VECTOR DRIVES

EASA June 2005

“REACHING NEW HEIGHTS”
Dave Ruehle and Bill Colton
Outline

• Define a Drive
• What is an Inverter Drive
• Why the Vector was Invented
• How Does a Vector Work
• What Types of Vectors Exist
• Typical Applications for Vector Drives
What is a Drive
• Parts and Pieces ⚫ Control Circuits
▪ Prime Mover ⚫ Ancillary devices
▪ Mechanical Reduction(s) ⚫ Couplings

⚫ Feedback
What is an Inverter
Drive
• Terminology

▪Scalar Drive
▪VFD
▪ASD
▪VVVF
▪VFI
What is an Inverter
Drive
• Speed Control Device
▪Controls STATOR frequency
▪Rotor changes speed with load
• Speed Changes dependant on motor slip

• NOT a current controller

▪Only a current limiter
Why the Vector was
Invented

• Increase Application Efficiency

▪Better Speed Control

▪Better Torque and/or Force Control
▪More Efficient Use of Power
Why the Vector was
Invented
• Performance Benefits

▪Rotor Speed Regulation

▪Lower Rotor Inertia Requirements
▪Much Wider Speed Ranges
▪Torque (or Force) Control
▪Zero Speed Full Torque
 How Inverter Control Is
Achieved
• Convert AC Input to DC
• Filter the DC Power
• Create a digital output pulse train varying the
frequency and voltage to Stator
How Vector Control is
Achieved
• Establish the motor/system Model

▪Stator Resistance
▪Stator Inductance
▪Rotor Resistance
▪Rotor Inductance
▪Air gap Losses
▪Machine Losses and Inertia
How Vector Control is
Achieved
• This is achieved in several fashions

▪Manual – Programming Each Item

▪Auto Tuning
• Program Basics
• Run Tests for Additional Items
▪Adaptive Tuning
• Continuously Adjusting for Changing
Conditions
• Now The System Model is Established
How Vector Control is
Achieved
• Hardware Components Inverter Vector
Comparison

Converter X X

Filter X X

Output X X

Feedback X
How Vector Control is
Achieved
• Monitoring the feedback
▪Speed
▪Current
▪Back EMF
• Comparing to Established Model

• Adjust accordingly
▪Amount of Deviation
▪Motor/System Model
How Vector Control is
Achieved Speed Changes
What Types of Vectors
Exist
• Open Loop (Encoderless) Vector
▪Establishes the Shaft Position from the current
(amp) measurement
▪Advantages
• Lower Initial Cost
• Reduced Wiring
▪Disadvantages
• Not as responsive
• Limited Speed Range
• Difficulty with Impact Loads
• Temperature Changes can be Problematic
What Types of Vectors
Exist
• Closed Loop Vector
▪Monitors Shaft Position via Feedback
• Encoder
• Resolver
▪Advantages
• Excellent Speed Regulation
• Full Torque at Zero Speed
• Systems Capabilities
• Very Responsive
• Higher Safety
• Easier to Tune
What Types of Vectors
Exist
• Closed Loop Vectors (Cont.)

▪Disadvantages

• Additional Initial Cost

• More Wiring
• Motor Length
• Requires Better Wiring Practice
What Types of Vectors
Exist
• Space Vector
▪A method of firing transistor to control a
specific element
• Current Feedback
• Voltage Feedback
• Hysteresis
• Sine Triggered (Coded) Vector
▪A method of firing transistors to control the
sine wave
Applications for Vector
Drives
• Extruders
▪Closed Loop for Clamped Dies
▪Open Loop for Continuous Feed
• Lifts
▪Closed Loop for Safety
▪Has been done with Open Loop and
Mechanical Load Brakes – consult
manufacturers
Applications for Vector
Drives
• Bridge Drives – Typically Scalar
• Trolley Drives – Typically Scalar
• Conveyors – Typically Scalar
• Centrifugal Loads – Typically Scalar
▪Potential Energy Savings with Encoderless
• Spindle Drives – Typically Closed Loop
▪Rapid Response Times
▪Accurate Speed for Tapping
▪Controlled Grind Speed
Applications for Vector
Drives
• Winders
▪Typically Closed Loop for Tension Control
• Mooring Winch – Encoderless
• Mixers – Typically Scalar
• Line Shaft Replacements – Closed
Loop with “electronic line shaft”
capability
• Cut to Length – Closed Loop with
Motion Control
Applications for Vector
Drives
• Flying Shear – Closed Loop with
Motion Controller
• Stacker Cranes
▪Horizontal (X) – Scaler or Closed Loop
▪Elevation (Y) – Closed Loop for Safety
▪Bins or Forks (Z) – Scaler or Closed Loop
• Crushers
▪Oversized Scaler
Applications for Vector
Drives
• Types of Braking

▪D.C. Injection
▪Shunt Braking – Most Common
▪Bus Sharing
▪Line Regenerative
Line Regenerative
Applications
• Elevators
• Hoists
• Presses
• Centrifuges
• Unwind Stands
• Windmills
• Pumping Jack Drives
• Application where Heated Resistors are a
problem
• Test Stands (dynamometers)