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Electrical Machines and Drives
Electrical Machines and Drives
Contents
Chapter 1 - Introduction ............................................................................7
General ..............................................................................................7
Chapter 2 - Processes and their requirements ..........................................8
Why variable speed control? ...............................................................8
Industrial segments with VSD processes..............................................9
Variables in processing systems ........................................................10
Machines are used to alter materials properties... .............................11
Well defined shape .......................................................................11
Indefinite shape ...........................................................................11
...and to transport materials ..............................................................12
Solid materials .............................................................................12
Liquid materials ...........................................................................12
Gaseous materials .......................................................................12
Chapter 3 - The workhorse of industry: the electric motor ......................13
Electric motors drive most machines .................................................13
Motors convert electrical energy into mechanical energy ....................14
Frequency converters control electromagnetic induction .....................15
The efficiency of the drive system ......................................................16
Reversed rotation or torque is sometimes required .............................17
The load, friction and inertia resist rotation .........................................18
The motor has to overcome the loading torque ..................................19
The drive torque and load torque are equal at nominal speed .............20
Chapter 4 - Variable volumes require some form of control ....................21
Variable material flow and input/output requirements ..........................21
Simpler control methods ...................................................................22
The best control method is VSD ........................................................23
Mechanical, hydraulic and electrical VSDs .........................................24
Hydraulic coupling .......................................................................24
DC drive ......................................................................................24
AC drive ......................................................................................24
Electrical VSDs dominate the market .................................................25
Maintenance costs .......................................................................25
Productivity .................................................................................25
Energy saving ..............................................................................25
Higher quality ..............................................................................25
The AC drives market is growing fast .................................................26
Chapter 5 - AC drive: The leading control method ..................................27
The basic functions of an AC drive ....................................................27
A motors load capacity curves with an AC drive ................................28
Chapter 1 - Introduction
General
This guide continues ABBs technical guide series, describing
different variable speed drives (VSD) and how they are used in
industrial processes. Special attention has been given to electrical VSDs and especially to AC Drives.
The guide tries to be as practical as possible. No special knowledge of VSDs is required, although basic technical know-how
is required to fully understand the terms and descriptions used.
Examples
Industrial:
Chemical industry
Pulp, paper, printing
Food & beverage
Power plants
Mining
Metal industry
Machine shops
Non-industrial:
Plastics
HVAC
Textiles
Water treatment
10
12
14
16
18
T[Nm]=9550 x
P[kW]
n[1/min]
The drive torque and load torque are equal at nominal speed
A motors torque/speed curve is unique and has to be calculated
for every motor type separately. A typical torque/speed curve is
shown in the graph as Tm. As can be seen, the maximum load
torque is reached just below nominal speed.
Load torque Tl usually increases with speed. Depending on the
application it can be linear or quadratic. The motor will automatically accelerate until the load torque and motor torque are
equal. This point is shown on the graph as the intersection of
Tm and Tl. Actual torque (Tact) is shown on the y-axis and actual
speed (nact) on the x-axis.
These are the principles that govern how an ordinary squirrel
cage motor works. With a frequency converter, optimal control
performance can be obtained from the motor and the whole drive
system. This will be introduced later in this guide.
20
Output
Input
Process
Interference
Typical cases
Application
Input
Submersible pump
Water level
Interference
Pump application
Water level
FD fan
Heat demand
Atmospheric pressure
Sawmill line
Log diameter
Hardness of wood
Screw conveyor
Feeder
Hardness of material
Grinder
Output
Water flow
Material volume
Load
22
26
28
Important features:
- inputs and outputs
- reversing function
- ramp times acceleration/deceleration
- variable torque V/Hz settings
- torque boosting
- eliminating mechanical vibrations
- load limits to prevent nuisance faults
- power loss ride-through
- stall function
- slip compensation
- flying start
Reversing
Reversing the motor rotation is simple to accomplish with an AC
drive. With ABBs frequency converters it can be achieved simply
by pressing one button. Furthermore, it is possible to set different
acceleration and deceleration ramp times. The ramp form can
also be modified according to the users wishes. In the diagram
(above, left) an S-ramp has been presented. Another possibility
could be a linear ramp.
Torque control
Torque control is relatively simple with an AC drive. Torque
boosting, which was presented earlier, is necessary if a very
high starting torque is required. Variable torque U/f settings
mean that maximum torque can be achieved at a lower speed
of rotation than normal.
Eliminating mechanical vibrations
Mechanical vibrations can be eliminated by by-passing critical
speeds. This means that when a motor is accelerated close to
its critical speed, the drive will not allow the actual speed of
the motor to follow the reference speed. When the critical point
has been passed, the motor will return to the regular curve very
quickly and pass the critical speed.
30
Slip compensation
If the motor load torque is increased, the speed of the motor will
decrease as shown in the diagram (above, left). To compensate
for this slip, the torque/speed curve can be modified with the
frequency converter so that torque increase can be accomplished
with the same speed as previously.
