Professional Documents
Culture Documents
By
Sarat Kumar Sahoo
Assistant Professor (Senior)
School of Electrical Engineering
VITU Vellore
Outline
Introduction
AC Machine Types
Power Converter Topologies
AC Drives Types
Possible Control Method
- Scalar Control (U/f Control)
- Field Oriented Control (FOC) or Vector Control
- Direct Torque Control (DTC)
Programmable Logic Devices for Drives ( ASICs, FPGA and CPLD)
Future Trends and Needs
Classification of Electrical Motors
Popular AC Motors for Electric Drives
Gating arrangements
- Square Wave Operation
- PWM technique
- Space Vector PWM
Two-level Voltage Source Inverter
Inverter Configuration
SENSOR-
• Open loop “Sensorless Vector” Drives LESS
VECTOR
FLUX
• Closed loop “Flux Vector” Drives VECTOR
All are Pulse-Width-Modulated (PWM)
Some manufacturers offer 2-in-1 & 3-in-1 Drives,
combining these attributes.
Open loop “Volts / Hz” Drives
o
l 230 eB
oo
st
t To
rqu
s
0 30 60 Hz
900 1800 RPM*
(Base) *( 4-pole motor)
• Motor voltage is varied linearly with frequency
• No compensation for motor & load dynamics
• Poor shock load response characteristics
Sensorless & Flux Vector Drives
o
l 230
t
s
0 30 60 Hz
900 1800 RPM*
(Base) *( 4-pole motor)
0 30 60 Hz
900 1800 RPM
All PWM inverters (V/Hz, Vector & Sensorless Vector) share similar power circuit
topologies.
AC is converted to DC, filtered, and inverted to variable frequency, variable
voltage AC.
PWM Power Circuit:
AC to DC Converter Section
AC to DC
DC Filter
Rectifier
AC DC +
Input Bus
Caps
-
Input Reactor
(option)
DC Reactor
The AC input is rectified and filtered into fixed-voltage DC
• Certain manufacturer’s units contain an integral DC reactor (choke)
as part of the DC filter.
• Adding an external AC input reactor will yield similar benefits.
• Both reduce harmonics, smooth and lower peak current.
PWM Power Circuit:
DC to AC Inverter Section
V
DC to AC u-v
DC Filter
Inverter
AC
Output
+
U
IGBTs M
V
- W
Imotor
IGBT Firing
Signals
Speed reference
EQ PROG
M L
controller
R
F
JOG W
RE
D
V
RUN STOP
RESET
RESET
Flux Vector Control Elements
Input, Feedback and Control Signals
Encoder Feedback
LO
v 1.3 µp, µc, DSP, FPGA
Speed and / or CA REF
S
E L
EQ PROG
Torque reference
JOG
M
W
F
RE
L
R
controller with
Vector algorithm
D
V
RUN STOP
RESET
RESET
AC V/Hz Drives Pro’s & Con’s
Advantages Limitations
• Simple, “look-up table” control of • Low dynamic performance on
voltage and frequency
sudden load changes
• Good speed regulation (1-3%)
• Limited starting torque
• No motor speed feedback needed
• Lacks torque reference capability
• Multi-motor capability
• Overload limited to 150%
Advantages Limitations
• Ultra-high torque and speed loop • Requires encoder feedback
performance & response • Single motor operation only
• Excellent speed regulation to .01% • May require premium vector motor for
• Full torque to zero speed full performance benefits
AC V/Hz 1 - 5% . 1 - 2 Hz 10 - 20% 5 - 10 Hz
AC Sensorless Vector .1- .5% 15 - 25 Hz 2 - 10% 75 - 200 Hz
AC Flux Vector .01 -.05% 20 - 100 Hz .5 - 1% 200 - 1000 Hz
REVERSE FORWARD
REGENERATING MOTORING
- RPM + RPM
REVERSE FORWARD
MOTORING REGENERATING
Counter-
Clockwise
TORQUE
AC Drive Regeneration
AC DC +
Bus IGBTs M
Input
Caps
_
• Current flows back into the DC bus, via the IGBT switching & back diodes.
• AC Drive front-end rectifier is unidirectional; energy cannot flow back into the AC
line.
• Some returned energy is dissipated in losses in the capacitors, switches, and motor
windings (10-15%).
• Excessive regeneration can cause problems, such as DC Bus Overvoltage.
Dynamic Braking on AC Drives
V DC Feedback
DBR
AC DC +
Input Bus
_ M
Caps
SIGNAL
DB is NOT ACTIVE when:
DB is ACTIVE when:
DYNAMIC • Decelerating a frictional load
• Motor has an overhauling load
BRAKING • Stopping in coast-to-rest mode
• Fast decel of high-inertial load
CONTROL • Drive is disabled or if power
• Stopping in ramp-to-rest mode
is removed
AC
DRIVE
NET
As individual drives
POWER MOTORING
regenerate, the
returned energy is re-
AC distributed to
Net power usage DRIVE motoring drives via
is minimal, due the common DC bus.
to the efficient REGEN
use of returned
energy. AC
DRIVE
MOTORING
AC Drives on a Common DC Bus: Typical
Connection Diagram
THERMAL- MAG
BREAKER
INPUT LINE
REACTOR
AC AC AC
DRIVE DRIVE DRIVE
SEMICONDUCTOR
FUSES
INTERLOCKED
DC CONTACTOR
Line Regenerative AC Drives
BI-DIRECTIONAL POWER FLOW
V DC Feedback
LINE M LOAD
PWM
microprocessor
controller
• Two sets of 6 - IGBT bridges
• Gating control for both sets
• Converter IGBTs modulate on when bus voltage is excessive.
