by the PDL Microvector
range. This type of controller has very fast torque response, making it suitable for precision torque, speed
and position control applications. The ability to get up to full pull-out torque of the motor at all speeds,
including standstill, makes this controller suitable for cranes, hoists and elevators.
3.2 Review of Basic Motor Principles
F: force on
conductor
(newtons)
L: length of
conductor
(metres)
4506-042 Rev A
i: current in
conductor F=BiL
(amps)
Figure 3.1: Force on Current-carrying Conductor in a Magnetic Field
All electric motors work on a basic principle of electromagnetism. According to this principle, when an
electric current is passed through a conductor that is in a magnetic field, a force acts on the conductor. This
is shown in Figure 3.1. If the current-carrying conductor is at right angles to the field, then the magnitude of
the force can be calculated from the equation
F = BxixL
where F = force in Newtons, B = magnetic flux density in Teslas, L = conductor length in metres.
The direction of the force can be deduced from the left-hand motor rule. Extend the thumb, forefinger and
middle finger of the left hand so they are mutually perpendicular. If the forefinger represents the direction of
APPLICATIONS BULLETIN
the magnetic flux lines, and the middle finger the direction of (conventional) current flow, then the thumb
points in the direction that the conductor is pushed. Control of the torque output of a motor is by control of
the above forces on the rotor conductors, by controlling either the field strength (B) or the rotor current (i).
In a separately excited DC motor, torque control is comparatively straightforward, as discussed in Section
3.3. However in an AC induction motor, the rotor conductor current is achieved by induction, that is, by the
stator field B cutting past the rotor conductors at slip speed and generating currents in the rotor bars. Thus
the same current forced into the stator windings gives rise to the motor flux (B) and induces the rotor current
(i). Thus to control the torque output of an AC induction motor, we need to control the instantaneous
magnitude and phase of the three-phase stator currents to enable direct and independent control of B and I.
This is called Field Orientated Flux Vector Control.
3.3 Review of DC Motor
The separately excited DC motor, as shown in Figure 3.2, is an example of a vector controlled motor. The
armature (torque producing) current is kept in quadrature (at right angles) to the field producing current by
the commutator and brushgear. The field flux is directly proportional to the field current, and can be
controlled independently of the armature current. The shaft torque is proportional to the product of the field
flux and armature current. If the field current is kept constant, the motor output torque can be controlled by
controlling armature current. Response to a step change in armature current is fast and well damped.
Field poles
Brushes Ia T = Kd x If x Ia
Stator
Ra
Vf Ia (torque producing)
Vs
Ea M
Field Field
flux
Φf
Φf
Commutator Armature Armature (magnetising)
(a): End View of DC Motor (b): Wound-Field DC Motor Circuit (c) Current and Flux Vectors
20
APPLICATIONS BULLETIN
Magnetising
inductance Im
Load resistance:
Vs 1 - S Rr reduces with
Lm S increasing slip
4501-045 Rev C
Stator Rotor
Figure 3.3: Steady-state Equivalent Circuit of Induction Motor
Figure 3.3 shows the equivalent circuit of a phase of an induction motor. Circuit parameters are as follows:
Lls = stator leakage inductance - due to imperfect magnetic coupling between adjacent turns
Rs = stator winding resistance - due to resistance of copper wire - cause of stator losses
Lm = stator magnetising inductance - gives rise to rotating stator field
Llr = rotor leakage inductance
Rr = rotor resistance
Rr (1-s)/s = equivalent load resistance - changes with motor slip
There are two components of current into the motor:
IM(t) magnetising current, i.e. flux producing current. This current is mainly imaginary,
i.e. inductive. A small real, i.e. resistive, current component flows, due to iron losses
in the stator.
IR(t) load current, i.e. torque producing current. This component is mainly real,
i.e. resistive or work-producing current. A small imaginary, i.e. inductive, current
flows, due to rotor and stator leakage inductances.
The produced torque can be expressed as:
T = Ka x IM(t) x IR(t) x sin α
It must be remembered that these two quantities are alternating, having the same frequency but not
necessarily in quadrature. The phase difference α between the two currents will vary from 90O due to the
effects of the leakage inductances. This variance will be worse at low speeds and under heavy loads.
