CH 1 Power Electronics and Mechanics Interactions

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Training
Institute
Power Electronics and

Mechanics Interactions
Reproduction prohibited Power Electronics and Mechanics Interactions

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Training
Institute
Automated Systems

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Training
Institute
Automated System Structure

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Training
System Integration in Installation
Institute

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Training
Institute
Electronic Power Control

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Training
Institute
Electronic Power Control Functions
 Starting/deceleration
 Speed variation
 Speed variation/regulation
 Plus integrated automated system functions:

 communication, jog, PID, etc.

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Technologies When Associated with
AC Motors
Training
Institute
Starter
Motor power
3-phase M from several kW to
AC ~ several MW
Thyristors
Speed drive
Motor power
Single-phase M
or 3-phase from around 100 W to
AC ~ several MW
Transistors/IGBT
Speed drive/regulator
Motor power
3-phase M from several 100 W to
AC ~ several MW
Speed feedback
GI
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Technology When Associated with
DC Motors
Training
Institute
Single-phase speed drive/regulator
Inductor
Single-phase M Armature
Motor power
AC from 0.5 kW to 10 kW
Thyristor
Speed
feedback
3-phase speed drive/regulator

Inductor
3-phase M Armature
Motor power
AC from 6 kW to 1.5 MW
Thyristor
Speed
feedback

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Training Reasons for Electronic Power Control
Institute
 Production constraints
 Productivity and quality improvement
 Reduced investment costs
 Reduced operating costs
 Physiological aspects
 Mechanics protection
 Human-machine dialogue and speed control
 Automated system functions

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Training
Institute
Production Constraints
Application:
Cloth reel drying by passage through
oven at constant speed.
Solution:
Produce speed variation using electronic
speed drive (to avoid stretching cloth and
to obtain constant drying time).

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Training Productivity and Quality Improvement
Institute
Application: Application:
Timber machine or machining Bottle conveyor
Problem: Different approach and Problem: Bottle breakage at
machining speeds. starting.
Solution: Produce speed variation Solution: Soft starter or electronic

using electronic speed drive. speed drive.

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Training Reduced Investment Costs
Institute
 Application: Stone conveyor or large hoisting machine with extremely high current
inrush at starting causing substantial scattering.
 Solution: Soft starter or electronic speed drive.

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Training Reduced Operating Costs
Institute
 Application: Ventilation with airflow

variation by louvre gates causing
heavy consumption.
 Solution: Flow regulation with

electronic speed drive.

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Training
Institute
Physiological Aspects
 Application: Lift requiring certain

degree of comfort.
 Solution: Electronic speed drive assuring

acceleration and deceleration.

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Training Mechanics Protection
Institute
Application: mechanical stairway

with frequent starts and stops
stressing mechanics.
Solution:
Electronic speed drive
assuring acceleration and
deceleration, limiting torgue jerking.

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Human-Machine Dialogue and
Training
Institute Speed Control
Application: Machine with mechanical speed variation necessitating stop for human
intervention on speed adjustment.
Solution: Electronic speed drive enables

speed changes:
- without machine stop,
- remotely,
- adapted to process, without human
intervention (regulation, PLC control).

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Training Automated System Functions
Institute
Insertion in complex architectures
 The control of the application is completely centralised
 The DRIVE is used by the application only to control motor
Machine
Application
HMI in PLC
CANopen
Control motor
only

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Training
Institute
Mechanical Characteristics

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Operating Part
(Machine and Actuator)
Training
Institute
Materials
Machine Motor
torque = torque
Energy
Machine Motor
speed = speed
Products

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Training
Institute
Work
Linear movement:
F Work = Force x Distance
W (J )  F ( N )  l (m )
A B
Angular movement: • Work = Force x Distance

B B F1
  W ( J )  2.F1( N ).r (m ). (rad )
r A r A
• Torque = Force x Radius
F1
C ( Nm )  F1( N ).r ( m )  2.F1( N ).r (m )
F
W ( J )  C ( Nm ). ( rad )

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Training
Institute
Power
The WORK divided by the total time to execute the task defines the power:
W
 POWER
t
FOR RECTILINEAR MOVEMENT:

