VVVF and its performance Scalar, Vector and Sensorless control Selection and Applications (pumps, transport, wind) References Modern Power Electronics and AC drives, B. K. Bose Power Electronics, Mohan
1- Introduction
Definition (Ac Drive) VV, VVVF Important of using ac drives. Important of using induction motor.
Definition
An Ac drive converts constant volt constant frequency supply to variable volt variable frequency VVVF supply to feed an Ac motor Alternative names (frequency changer, converter, inverter, adjustable speed drive ASD, and others)
Starting and Speed control methods developed over the years (VC, PC, VVVF)
Type
Y-D starter Autotransformer Soft starter Double cage/Deep Bar Rotor added R Stator Added R Voltage control Pole changing Slip energy recovery VVVF control (VSI,CSI)
Control
Simple Simple Moderate No con Simple Simple Simple Simple Complex Complex
Cost
Low High Low Moderate High Moderate Low Moderate high High
General configuration
Ac Drive
Ac Motor
Mechanical output =T
Constant load
T ny
H, AT
Volts/hertz control
-1.1
0.9
-1.1
0.9
0
0 . 0 2
0 . 0 2
0 . 0 4
0 . 0 4
Reference Wave
0 . 0 6
0 . 0 6
0 . 0 8
0 . 0 8
0 . 1
0 . 1
+-
0 . 1 2
0 . 1 2
Comparator
Carrier Wave
0 . 1 4
0 . 1 4
0 . 1 6
0 . 1 6
0 . 1 8
0 . 1 8
0 . 2
0 . 2
0 . 2 2
0 . 2 2
0 . 2 4
sine
0 . 2 6
0 . 2 4
Hysteresis band
0 . 2 6
0 . 2 8
0 . 2 8
0 . 3
0 . 3
0 . 3 2
0 . 3 2
0 . 3 4
0 . 3 4
0 . 3 6
0 . 3 6
Driver Block
0 . 3 8
0 . 3 8
0 . 4
0 . 4
0 . 4 2
0 . 4 2
0 . 4 4
0 . 4 4
0 . 4 6
0 . 4 6
0 . 4 8
0 . 4 8
0 . 5
0 . 5
Features
Adjustable-speed drives (ASDs) allow induction-motor-driven loads such as fans and pumps to operate at speed ranges as wide as 10 to 300 percent of fixed speed. They replace dc drives in general and high performance except in very special cases.
ASD installations can increase energy efficiency (in some cases energy savings can exceed 50 percent), improve power factor and process precision, and afford other performance benefits such as soft starting and over speed capability. They also can eliminate the need for expensive and energy-wasting throttling mechanisms such as control valves and outlet dampers.
2.1- Reliability:
Reliability is a measurement for dependence on drive
Requirements for increasing reliability
-Improved understanding of circuit operation and power devices transients. - Liberal component de-rating. -Decreasing the number of parts through circuit integration and increasing design margins due to better device have resulted in typical annual field failure rates of 2-3%.
-Re-tune the drive setting. -Change entire algorithms. -Difference between (RS232C RS485).
Comparison Baud rate Communication distance
RS232C RS485
(9.6-19.2) K
200 K
(10-15) m
600 m
Immunity to self or external generation, ability to survive AC line transients, ride through capability during short(50msec) power loss.
