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Final Review & Closing Remarks: What Is A Drive? Why Drives Are Applied
Final Review & Closing Remarks: What Is A Drive? Why Drives Are Applied
The following information will serve as a final book summary. This will
assist the reader in preparing for the final “Check Your Knowledge” sec-
tion that follows. For a thorough review and before the final “Check Your
Knowledge” is taken, it would be helpful to review all chapter summaries
and questions.
There are various types of variable speed drives available for use in indus-
try. The basic categories are mechanical, hydraulic and electrical/elec-
tronic. Electronic drives can be further divided into the following
categories of eddy current, rotating DC, DC converters and variable fre-
quency AC.
The two types of voltage (electrical pressure) available are direct current
(DC) and alternating current (AC) . DC is typically found in battery cir-
cuits, and its output value does not fluctuate, until the battery goes dead.
AC is typically found as a power source for households and industrial
operations. The output value fluctuates depending on the time base of
transmission (positive to negative to positive output). Frequency is the
number of times complete cycles are seen in a power system (e.g. 60 Hz).
The two types of AC available are single phase and three phase.
There are three basic types of mechanical loads that are encountered by
any AC or DC drive system: constant torque (e.g. conveyors), variable
torque (e.g. centrifugal fans/pumps), and constant horsepower (e.g.
machine tools).
Speed, torque, and horsepower (HP) play a major role in the operation of
any application. Speed affects how much HP is required to perform the
function; faster acceleration (more speed), requires more HP. Torque is a
turning effort, and defines the ability of a system to start and keep moving
at a specified rate. Inertia (WK2 or WR2) is the measurement of an object’s
resistance to change in speed. This measurement is needed to determine
the acceleration time available from a drive system.
Gears, belts, pulleys (sheaves), chains, and sprockets all work to allow a
smooth transmission of mechanical power, and in some cases, change
speed and direction. Types of belts and pulleys include flat and V-belts,
synchronous belts, and chains and sprockets.
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Motors
AC and DC motors are the two major types used today in industrial and
HVAC applications. These motors provide the speed, torque and HP neces-
sary to operate the application. The motor changes one form of energy
(electrical) to rotational or linear motion (mechanical).
The two major components of a DC motor are the armature and field wind-
ing. The armature is the rotating part that is physically connected to the
shaft and develops magnetic flux around its windings. The field winding is
the part of the stationary frame and provides the flux necessary to interact
with the armature flux to produce rotation. The commutator acts as an
electrical switch and always ensures that a repelling force is taking place in
the armature flux circuit. This repelling force against the field winding flux
causes rotation of the armature. Brushes are the devices that physically
connect the voltage supply to the Armature circuit. Brushes are con-
structed of carbon material and require routine maintenance or replace-
ment in order to reduce arching at the commutator segments.
Two separate voltage supplies are connected to the DC motor, one for the
armature (variable DC voltage armature supply) and one for the field
winding (fixed voltage field exciter). Speed of the DC motor is directly
controlled by the magnitude of the armature supply voltage. Speed is also
inversely proportional to the magnitude of the field flux. Torque is a direct
result of the interaction of armature and field winding flux.
Various types of enclosures safeguard the DC motor against harm. For
example, drip-proof motors provide a degree of protection against vertical
falling materials, and also allows for the ventilation of cool outside air.
Totally enclosed motor frames provide a higher degree of protection, but
are not practical for large frame motors due to the inability to remove heat.
Motors are listed with many types of ratings that indicate the torque gen-
erating ability, altitude, heat capability, vibration, and electrical specifica-
tions. DC motors are constructed with several different types of field
winding circuit: series wound, shunt (parallel wound), and compound
wound.
AC motors are listed with one of two ratings: NEMA or IEC. All motors
can be classified into single phase or polyphase categories. The main com-
ponents of the AC motor are the rotor and stator. The rotor is the rotating
part and the stator is the stationary part connected to the frame. Only one
power source is required to set the rotor into motion. The stator windings
create magnetic flux that causes a magnetic field (flux) to be induced in
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the rotor. The attracting forces of the rotor and stator flux produce torque
and rotation of the rotor.
Drives
In DC Drive systems, an armature and field exciter are used to control the
two separate elements in a shunt wound DC motor. SCRs are used to vary
the DC voltage output, which has a direct bearing on the speed of the
motor. The DC Drive is the simplest of drive systems. The disadvantage of
using SCRs for the drive power structure is the inherent nature of line
notching. This notching is caused by the “phasing on and off” of the (6)
SCRs located in the drive input section.
regulation mode, the drive closely monitors the value of the current mea-
suring circuit. The drive ignores the speed controls and calculates the cur-
rent (torque) required by the load. The drive will automatically operate at
the speed required to allow the motor to develop the desired torque.
Field exciters are constructed of SCRs or the newer IGBT power semicon-
ductor technology. Some supplies are powered by single phase or 2-phase
power and have the ability to operate in “field control” mode. This mode is
the weakening of the shunt field strength, to allow above base speed oper-
ation. Form factor is the term used to compare the purity of the DC output
from the armature or field exciters.