In a AC induction motor, the same current forced into the three phase stator windings gives rise to the
magnetising (air gap) flux (B) and induces the torque producing (rotor) current (i). It is not possible to
separately and independently access these two quantities. The main function of the Vector Controller is to
overcome this problem by maintaining a quadrature relationship between magnetising and torque producing
components of the stator current, and decoupling the components in such a way that each can be
independently controlled, even under highly dynamic conditions.
Vector control needs to have a feedback from the motor of the magnitude and orientation of the air gap flux.
This then enables the two current components to be controlled. Early Vector Controllers employed direct
vector control, by using flux sensors in the air gap to produce the required signals. However this required a
special motor and did not achieve acceptance. Later controllers employ indirect vector control, where the
magnitude and orientation of air gap flux is computed from a knowledge of the motor's parameters (called
the motor map), and the instantaneous relative rotor position, measured using an incremental shaft encoder
driven by the rotor. Complex and tedious calculations have to be carried out on-line and at high speed in
order to achieve fast response. This has only been practical since the advent of fast and powerful
microprocessors. The PDL Microvector is an example of a modern indirect Vector Controller.
21
APPLICATIONS BULLETIN
Is
q-axis
d-axis
Iq
Id
θ ϕ
4506-041 Rev B
FIXED FRAME
22
APPLICATIONS BULLETIN
INDUCTION
Id Va MOTOR
PI
3R
EXTERNAL SPEED Vb SPACE
REFERENCE SPEED MOTOR INVERTER M
LOOP MAP VECTOR BRIDGE
2S MODULATOR
Iq Vc
PI
EXTERNAL TORQUE
REFERENCE
Ia
SPEED E
FEEDBACK 3R
Ib ENCODER
2S MOUNTED
Ic ON
d/ dt MOTOR
4506-011 Rev B
Figure 3.5: Block Diagram of Microvector Control Algorithm
A microcontroller continuously computes the necessary values and distribution pattern of stator currents.
This requires rotor change-of-position signals from an incremental shaft encoder mounted on the motor. The
microcontroller runs an algorithm which converts the measured motor currents from three-phase rotating
currents into two-phase direct currents, which are the equivalent of the armature and field currents in a DC
motor. These are compared with the reference values needed to produce the required torque, and the
errors are processed, reconverted to three-phase rotating voltage reference levels, and applied to the
inverter bridge. An internal speed control loop can be selected to enable the Microvector to be configured
as a precision speed controller if required. The incremental encoder is used as speed feedback for the
control loop. The result is that precision torque and speed control can is achievable. The response of the
motor is very fast - typically a 100% torque step can be applied to the load in less than 10 milliseconds.
3.8 Open Loop Vector Controllers
An open loop flux vector controller (also known as a tacholess vector controller) controls the speed of an
induction motor using techniques similar to that of a Microvector, to synthesise stator currents to deliver the
required motor torque. However a shaft encoder is not required on the motor. The result is an induction
motor controller that has near-vector performance (both in speed response and low-speed torque capability)
but without the problem of having to fit a shaft encoder to the motor. The rotor position is estimated by
measuring the motor's terminal voltage and applying a mathematical transformation. Such a controller
requires a very powerful microprocessor to handle the extra maths routines in the short cycle time required.
Open loop vector control is in its infancy but will probably be the control mode of the future. At the time of
publication of this edition, PDL Electronics has released the first models in a range of open loop flux vector
controllers, called the Microdrive Elite range.
23
APPLICATIONS BULLETIN
The direct-on-line starting characteristics of an induction motor can be better understood by studying the full
equivalent circuit of the motor. Refer to Figure 4.1.
Rs IT IR
Lls Ll r Rr
Magnetising
inductance Im
Load resistance:
Vs 1 - S Rr reduces with
Lm S increasing slip
4501-045 Rev C
Stator Rotor
Figure 4.1: Full Equivalent Circuit of One Phase of Induction Motor
Figure 4.1 represents the steady-state equivalent circuit of one phase of an induction motor. Circuit
parameters are as follows:
Lls = stator leakage inductance - due to imperfect magnetic coupling between adjacent
stator turns
Rs = stator winding resistance - due to resistance of copper wire - cause of stator losses
Lm = stator magnetising inductance - gives rise to rotating stator field
Llr = rotor leakage inductance
Rr = rotor resistance
Rr (1-s)/s = RL = equivalent load resistance - changes with motor slip
On start up, slip is at a maximum (1.0) and RL becomes very small, and appears as a short circuit. The
stator current on starting virtually all flows to the rotor and its magnitude is only limited by the stator and rotor
reactances (RS, LlS, Rr, Llr). Also voltage divider effects between stator and rotor reactances will ensure that
Lm does not get full input voltage supplied. Thus at start up, the field in the motor is weakened and the
motor's torque reduced to approximately 50% of peak.