AC Motor
Driver ct
Filter
R I V E r
Elec. signals
Reference Command
Controller
Mech. signals
Tacho
Components of ASD
Motors Power converters and devices Control algorithms and control implementation
Classification of motors
Motor comparison
Machine Type Feature
IM Wound field low low low high Complex high high low Multiphase Special design high low high high Complex Low high low High power high speed applications
Synchronous Machine Synch Reluctance low low medium v. high Complex high high high Torque pulsations PM BLDC-SPM high high high low simple low medium low Field weakening regions & PM materials
SRM
Efficiency Power density cost Max. speed Control algor. Noise Reliability Torq. ripples Research activity
medium low medium v. high Complex high high high Torque pulsations
Example
Select 3 different 10 Hp AC drives, one BLDC and one Induction motor drive and one SRM Compare between both drives based on the table given previously Set evaluation levels from 1-5 Use the best value of each feature as the highest grade and the lowest value as lowest grade and set the levels linearly Set a value for each motor Depending on the application multiply each feature by a weight Calculate the score for each type of drive and select the most suitable
Motor Technology
First design a basic motor matching general needs of adjustable-frequency power and variable-speed operation. Second, this design must inherently have the adaptability to be configured to match the specific needs of many different drive applications. Third, by relaxing inappropriate constraints associated with fixed-frequency, fixed-voltage, fixed-speed applications, the design can be tailored to meet the performance objectives by making the appropriate design tradeoffs. This includes the typical design tradeoffs specified below
Lower Inductances
Higher Efficiency
Standard Design
ASD Design
Multiphase motors
In ASD, no number of phase restriction Five six and nine are the most common Better reliability and redundancy Lower torque pulsations with higher freq. Reduced current harmonics and amplitude Excellent for EHV Ships & Aerospace When loosing a phase Limp home 32 voltage (30 non zero) space vectors
5- ph inverter
5-ph motor
3. POWER ELECTRONICS
Source \ Load AC DC DC AC
Uncontrolled Diode
On-Off Controlled
GTO
IGBT
ct.
P r o t e c t i o n
-Driving
ct.
P r o t e c t i o n
Dr ct
IGBT
Thyristor
Dr ct
Features Max freq. PWM BW Sw losses On resistance Cond losses Driving signal Dr ckt cost Drct complexity Avalaibility
BJT med small Med Low Low Current 0.110A High high complex Excellent
MOS high wide Low Med Med Voltage 5V100mA Low low simple Excellent
IGBT Med Small Low Low Low Voltage 5V100mA Low low simple Excellent (more expensive)
Devices LV
At LV IGBT has the lead 1200 V, 100 khz, 500A Limits of discreet devices are almost reaches
Devices H.V
GCT and HVIGBT are compared GCT at ultra high powers HVIGBT at high power
Vrms
GCT
Conventional IGBT
10
100
1000
10000
Arms
Notes
The switch maximum current Is is related to the motor RMS current Im by Is>Im*sqrt(2)*1.1*1.5. The Best PWM frequency represents the industry practice and it is the most economical compromise between Current Ripple, Acoustic noise, Device derating and Snubber losses. It isn t Economical to use any of the devices to its maximum ratings (better to use another one or some combinations).
Advance in the AC Drives Industry is mainly related to those great Breakthroughs In the field of Power electronics as it is the milestone of this industry.
Rectifier
Filter
Inverter
IM
Control Converter
Drive Topologies
Conventional voltage source PWM converter. Current source load commutated & PWM converter. Suppressed DC link converter. Resonant converter (series and shunt) Matrix converter.
PWM VSI
Bridge Rectifier L
3-phase input VVVF output
PWM Inverter
L reduces AC line harmonics and improve the PF. C keeps constant voltage on the DC bus. H controlled rectifier limit capacitor pre-charge currents Used for multi machine drives. May operate on voltage or current controlled mode.
CSI (LCI)
Bridge Controlled Rectifier L
3-phase input VVVF output
Ci
Co
For high power drives L keeps the supply current almost constant limited to single motor drive LCI is very popular in industry Co used to absorb motor leakage inductance energy Ci used for load commutation of induction motors
Motor maint. V good Performance Ratings Cost Typical App Good (dynamics)
Low & med (1.5M) High (20M) D-High M-Low Pumps, multi m/c D-Med M-low Fans, comp, single m/c
MV Drives
4. AC DRIVE CONTROL
Control Technology
Control Algorithms
Voltage and current control DSP, Qc, Qp PWM PLC, DCS, other ---------------------------------------Open loop Adjustable speed drive Closed loop VVVF Rectifier Inverter - Scalar V/F - Vector (FOC) Direct Indirect Sensorless DSP Electronic Voltage Board DTC gate drive and circuit current AI techniques Control
Estimation Algoritm
Control Implementation
Motor
load
sensing
Voltage regulation
A voltage controlled PWM can be implemented successfully in scalar and field oriented control techniques, which are providing command voltages. The basic principle of the PWM voltage regulation can be implemented on the PWM general form by considering the reference, and carrier signals. Generally, the output voltage in the basic system is suffering from harmonics. There are successful modified techniques were very active to decrease these harmonics.