The operation of the DC drive can be compared to a relationship of “quad-
rants.” A four quadrant drive would allow forward and reverse operation
as well as regenerative capability (regenerating voltage back to AC line
power.). This type of armature supply includes (12) SCRs in a bridge con-
figuration.
Braking methods include coast and ramp to stop, which are typically the
longest method of bringing a motor to a stop. Dynamic braking causes the
back-fed voltage to be dissipated in heat, through a high wattage power
resistor. The fastest “electronic” method of stopping a motor is through
regenerative braking. This allows full voltage to be fed directly back to the
AC line. Mechanical braking also allows fast braking of the motor arma-
ture, through a brake pad assembly similar to that of an automobile.
A concern of DC drive use is the generation of harmonics, line distortion,
and power factor. A line reactor is required ahead of the drive unit to
reduce the distortion back to the utility system. In order to avoid the gen-
eration of RFI, shielded control cable, and power cable are used. In addi-
tion, a shielded transformer is used ahead of the drive.
There are three basic designs of AC variable-frequency drives (VFDs): cur-
rent source inverters, variable voltage inverters (input inverters), and
pulse width modulation (PWM). All AC drives operate under the same
characteristic. They change a fixed incoming voltage and frequency to a
variable voltage and frequency output. With PWM drives, the incoming
voltage and frequency is rectified to a fixed DC voltage. That voltage is
“inverted” back to AC, with the output, 0–460V and 0–60 Hz (or 0–230V).
Braking methods for AC motors are similar to that of DC. In addition, the
AC drive has the capability to “injecting” DC voltage into the stator wind-
ings. In doing so, the drive sets up a definite N and S polarity in the motor,
causing high reverse torque, and bringing the rotor to a fast stop.
Torque control AC drives basically fall into two categories: flux vector
(feedback required) and sensorless flux vector (no feedback required).
Vector control drives have the capability of full torque at zero speed. The
drive forces the motor to develop the torque required, to effectively han-
dle the load.
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Since the introduction of IGBTs into the power technology ranks, the size
of AC drives has been reduced to less than half of its counterpart 10 years
ago. With IGBT technology comes a challenge in AC motors—high voltage
spikes caused by “voltage reflection.” PWM drives produce an inherent
oscillation between the drive output and motor input. Precautions to be
taken against this motor damage possibility include: use of inverter duty
motors, output reactors, or DV/DT output filters.
Encoders use a system of light beams, directed toward a light sensor. The
light beams are created by shining a light source through a rotating, slotted
disc. The disc is connected to the encoder shaft, which is connected
directly to the motor shaft, through a coupling.
Resolvers are position type devices. These devices are typically used on
servo applications where precise feedback of the rotor position is required.
Resolvers are similar to an AC induction motor, as well as acting like a
revolving transformer.
DC drive control methods include closed loop control using a tach feed-
back device. It would also include armature voltage feedback or EMF con-
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Dynamic and static speed regulation are part of the set-up process of the
performance drive application. The accuracy of the speed or torque is
dependent on the feedback device, as well as the closed loop control cir-
cuit within the drive. The amount of “dampening” will determine if the
system will be stable, or produce oscillations.
Drive Systems
Drive systems operate in a coordinated fashion—with control between the
controller (PLC) and the drive unit. A variety of sensors, switches, and
transducers are a part of the overall scheme of automation.
Ensure that the drive is not located in an area where moisture could be of
concern. Less than 95% humidity, no condensation allowed is the stan-
dard rating for all drives. Moisture is a major enemy of electronics, as is
excessive heat.
Check tightness of connections as part of a routine periodic maintenance
procedure. Don’t over-tighten power connections. Mechanical overstress
of the bolt or nut could actually reduce the clamping power of the device.
Closing Remarks
The use of electronic motor speed controls has grown tremendously since
the early 1960s. The increased use can be attributed to technology
improvements not seen in years prior to the 1060s. Motor speed control is
a multi-billion dollar industry worldwide. The use of AC and DC drives,
brushless DC drives, permanent magnet AC drives, and stepper drives, all
play a part in today’ s industrial and HVAC marketplaces.
The use of electronic motor speed controls is expected to grow in non-tra-
ditional applications. Applications like automotive subsystems, household
appliances, electric vehicles, people movers and marine propulsion units
can all benefit from the technology drives offer.
The trend in AC drives appears to include several factors that all users can
benefit from. First of all, drives will continue to have increased intelli-
gence. Drives of today and tomorrow are more than just a “motor turner.”
They are a mini-PLC and personal computer, rolled into one unit. The abil-
ity to customize drive functions is becoming easier, due to windows based
development tools. Custom application software and custom programming
tools will continue to be a trend in AC drive development.
The use of micro-drives will also increase in the future. These types of
drives will present increased functionality and tout the ability to be flexible
during process changes. Industry demands the ability to make changes
quickly and efficiently. This is no exception when micro-drives are in use.
Since standard consumer products will continue to demand energy savings
and flexibility during use, user-oriented programming tools will be the
norm, rather than the exception.