• More complex regulator design
• More conducted noise to power line
Cost of drive is 1.8 times standard non-regen AC Drive
Multi-motor Applications
Motor amps must total less than
controller amp capability
• Each motor must have its own overload
• Drive must be in the “V/Hz” control mode AC DRIVE
(V/Hz mode)
• Motor speeds will be within slip-speed OVERLOAD CONTACTS
range, with respect to each other. 30 HP
38 Amps
• Interlock output contactors to drive run
logic, when used.
2 hp 3 hp 10 hp 2 hp 3 hp 5 hp
2.8 amps 3.9 amps 12 amps 2.8 amps 3.9 amps 7.2 amps
Total HP = 25
Total Amps = 32.6
Application of Contactor
Bypass on AC Drives MAIN CB
Provides back-up, across-the-line
operation of motor
• Single-speed operation on line only (must
have mechanical control in place)
INVERTER
• Motor overloads are mandatory. DISCONNECT
INVERTER BYPASS
MOTOR
OVERLOAD
TYPICAL 3-POSITION
SELECTOR SWITCH
AC Drives and Power Factor
REACTIVE
FLOW
AC
Input M
AC to DC
Cap losses = .5%
DC to AC
96% EFFICIENCY
SCR / Diode losses IGBT losses = 1.5%
= 1%
Diode
rectifier
L
Vs C
- +
Vo ωe Vd
+
Vo DB
Boost + Vs*
voltage Vs*' va*
va*= 2 Vs sin θe
G Vs*'/ωe 2π vb*
vb*= 2 VsSin(θe − 3 ) Inverter
ω*e θ*e 2π vc*
ω*e ∫ vc*= 2 VsSin(θe + 3 )
Speed or frequency
command
Induction
motor
CLOSE LOOP SLIP-CONTROLLED DRIVE
WITH VOLTS/HZ CONTROL
-Vd +
Vs*
Inverter
ωsl* ωe*
K2
ωr* K1+
+ S +
- +
ωr P-I
Controller ωr
Motor
Speed
Encoder
a
a b
2 3 TL' b
2 1
1 TL
ωr ωr
ωr
FEATURES OF VOLTS/HZ CONTROLLED DRIVE
SIMPLE AND INEXPENSIVE – VERY POPULAR
TWO-QUADRANT OPERATION
Field Orientation
Te – electromagnetic torque
Ka - armature constant
λf - flux produced by field circuit
ia - armature current
• λf = const → Te is proportional to ia
• Flux λf and ia can be controlled independently → high dynamic
performance.
Rotor Flux Orientation
• Direct FOC
Rotor flux angle θf is obtained by using flux-
sensing devices embedded inside the motor or
using measured motor terminal voltages and
currents
• Indirect FOC
Rotor flux angle θf is obtained from detected rotor
position angle θr and calculated slip angle θsl
θf = θr + θsl
Direct FOC
Indirect FOC
DISADVANTAGES OF VECTOR CONTROL
Torque ripple
Flux control : - Indirectly controlled by stator currents
- Slow dynamics
DTC Principle
Switching Logic
These PLDs are taking advantage of matured front-end design tools and philosophy of
application-specific integrated circuits (ASICs). With higher gate densities and lower
costs, FPGAs can target a large market of application specific standard products
(ASSPs).
With increasing densities of PLD, ac drive applications have evolved from mere
components like pulse width-modulation (PWM) controller or encoder feedback to
complete drive controller capable of executing feedback, control, and communication
functionality.
Advantages of FPGA-based Control
Rapid Prototyping
Easy use
Low Cost
High Performance
Bit widths for data registers can be selected based on application needs
Complex, digital control operations and controller interface peripherals can both be
contained in a compact form factor
Multiple digital control loops in one FPGA can replace analog control loops
implemented in many space consuming and power hungry radiation tolerant analog
IC’s
(Hardware Description Language) HDLs
High-density digital design has become feasible by the use of
HDLs. Two of the most popular HDLs used for digital design are
very high speed integrated design HDL (VHDL) and Verilog.
Current Loop Control: The current or torque loop is the fastest loop for motor control.
The system microprocessor has to devote considerable bandwidth to update the
current loop. Chip vendors have reported update times of 4 µs for this loop using
dedicated hardware logic . Due to fast computation needs, motor current control
algorithms have attracted a lot of PLD usage.
Speed Profile Generation: An FPGA can be used for generating velocity profile for a single-axis
control system. An acceleration and deceleration circuit for industrial robots and CNC machines
has been designed using HDL and FPGA. HDL blocks like counter, comparator, and position
increment are used to generate a velocity profile.
Complete Motor Control
Motion Control Within System Design
Power Electronic Control