Modern, high-performance induction drives can be used where D-C or brushless drives were previously needed. ‘The power conversion section is ‘common to virtually all PWM drives, whether they use a VVVF or vector regulator. Vector Drive Basics Ken Deken Reliance Electric Company Cleveland, Ohio Several drive manufacturers are touting the vector drive ~ the newest type of ‘ACC variable-frequency drive (VFD) — as the A-C solution for tough variable- ‘speed applications. In many ways, vector drives offer users the best features of both A-C drives and D-C drives in a single, problem-solving package. New electronics. technology has dramatically reduced the complexity and cost of vector drives to make them practical for new uses. ‘This article 1) explains what a vector drive is, 2) shows how itis different from a standard A-C drive, and 3) discusses some application and pricing comparisons with D-C and brushless drives. ‘Vector Drives Provide Independent Control What is a vector drive and where does it get that mysterious name? You ‘may recall from math classes that a “vector” quantity has both magnitude and direction. A vector drive borrows that name, since it uses a more so- Phisticated electronic regulator to control both the magnitude and direction (or strength and speed) of the magnetic flux in an A-C motor through inde- Pendent control loops. Conventional “variable-voltage, variable-frequency” (VVVF) A-C drives lock together the excitation control of the magnitude and direction of magnetic flux in the motor. The control stratecy of VVVF drives is fine for steady-state conditions, or for loads encountered in applications such as fans and pumps that allow lots of time for a speed change. But in many real-world applications, loads, speed, (or position are likely to change abruptly. Vector drives are much better suited to handle these conditions since they provide direct torque control, as well as a dynamic response capability that is ten times that of VWVF drives.‘The block diagrams in Figures 1, 2, and 3 provide more details about the sim- llarities and differences between vector drives and conventional VWF drives. PWM Power Conversion Tee pair griagr rer Seed Figure 1 — Pulse Width Modulation (PWM) Technology Note first the power conversion section shown in Figure 1. That portion of the drive is common to virtually all pulse-width-modulated (PWM) drives, whether they use a VWVF or vector regulator. Three-phase A-C power flows through the six input diodes which rectify it into D-C power of a fixed voltage. The D-C power is smoothed by the fter capacitor. A set of six transistors with diodes. in the switching section are controlled to tur the D-C power back into A-C. power of variable voltage and frequency. That “synthesized A-C” power is fed to the motor. ari i Figure 2 ~ Voltz/Hertz Block Diagram Figure 2 shows a simplified block diagram of the regulator of a conventional WWF drive. The speed reference command from the user is fed to a ramp block to convert step-function speed changes to slower-changing ramps that limit current flow and save machine wear and tear. The signal then moves to a section that sets both the rate of change and strength of the magnetic field in the motor. Its important to recognize that the single-speed control input ‘command controls both of these variables in a WWVF drive.lize Figure 3 — Vector Block Diagram ‘A vector drive regulator block diagram is shown in Figure 3. Two separate control loops have been added, making it more complex. The control loops allow independent control of the speed and strength of the motor’s magnetic field. They also allow the regulator to measure the actual speed of the motor ‘and to estimate closely the amount of torque being produced. The “Motor Model Block” Secret ‘The “Motor Model Block,” shown in Figure 4, is the secret of the vector drive. Ituses high-speed electronics technology (often a micro-processor or digital- signal processor) to compute torque calculations at 2,000 times per second or more. ‘The Motor Model Block makes use of a very important principle for A-C induc tion motors: Torque, Current, and Slip are related. Slip, Current and Torque are Related 0 85 0 1 10.3 15 2 144 30 33 19.41 45 47 25.0 60 SLIP = STATOR RPM - ROTOR RPM (Data for Reliance Electric Model P25G312, 20HP, 360460V AC, Std. Eficiency) Figure 4 ~ Motor Model Block‘The “Motor Model Block” makes use of a very important principle of A-C induction motors: Torque, Current, and Slip are related. Look at the Table in Figure 4. It compares the slip, current, and torque versus load for a single motor. (Slip is defined as the difference between the synchro- ‘nous electrical excitation speed of the stator and the motor’s actual shaft ‘speed. Current is the value of A-C current that is measured by using a clamp- ‘on ammeter on one of the motor leads. Torque is the output torque of the mo- tor at the shaft, It's easy to gain an intuitive understanding of the data in this, table. We expect thet an induction motor will sow slightly and draw more cur- rent as the load connected to itis increased. Torque and slip are directly related. An increase in load torque requires a pro- portional increase in slip. However, even though current increases with torque, the change is not linear. Fortunately, the change of current with torque varies in a predictable way. The total current drawn by the motor has two components. The first is no-load or ‘magnetizing current, This portion is simply reactive current that does not rep- resent mechanical power. The second is torque-producing current that is electrically in-phase withthe voltage applied to the motor. This is the portion that delivers power to the motor and varies directly with output torque. retizing urrent 85Amps ‘Torque-Producing Current 235 Amps Vector calculates Torque-Producing Current by knowing actual amps and magnetizing current. (Magnetizing Amps = No Load) Figure 5 ~ Current Diagram