Flying start
The flying start feature is used when a motor is connected to a
flywheel or a high inertia load. The flying start works even without
a speed feedback. In case of rotating motor, the inverter is first
started with a reduced voltage and then synchronised to the
rotating rotor. After synchronised the voltage and the speed are
increased to the corresponding levels.
32
Environmental features
Any drive system has to handle different environmental stresses
such as moisture or electrical disturbances. The squirrel cage
motor is very compact and can be used in very hostile conditions. The IP54 degree of protection guarantees that it can work
in a dusty environment and that it can bear sprinkling water from
any direction.
The frequency converter usually has an IP21 degree of protection. This means that it is not possible to touch the live parts and
that vertically dripping water will not cause any harm. If a higher
degree of protection is required, it can be obtained, for example,
by installing the drive inside a cabinet with the required degree
of protection. In such cases, it is essential to ensure that the
temperature inside the cabinet will not exceed the allowed limits.
EMC
Another important environmental feature is electromagnetic compatibility (EMC). It is very important that a drive system fulfills the
EMC directives of the European Union. This means that the drive
system can bear conductive and radiative disturbances, and that
it does not send any conductive or radiative disturbances itself
either to the electrical supply or the surrounding environment.
If you require more information about the EMC directives and
their effects on drives, please refer to ABBs Technical guide No.
3, EMC Compliant Installation and Configuration for a Power
Drive System.
At the moment there are still plenty of motors sold without variable speed AC drives. This pie chart shows how many motors
below 2.2 kW are sold with frequency converters, and how many
without. Only 3% of motors in this power range are sold each year
with a frequency converter; 97% are sold without an AC drive.
This is astonishing considering what we have seen so far in
this guide. Even more so after closer study of the costs of an AC
drive compared to conventional control methods. But first lets
review AC drive technology compared to other control methods.
34
36
Conventional methods:
AC drive:
all in one
saves energy
38
Throttling
AC drive
Installation material
20 USD
10 USD
Installation work
5h x 65 USD =
325 USD
1h x 65 USD =
65 USD
Commissioning
work
1h x 65 USD =
65 USD
1h x 65 USD =
65 USD
Total
410 USD
140 USD
Throttling
AC drive
saving 50%
Power required
0.75 kW
0.37 kW
3000 kWh
1500 kWh
300 USD
150 USD
Maintenance/year
40 USD
5 USD
Total cost/year
340 USD
155 USD
USD/kWh
40
Chapter 7 - Index
A
ABB 30, 33, 41
AC drive 24, 25, 26, 27, 28, 29,
30, 31, 34, 35, 36, 37, 38, 39, 40,
41
AC drives market 26
AC motor 13, 14
active power 16
B
belt drives 24
blowers 18
braking 17, 23
bypass control 22
C
coefficient of efficiency 16
Commissioning 39
commutator 24, 26
contactors 36
crane 17, 19
critical speed 30
crusher 18
current 14, 15, 16, 24
D
DC bus 14, 15
DC converter 24
DC drive 24, 26
DC motor 24, 26
Direct on-line starting 25
drive frequency 31
drive software 31
drive system 16, 20, 29, 33
E
electrical disturbances 33
electrical equipment room 24
electrical supply 16, 27, 33
electromagnetic compatibility 33
electromagnetic induction 14, 15
EMC 33
EMC directives 33
energy 14, 15, 22, 25, 26, 31, 37,
40, 41
F
fans 18
flux 14, 15
flying start 29, 32
flywheel 32
four quadrant drive 17
frequency converter 14, 16, 17,
20, 24, 28, 32, 33, 34, 40, 41
friction 18
fuses 36
42
H
harbour 19
hydraulic coupling 24
I
industrial processes 13
inertia 18, 32
input power 16
interference 15, 21
inverter 14, 15, 24
IP21 33
IP54 33
L
linear ramp 30
load capacity curves 28
M
machine 11, 13, 24, 29
magnetic flux 14, 15
maintenance 24, 25, 26, 37, 40
mechanical power 16
mechanical vibrations 29, 30
motor load 32
motor losses 16
motor phase 14
motor size 16
motor stall condition 31
motor windings 14, 15
N
nuisance faults 29
O
output power 16
P
power factor 16
power loss ride-through 29, 31
power plants 22, 37
process control 25, 26, 27, 29
processing system 10
pump 24, 25, 36, 40
R
rated speed 16
Reactive power 16
reactive power 16
reactors 36
rectifier 14
reference speed 30
reversing function 29
right hand rule 14
Index
S
S-ramp 30
slip 14, 29, 32
squirrel cage motor 20, 24, 33
stall frequency 31
stall function 29, 31
stator 14
stepless control 15
T
temperature 15, 33
throttling 22, 36, 39, 40
torque 16, 17, 18, 19, 20, 28, 29,
30, 31, 32
transistors 16
V
valve 40
valves 24, 36
variable speed control 8, 21, 24
Variable Speed Drives 1, 3
voltage 14, 15, 16, 24, 27, 31
VSD 9, 15, 22, 23, 24, 25, 26
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