W F .l l
P  et :  V linear speed in metres/second
t t t
therefore P (W )  F1 ( N ).V (m / s )
FOR ANGULAR MOVEMENT:

W C . 
P  et :   angular speed in radians/second
t t t
2N (tr / mn)
therefore P (W )  C ( Nm ). (rad / s ) or  (rd / s ) 
60

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Training
Institute
Exercise: Torque-Speed
►Take two identical winches T1 and T2 equipped with two motors M1

and M2.
Motor characteristics are:
for M1: P1 = 15 kW N1 = 1 500 rpm

for M2: P2 = 22 kW N2 = 3 000 rpm
Which winch can raise a load of 90 N?

1m
r=
F1 = 90 N
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Training Different Torques Opposed by Machines
Institute
RESISTIVE TORQUE DRIVING TORQUE
F F
Resistive torque Driving torque

opposes movement assists movement

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Training
Institute
Resistive Torque
Cr
Cm
Rotation
Resistive torque (Cr) ≤ Motor torque (Cm)
Motor imposes speed

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Training
Institute
Resistive Torque
Cr = Constant Cr = K
Torque Torque
- Conveyors - Archimedes screw
principle
- Conveyor belts
Speed Speed
2
K
Cr = K Cr = 
Torque Torque
- Fans - Winders
- Centrifugal - Machine tool

pumps shafts
Speed Speed

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Training Breakaway Torque or Starting Overtorque
Institute
Torque
Cr=k2
Cr=k
Cd Cr cst
Cr=k/
Speed
- - - - - - Cd: BRAKEAWAY TORQUE

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Training Mechanics
Institute
All machines, whatever their resistive torque, can oppose greater or lesser breakaway torque at starting. If
this is incorrectly quantified during movement study and if it is too high, it can prevent starting or
significantly slow down speed pickup.
Breakaway torque can be several times torque at rated speed.
EXEMPLES: Extract from TELEMECANIQUE power electronics catalogue.
BREAKAWAY TORQUE SPEED DRIVE CHOICE

MACHINE TYPE OR OPERATING
OVERTORQUE
110 to 125% Normal
Machines with roller bearings or rollers
Machines with smooth step levels 130 to 150% Normal
Conveyors or high friction level 160 to 250% Overdimension speed drive

machines and possibly motor
Machines with jerking operating cycle 250 to 600% Overdimension speed drive
(press, machines with cams or rod-lever and motor
systems).
High inertia machines with inertia wheel Speed drive dimensioning will
or rotating weights (centrifuge) depend on time desired for starting
and/or braking

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Some Machines with Wide Torque
Variation
Training
Institute
Torque
Screw compressor with drawer
Piston compressor
No-load compressor
Speed

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Training
Institute
Driving Torque
Ce Cf
Brake
Rotation
Driving torque (Ce) ≤ Braking torque (Cf)
Machine imposes speed

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Training
Institute
Driving Torque
 Driving torque exists when the mechanics drive the motor.
 HORIZONTAL MOVEMENTS
 By action of an external element

 Example: action of wind on a vehicle.
 VERTICAL MOVEMENTS
 By effect of gravity.
R
Driving torque = F x R
F
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Training
Institute
Energy Transfer
On resistive torque
Electrical losses
Mechanical losses
Electrical
Load Mechanical MOTOR
MECHANICS energy
displacement energy
On driving torque
Mechanical losses Electrical losses
Driving Mechanical GENERATOR Electrical

MECHANICS
load energy energy

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Training
Institute
Conclusion
Whatever their resistive torque characteristics, all mechanics are sometimes

receivers, sometimes generators of energy.
To enable the correct choice of motor-speed drive combination it is important to

be aware of the resistive and driving torque characteristics of the machines
used.
It is this use with regard to the application that will decide braking suitability and
mode.
Their inertia can be useful in definition transient states.