Refer to Figures 4.2, 4.3 for typical Torque vs Speed and Current vs Speed curves for squirrel cage motors.
MOTOR MOTOR
TORQUE CURRENT
600%
Starting
current Generation &
200% Pull-out distribution system
torque 500% musr be rated to
handle starting
Excess torque current surge.
150% available to load 400%
Switchgear must be
during acceleration rated to make and
Starting of motor after DOL break starting
torque start. Can cause 300%
current level.
100% transmission shock,
water hammer, etc.
200%
50% Load
torque 100%
No-load
current
20% 40% 60% 80% 100% 20% 40% 60% 80% 100%
4501-047 Rev C
MOTOR SPEED MOTOR SPEED
Figure 4.2: Torque vs Speed Curve Figure 4.3: Current vs Speed Curve
24
APPLICATIONS BULLETIN
V = 100%
150%
100%
V = 70%
50%
V = 50%
25
APPLICATIONS BULLETIN
Anode positive
IG > 0 IG = 0
IL
V BR V RSM IH
VH V T V DSM VBF V
Anode negative
cathode gate
Reverse blocking region
SCR Symbol and Terminals Static I-V Characteristics for SCR
cycles, SCR1 controls the current flow to the load. 4501-051 Rev C
H H H
t t t
SCR SCR SCR
firing firing firing
angle angle angle
4501-052 Rev B
(a) Large firing angle: (b) Medium firing angle: (c) Small firing angle:
small voltage to load half voltage to load large voltage to load
Figure 4.7: Phase Control of AC Waveform
26
APPLICATIONS BULLETIN
SCR1
SCR6
V M
L2
SCR3
SCR2
W
L3
4501-053 Rev C
3-phase
supply SCR5
Current
Firing pulses to SCRs Feedback
27
APPLICATIONS BULLETIN
ts
ol
tV
Refer to Figure 4.9(a). In this example the output 75%
pu
75%
lts
ut
Vo
O
voltage of the starter is ramped from 0 to 100% in
t
pu
ut
50% 50%
O
four seconds. However it should be noted that
there is a time delay between the ramp starting 25%
25%
and the motor starting to rotate. The ramp time is 4501-054 Rev C
start at a preset level, and ramp up from there. In (a): Voltage Ramp Starting (b): Application of "Start Volts"
the example in Figure 4.9(b), this "Start Volts" Figure 4.9: Voltage Ramp Starting
level is set to 40%. This ensures that the motor
starts turning immediately on start-up, but without
"grabbing".
TORQUE
TORQUE
In Current Limited Starting, the maximum
required start current is preset by the user. When
started, the Reduced Voltage starter will ramp up 100% 100%
ue
at the preset ramp rate until motor current
rq
e
rqu
To
r To
or
Moto
reaches the preset level. At this point the output
ot
M
50% 50%
voltage ramp is automatically adjusted to hold the motor will not accelerate
starting current at or below this level. This beyond this point
100% 100%
method is suitable if the maximum start current is 50%
MOTOR SPEED 4501-055 Rev C
50%
MOTOR SPEED
to be limited due to, for example, inadequate (a): Successful Current Limit Start (b): Unsuccessful Current Limit Start
mains capacity, or for starting high inertia loads Figure 4.10: Current Limited Starting
which are loaded up only when they reach full
speed, e.g. fans, saw blades, etc.
In Figure 4.10(a), a current limit of 400% has been set, and the load accelerates to full speed successfully.
However in Figure 4.10(b), the current limit has been set down to 200%, and at a point in the start cycle, the
torque required by the load exceeds the torque available from the motor. The motor will not accelerate
beyond this point, and will enter a "rolling stall".
The motor will continue to draw twice full load current, and because of its reduced speed will have reduced
cooling. Thus the motor will overheat very quickly. This illustrates the danger of setting too low a current
limit level.
28