Figure 5 may help explain the last concept. It shows a “current diagram.” Magnetizing current of 8.5 amps is represented by the Y axis. The X axis rep- resents torque-producing current of 23.5 amps. The actual full load current ‘measured at the motor (25.0A) is represented by the hypotenuse of the right triangle formed by the X/Y components. Once again recalling the use of “vec- tor’ from math classes, you will see that the actual current drawn by the motor is the vector sum of the magnetizing and torque-producing components of current. In real applications, we can obtain the magnetizing current from the motor ‘manufacturer (or approximate it by measurement). We can certainly measure the total current drawn by the motor by using high-speed hall-effect current sensors. The regulator must then solve the following equation to determine the torque-producing component of current that is the last part ofthe Motor Model Block puzzle: [2 2 Irorauz \/ 1 MEASURED ~ I MAGNETIZING That's enough theory! What will vector drives do for you and what are their advantages?Vector Drive Advantages Start with all advantages of Vector drives provide all the benefits and advantages of VWVF drives and standard VWF A-C drives. more. Start with all the advantages of VWVF drives: 1. Use “standard”, low-cost, induction motors. Explosion-proof motors and other special construction is widely available, Brushes, commu- tators, or special ‘permanent-magnet” rotors are not required. 2. High-input displacement power factor (about 95%), for lower-cost power. ‘3. Some inherent ability to “hold back" loads through regeneration with- out extra hardware. 4, High-speed capability (6,000 RPM is easily attainable). Unlike “brushless” drives, which Add to those the folowing advantages not achievable with standard VVVF have been sold as replacements for drives: D-C drives, vector drives do not need special design motors with ‘permanent-magnet rotors. Closed-loop speed regulation to 0.01%. High-dynarric response of greater than 50 radians/second. ‘Smooth low-speed operation, even under changing loads. High breakaway torque (150% or even 200% is common), 5. Linear torque control for positioning or tension. ‘These advantages make vector drives the best answer for many applica- tions. Compared with D-C drives, a vector drive's high power-factor, high-speed capability, and the ability to use induction motors are important advantages. Unlike “brushless” drives, which have been sold as replacements for D-C drives, vector drives do not need specially-designed motors with permanent: hope magnet rotors. Ce % cos | oors "oe oe vee ‘ors | mont vewo [ves %0 ves ves «1 m a Non woe | me | we |e | oe om | cm | como | cso | com ine | swosen | swussen | swosen | swesen o 1 = a Ey wes wes "0 "0 ves {D Seca fen nears nae Sloncieneson sian ecu mace srr ack Figure 6 ~ Vector Drive Comparison Chart Figure 6 shows some comparisons among vector drives and other technolo gies. This data may vary somewhat by manufacturer, but nonetheless pro- vides general guidelines.Applications which require ‘dynamic braking will require different solutions when vector drives are used. ‘Special consideration should be given to the motors used with vector drives to obtain optimized performance. Pricing for A-C vector drives is competitive with D-C drives in applications below 50 HP. Vector drives are often more expensive than D-C drives in larg- cr ratings, primarily due to the more expensive power semi-conductors found in A-C drives. The lower cost of A-C motors offsets some of this difference, though. Application considerations may also justify a premium for vector drives in those cases where the initial cost is higher. Special Considerations While vector drives offer many advantages, they have a few limitations, to. First, virtually all of today's vector drives require tachometer feedback from the motor. The tach increases the price of the A-C motor, and there is cost associated with mounting, wiring, and maintaining it. However, brushless drives and many D-C drives also require tachometer feedback when speed regulation better than 1% is required. ‘Second, regeneration is more difficult with vector drives and with brushless drives than with conventional thyristor D-C drives. Snubbers, add-on regen- eration kits, and common-bus configurations have all been used for regenera- tion with vector drives, but D-C drives have the advantage for low-cost, single-section regeneration. Third, applications which need dynamic braking (slow-down braking without the drive operating) will require diferent solutions when vector drives are used. D-C and brushless drives make use of the fact that they can operate as ‘generators without an active regulator to provide a dynamic braking function. Vector (and other A-C) drives may require D-C injection braking or mechani cal brakes to provide the functional equivalent of dynamic braking. This is necessary because the regulator on A-C drives must be active to brake the load Finally, a word about motors is appropriate. Throughout this article it has been noted that “standard” induction motors may be used with vector drives. However, the high-performance capabilities of these drives can place heavier demands on the motors they power. Special consideration should be given to using motors optimized for constant-torque, high-overload duty over a wide speed range. Several manufacturers now offer “vector-duty” motors with tachometer-mountirg provisions and blower-cooling. Some companies have gone a step further ‘0 design vector-duty motors with lower inertia and special Construction features designed exclusively for variable-speed duty. Vector drives represent the step forward in performance that many applica- tions have needed to enjoy the advantages of A-C technology. Itis clear we will see them widely used in new applications. They can also be an alterna- tive to existing mechanical and electrical variable-speed drives.