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Training
Institute
Movement Study

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Training
Institute
Horizontal Movement
Q4 F>0
V<0
P<0
Force
+
F>0
V>0
P>0
Q1
Braking
F
F
Driving load at deceleration Speed

Normal forward
– +
Normal
0 Driving load at deceleration
reverse
F F
Braking
–
Q3 F<0
V<0
P>0
F<0
V>0
P<0 Q2
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Training
Institute
Vertical Movement
Q4 Driving load in
Force
permanent operation
and at deceleration
+
Q1
F F
Normal descent
Normal ascent Speed
– +
0
Driving load on
deceleration only
F
F
Q3
Starting on descent
Braking on ascent
Q2
–

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Training Motor Operating Quadrants
Institute
Torque
Q4 + Q1 + Speed
- + Torque
P>0
P<0
Energy transfer
Energy transfer Network Motor
Motor Network
Speed
Q3 Q2
+
-
- -
P>0
P<0
Energy transfer Energy transfer
Network Motor Motor Network

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Training Motor Operating Quadrants
Institute
The main indication to be given to characterise a variable speed electrical

drive is the number of quadrants of the torque/speed plane in which the
motor can operate.
We carry out a power assessment: P=Cω
Quadrants 1 and 3 have positive power. This corresponds with motor

operation. The energy is supplied by the network. The mechanics are driven.
Quadrants 2 and 4 have negative power. This corresponds with generator

operation. The energy is supplied by the mechanics. The mechanics drive.

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Training Exercise: Operating
Institute
States
►Complete the figures in quadrants 2, 3 and 4 by indicating the
direction of the arrows and the operating mode (ignore inertia
effects in this exercise).
Torque (Cm) Arbitrary forward direction

Q4 Q1
Cm  Cr Cm  Cr
Speed ( ω )
Q3 Cm  Cr Q2 Cm  Cr
Cm: Motor torque

Cr: Resistive torque
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Training
Institute
Movement Phases
Acceleration Any movement can be broken down

Steady state into a succession of these 3 phases
Deceleration
Speed Speed
Acceleration Deceleration Time Time

0
Steady
state

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Training Torques Provided by Motor
Institute
Acceleration
Speed
Steady state
Deceleration
Time
Acceleration Steady Deceleration

0 state
Cm = Ca + Cr Cm = Cr Cral= Cr + Cf
Ca = 0 Cral = - Ca , Cf = - Cm

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Training
Institute
Torques Provided by Motor
STEADY STATE
The torque provided by the motor (C m ) is equal to the resistive torque (C r ):
Cm  Cr
ACCELERATION
The torque provided by the motor (C m ) is equal to the resistive torque ( C r ), plus the torque required for
acceleration of mobile ( C a ): C C C with C a = acceleration torque.
m r a
The motor torque C m is also called starting torque C d . The acceleration torque is linked to
desired acceleration of mechanics  and to inertia of mechanics J: 

t Ca  J
t
DECELERATION
In this case, the "acceleration" torque is negative. It is called slow-down torque: C ral (C ral   C a )
If the machine is left alone at supply voltage cut, the deceleration torque is equal to the resistive torque:

C ral  C r  J
J t
Stop is produced after time t linked to the moment of inertia: t 
C ral
If this time is not acceptable, slow-down torque must be supplemented by a braking torque C f
(C f  C m ) such as:

C ral  C r  C f  J
t
Acceleration at Constant Motor Torque
Freewheel Stop
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Training
Institute
(Resistive torque of fan or similar)
Torque
Q1
A
B
Speed
Ca = Cm - Cr Cm  n B, D
B
-Cr A A E
Speed
0 0
Cr Cral=Cr t1 t2 t3
E Time
Q2
D

Acceleration at Constant Motor Torque
Freewheel Stop
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Training
Institute
(Resistive torque of conveyor or similar)
Exercise: Trace speed as a function of time

during transient phases
Speed
Torque
A
Cm(max) B B C D
Ca
C
- Cr Cm
n
E
Speed A t1 t2 t3 Time
Cr Cral
E D

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Acceleration and Deceleration at Constant
Training
Institute Motor and Braking Torque
Torque
B
A
Cm
Ca
Q1 Speed
0  n
B B, D
- Cr 20%
Cr Speed
80% 20%
Cf A E
Q2 20% 80% 20%80%
0 t1 t2 t4 Time
Cral = Cr+Cf
E