PWM
Carrier and reference signal Frequency ratio and Modulation index Over modulation Analog and digital generation Ac= 1
vtri
vcontrol_A
vcontrol_
B
vcontrol_C
V C0
V B0
Locus comparison of maximum linear control voltage in Sine PWM and SV PWM.
Current regulation
A current controlled PWM converter operated with a switching frequency in kHz range with good dynamic response and low harmonic content. It is the most commonly used power converter in the low to medium power range of high performance drives . The control circuit generates the sine reference current wave of desired magnitude and frequency, which is compared with the actual phase current. As the current exceeds a prescribed hysteresis band, the upper transistor in the half-bridge is turned off and the lower transistor turned on. As a result, the output voltage is transitioned from +0.5Vd to 0.5Vd and the current starts to decay. As the current crosses the lower band limit, the upper transistor is turned on, and the lower transistor switched off. The actual current wave is thus controlled to track the sine reference wave within the described hysteresis band by back-and-forth switching of upper and lower transistor .
Current regulation
Hysteresis block DC
I*as
+
PWM
Controller
i*bs i*cs
Inverter
IM
Hysteresis band
Reference wave
(b)
t
+ 0.5 Vd
Control of ASD
IM
+
Controller
+ V
V/Hz
V*S
*e
The frequency [*e is the command variable and it is close to the motor speed, neglecting the small slip frequency. The scheme is defined as volt/hertz control because the inverter voltage commands V*s is generated directly from the frequency signal through a volt/hertz constant gain G. In steady state operation, the machine air gap flux ]m is approximately related to the ratio Vs/[e. Maintaining the rated air gap flux will provide maximum torque sensitivity with stator current which is similar to that of a dc machine. As the frequency approaches zero near zero speed, the stator voltage will tend to be zero and it will essentially be absorbed by the stator resistance
Rectifier
Inverter
Vdc
IM
Controller
+ +
V*S
G3
*e
Tacho
Current limiter
IM
*e V*S
G3
Tacho
Controller
*
+
G1
T*e+ Ter
sl
G2
+ +
*m
v abc
Te , m Estimator
i abc
VR
* R
Vd Id
* e
IM
G1 Tacho I
* d * sl
+ +
r
Controller
c-axis
DQ0-ABC Transformations
Dq0---abc
as i* ibs ! * ics
*
* ds i* i qs * i0 s
Abc dq0
cos U s * ds i* 2 sin U s i qs ! 3 * 1 i0 s 2
Vector or FOC
e
e
Iqs I`q s Vs
q- axis
Ids
Ids Is d- axis I`s
DC
+ * + -
G1
Id* Iq*
G2
IM
Unit Vector
Controller
Sensed Parameters
DSP-TC9486F/XB series
A/D, PWM channels w/ dead time features Event manager and SW tools C and Asm programing
IT IS EXPECTED THAT WITH DECREASING PRICE, DSPS WILL BRING DSP A TRULLY COMPUTER POWER WITH VERY HIGH PERFORMANCE THIS COMPUTING POWER WILL BE USED IN THE SPECIAL DRIVES TO IMPROVE THE DRIVE DYNAMIC PERFORMANCE
Closed loop
SensVector Good (Ind) Poor (Dir) excellent Yes (Ind) No (Dir) high complex Sensorless Medium V. good Yes low none
Applications
PLC Wind energy Pumps Multiple Centrifugals and energy management Others
PLC control
It is required to program the drive to run on a desired schedule and repeat it Other machines will run at at the same schedule and shifted The schedule is 0 to 20s charge at 100 rpm, 20 to 30s acc to 1200rpm, 30s to 3m at 1200rpm, 15s to drop to 50rpm and run for 40 s at 50 rpm go back to 100 rpm in 5s
PLC
0 1 2 3 4
AC drive x1|x2|x3|x4|
PLC
L1|L2|L3|T1|T2|T3 F|R|Sp1|Sp2|ac/dc|db|c c|y1|y2|y3|y4|y5
1200 1 0
1 1
Acc1=10 Dec0=15
1200 50 50 50 100
0
3:15-3:55 1 0 3:55-4:00 1 0
1 . 2 ! mv 2
.A.v (kg/s)
Pmech
1 ! V . A.v 3 2
3
Z .R P! v
Tip-speed ratio is the ratio of the speed of the rotating blade tip to the speed of the Wind stream.