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Training
Institute
Constant Acceleration and Deceleration
Torque
B
Speed
Q1
 n
A Cm B, C C, D
C
Ca Cm
- Cr A
E
Speed
0 0 t1 t2 t3 Time
Cr
Cf
Ramp function on speed drives:
Q2 ACC = Cste  Ca = Cste
Cral if Cr =  Cm =
E D DEC = Cste  Cra = Cste

if Cr =  Cm =

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Training Acceleration
Institute
The objective of electronic speed variation is to limit mechanical jerking. This can be achieved by
ensuring constant acceleration and deceleration. That is, speed increase is linear as a function
of time. Acceleration is linked to inertia and to acceleration torque.
  C a
Ca  J 
t t J
Production of constant acceleration and deceleration is achieved by constant acceleration and
deceleration torques.
Resistive torque is subtracted from starting torque to create acceleration torque.
Resistive torque is added to braking torque to create deceleration torque.
An electronic speed drive operating following a ramp is the simplest means of accelerating at
constant acceleration and decelerating at constant deceleration.
Acceleration and deceleration times and spaces covered can then be easily calculated.

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Training
Institute
Exercise: Motor Operating Quadrants
►Indicate motor operating quadrants for each application.
• Fans, pumps
• Trolley on horizontal track
• Hoist (figure below)
• Machine tool shaft
brake
motor

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Training
Institute
Motor Operating Quadrants
In the cycle below, determine the different operating quadrants of the motor.
The movement shown has constant resistive torque.
Speed
Deceleration gradient obtained
with resistive torque only.
0
Time

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Training
Institute
Deceleration
►What are the torques delivered by the rotating machine on decelerations in this second
part of the exercise?
FAST DECELERATION SLOW DECELERATION

Torque Torque
Q1 Q1
Speed Speed
Cr
Cral
Cral Cr
Q2 Q2

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Training
Institute
Speed Reducers

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Training
Institute
Speed Reducer Principle
Torque Torque
REDUCER
Load Speed Speed
Losses
HIGH TORQUE low torque
low speed HIGH SPEED
C. P  c.

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Training
Institute
Speed Reducer Types
Gear reducer Cyclo reducer

Cross-section
Crown axes
Disc-cam
Eccentric
Input shaft
Indexes-
Output shaft sockets
Planetary gear reducer Worm gear reducer
Output slow shaft
or hollow slow
shaft

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Training
Institute
Speed Reducer Characteristics
TYPES K  ADVANTAGES DISADVANTAGES
5 0.98 Efficiency good Noisy

Gear to to Reduction OK
150 0.93 Price: X
5.6 0.96 Efficiency OK Noisy

Planetary to to Reduction high Price: 1.5 X
992 0.88
6 0.95 Efficieny Price: 2.5 X

Cyclo to to Reduction v. high
6x 1<x<6 0.85 Dimensions
10 0.91 Silent Efficiency

Worm to to Reduction
60 0.34
Figures shown do not cover all catalogues.

Efficiency given is motor run-in and on-load.
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Training
Institute
Speed Reducers and the 4 Quadrants
REDUCERS
Load P1
•Gear
•Planetary P2
•Cyclo (some)
•Worm **
Losses
Q1, Q3
P1 =  P2 The motor drives
Q2, Q4
The mechanics drive P2 =  P 1
** Worm gear reducers are not normally reversible

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Training
Institute
Speed Reducer Values
MACHINE
SPEED
REDUCER
Reduction ratio = K MOTOR
Efficiency = 
Speed =  1
Torque = C1 Speed =  2
Power = P1 Torque = C2
Kinetic energy = W1 Power = P2
Inertia = J1 Kinetic energy = W2
Inertia = J2

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Training
Institute
Speed Reducer Value Relationships
 2n
SPEED: 1  2 in Rad/s (K > 1),   , n = Speed in rpm
K 60
TORQUE: • Motor driving C 1  K C 2 in Nm
• Motor driven C1
C2  
K
POWER: • Motor driving P1 =  P2 in W
• Motor driven P2 =  P1
J112 J 222
W1  , W2 
KINETIC ENERGY: 2 2
W1  W 2
J1
INERTIA: J2 
K 2
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Training
Institute
Exercise
 Speed reducer and motor selection
 Hoisting winch application.
 Maximum load: 4 tonnes.

 Load raising speed: 0.8 m/s.
 Winch efficiency: 0.9.
 ø of drum: 0.34 m.
 Question:
 Select appropriate reducer and motor (consult catalogues).

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Training
Institute
Speed Reducer Manufacturer Catalogue
ROSSI Motor Reducer catalogue
Factory-produced
WEG motor/ Rossi reducer
association
Definitions:
P1: Power
n2: Output speed
M2: Output torque
fS: Service factor
i: Reduction ratio

Schneider
Training
Institute
Speed Reducer Manufacturer Catalogue
ROSSI Motor Reducer catalogue
Factory-produced
WEG motor/ Rossi reducer
association
Definitions:
P1: Power
n2: Output speed
M2: Output torque
fS: Service factor
i: Reduction ratio

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Training Speed Reducer Manufacturer Catalogue
Institute
WEG motor catalogue
Cn = Torque at full load
Id/In = Starting current
Cd/Cn = Starting torque
Cmax/Cn = Maximum torque
In = Current at full load

CH 1 Power Electronics and Mechanics Interactions

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CH 1 Power Electronics and Mechanics Interactions

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Schneider

Power Electronics and

Reproduction prohibited Power Electronics and Mechanics Interactions

Reproduction prohibited Power Electronics and Mechanics Interactions

Reproduction prohibited Power Electronics and Mechanics Interactions

Reproduction prohibited Power Electronics and Mechanics Interactions

Electronic Power Control

Reproduction prohibited Power Electronics and Mechanics Interactions

 Plus integrated automated system functions:

Reproduction prohibited Power Electronics and Mechanics Interactions

Single-phase speed drive/regulator

3-phase speed drive/regulator

Reproduction prohibited Power Electronics and Mechanics Interactions

 Productivity and quality improvement

 Reduced investment costs

 Reduced operating costs

 Human-machine dialogue and speed control

 Automated system functions

Reproduction prohibited Power Electronics and Mechanics Interactions

Reproduction prohibited Power Electronics and Mechanics Interactions

Solution: Produce speed variation Solution: Soft starter or electronic

Reproduction prohibited Power Electronics and Mechanics Interactions

 Solution: Soft starter or electronic speed drive.

Reproduction prohibited Power Electronics and Mechanics Interactions

 Application: Ventilation with airflow

 Solution: Flow regulation with

Reproduction prohibited Power Electronics and Mechanics Interactions

 Application: Lift requiring certain

 Solution: Electronic speed drive assuring

Reproduction prohibited Power Electronics and Mechanics Interactions

Application: mechanical stairway

Reproduction prohibited Power Electronics and Mechanics Interactions

Solution: Electronic speed drive enables

Reproduction prohibited Power Electronics and Mechanics Interactions

 The control of the application is completely centralised

 The DRIVE is used by the application only to control motor

Reproduction prohibited Power Electronics and Mechanics Interactions

Reproduction prohibited Power Electronics and Mechanics Interactions

Reproduction prohibited Power Electronics and Mechanics Interactions

F Work = Force x Distance

Angular movement: • Work = Force x Distance

Reproduction prohibited Power Electronics and Mechanics Interactions

FOR RECTILINEAR MOVEMENT:

FOR ANGULAR MOVEMENT:

Reproduction prohibited Power Electronics and Mechanics Interactions

►Take two identical winches T1 and T2 equipped with two motors M1

Motor characteristics are:

for M1: P1 = 15 kW N1 = 1 500 rpm

Which winch can raise a load of 90 N?

RESISTIVE TORQUE DRIVING TORQUE

Resistive torque Driving torque

Reproduction prohibited Power Electronics and Mechanics Interactions

Resistive torque (Cr) ≤ Motor torque (Cm)

Motor imposes speed

Reproduction prohibited Power Electronics and Mechanics Interactions

- Centrifugal - Machine tool

Reproduction prohibited Power Electronics and Mechanics Interactions

- - - - - - Cd: BRAKEAWAY TORQUE

Reproduction prohibited Power Electronics and Mechanics Interactions

BREAKAWAY TORQUE SPEED DRIVE CHOICE

Machines with smooth step levels 130 to 150% Normal

Conveyors or high friction level 160 to 250% Overdimension speed drive