Cp vs. P
Generator rating = 1.1 Turbine Rating Converter Rating = 1.2 Turbine Rating
1. Higher initial cost due to high price of magnets used 2. Permanent magnet costs restricts production of such generators for large scale grid connected turbine designs 3. High temperatures and sever overloading and short circuit conditions can demagnetize permanent magnets
Power electrical = I Vx pf
Where: Power electrical = [W], V = voltage [V], I = Current [A]
Power mechanical=2
* T* N/60
Power fluid = g Q H
water
Where: Power fluid = [W], g = 9.81 m/s2, Q = Flow quantity [m3/s], H=Pressure head [m], water = density of water
The following table shows the theoretical power required as the motor speed & system flow decrease p1/p2= (n1/n2)3 Speed
100% 90% 80% 70% 60% 50% 40% 30%
Flow
100% 90% 80% 70% 60% 50% 40% 30%
Power Required
100% 72.9% 51.2% 34.3% 21.6% 12.5% 6.4% 2.7%
If you have a system using a motor that serves a varying load, an Adjustable Speed Drive (ASD) may benefit you. Examples of such systems are fans that reduce flow for non-design conditions or pumps that use control valves to vary flow. ASDs tailor motor performance to match present conditions. Advantages include:
Energy savings Improved process flow Softer/easier motor starting Faster response than valves or dampers
Throttling verses Speed change for pump system H-Q curves and power savings
Throttled Operating Point head Hs H H2
Ps
N1 Q ! Q2 N 2
Operating point
P P2
H N1 ! H2 N2 P N1 ! P2 N 2
flow
q2
Example
The following example show the energy saving when operate a pump (rated flow=0.25m^3/sec, at speed 1500rpm) with constant speed to fill a canal with dimension (500m length, 5m width, 3m height).
The volume of water required = 5 x 3 x 500=7500 m^3 The number of hours required =7500/(.25 x 60 x 60)=8.33 hr Assume the input power to the pump = P kW The energy consumes 8.33P kWh
If operate the pump with VSD to fill the same volume Operate 2 hours at rated speed q=0.25m3/sec, v1=0.25 x 2 x 60 x 60=1800m3 Operate 4 hours at 0.75 x 0.25 m3/sec v2=2700m3 V3=7500-2700-1800=3000m3 Operate at 0.5 x 0.25 m3/sec, it s operating for 6.67 hr From affinity laws P proportional to cubic speed P (at 0.25)=P kW, P (at 0.75 x .25)=0.42P kW, P (0.5 x .25)=0.125P kW Energy required 2 x P+4 x 0.42 x P+0.125 x 6.67 x P=4.5P kW Percentage of energy saving = 8.33P-4.5P/8.33P=45.8%
Example 2
The opposite figure shows an operating point of a pump at speed n1=1450 rpm. By using throttled valve it operate at flow QM =500m3/hr,h1=65m,and eff.=75%. And by using inverter to provide variable speed operation its operate at the same flow QM but at head h2 = 12.5 m, and eff.=85%. Required 1. 2. 3. 4. 5. Power input with the valve control Power input with the speed control Power saving Energy saving (assume the pump operate 8000 hr/year) Saving and payback period (assume cost of kWh = 8 piaster)
Solution
power with valve = QM * h1*p*g/eff.1=118 kw power with VSD = QM *h2*p*g/eff.2=20kw power saving =(118-20)/.9=109kw energy saving = 109*8000 (op hours) =871000 kWh/y Operating cost saving = 871000*.08=6980 L.E. Payback period =10000 (ASD cost)/6980= 1.435 year
time
Drives can share dc bus or use CSI drives which have regeneration capabilities
200 kW
=
Inverters
End Of Ac Drives