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A Variable Frequency Drive is a type of electronic controller designed to change the frequency &
voltage supplied to AC motor, which will result in the change of motor speed as per requirement
changes, the VFD can simply turn up or down the motor speed & voltage to meet the speed and torque
requirements.
In order to control the motor’s rotational speed, a Variable Frequency Drive controls the frequency of
the electrical power supplied to it. Frequency (or hertz) is directly related to the motor’s speed (RPMs).
The faster the frequency, the faster the RPM of the motor. As the application’s motor speed
requirements change, the VFD can simply turn up or down the motor speed to meet the speed
requirement, ultimately saving energy.
A Variable Frequency Drive can be found operating ventilation systems, pumps, conveyors and
machine tool drives, on board ships, it is used for bow thrusters, azipod system etc. Other names for a
VFD are variable speed drive, adjustable speed drive, adjustable frequency drive etc.
Variable Frequency Drive interfaces allow the user to adjust operating speed, start and stop the motor.
The interface might also allow the user to switch and reverse between automatic control, or manual
speed adjustment.
1. Rectifier: For changing the incoming AC supply to DC. Different designs are available and these are
selected according to the performance required to the VFD
2. Intermediate circuit: Rectified DC supply is then conditioned in the intermediate circuit, normally by a
combination of inductors and capacitors.
Stages of VFD
3. Inverter: For converting the rectified and conditioned DC back into an AC supply of variable frequency
and voltage
4. Control unit: The control monitor and control the rectifier, the intermediate circuit and the inverter to
deliver the correct output in response to an external control signal. The entire process is controlled by a
microprocessor which monitors the following :
1. Incoming supply voltage
2. Speed set point
3. DC link voltage
4. Output voltage and current to ensure the operation of the motor is within the established parameters.
BASIC
CIRCUIT OF THE 3-PHASE INVERTER
METHOD TO CREATE 3-
PHASE AC FOR VFD
in order to obtain 3-phase AC, the switches S1 to S6 simultaneously turn On/Off. if the order of turning
On/Off of the switches is changed, the phase sequence is changed between U-V, V-W and W-U and
the direction of rotation can be changed.
note:- It is important to remember that when the output frequency of a VFD is changed, the output
voltage must also be changed; this ensures the balancing of the speed-torque characteristic of the
motor.
Torque Tm = K x Φ x I = K x (V/F) x I
suppose if the voltage is fixed and only the frequency is decreased, the increased magnetic flux (Φ)
causes the iron core to be magnetically saturated and then the increased current causes overheating and
a burnout.
So changing the voltage applied to a motor (V) and the frequency (F) with their relationship kept
constant allows the motor output torque to be constant even if the motor is changed.
If we want to reduce the motor frequency to 30 Hz, then we simply switch the inverter output transistors
more slowly. But, if we reduce the frequency to 30Hz, then we must also reduce the voltage to 240V
in order to maintain the V/Hz ratio
Let us assume that the drive is operating on a 440V power system. The 440V rating is “rms” or root-
mean-squared. The peaks on a 440V system are 620V.The VFD dc bus has a dc voltage with an AC
ripple. VFD can eliminate the AC ripple on the DC bus by adding a capacitor. These capacitor absorbs
the ac ripple and delivers a smooth DC voltage. Thus, the voltage on the DC bus becomes
“approximately” 620VDC. The actual voltage will depend on the voltage level of the AC line feeding
the drive, the level of voltage unbalance on the power system, the motor load, the impedance of the
power system, and any reactors or harmonic filters on the drive.
VFD’s do not produce a sinusoidal output. It produces rectangular waveform would not be a good
choice for a general purpose distribution system but is perfectly adequate for a motor.
What are the different types of
Variable Frequency Drive?
There are commonly three types of VFDs that are used upon the requirements. And these are:
Pulse Width Modulation VFD uses a diode bridge rectifier to convert the incoming AC voltage to DC
voltage. The DC output uses large capacitors to remove the ripple after the rectifier and creates a stable
DC bus voltage.
The rectified and conditioned DC voltage is then converted back into AC by the inverter. This
conversion is typically achieved through the use of power electronic devices such as IGBT power
transistors using a technique called Pulse Width Modulation (PWM). The DC voltage is chopped into
variable width, but constant level. By varying the pulse widths and polarity of the DC voltage, it is
possible to generate an averaged sinusoidal AC output over a wide range of frequency, typically 0.5-
120 Hz.
comparing
voltage to current for a PWD VFD
Due to the smoothing effect of the motor inductance, the motor currents appear to be nearly sinusoidal
in shape.The frequency supplied to the motor is determined by the number of positive to negative
transitions per second by output.These transistors are controlled by a microprocessor or motor IC
which monitors various aspects of the drive to provide the correct sequencing.
The Pulse Width Modulation (PWM) Variable Frequency Drive (VFD) is among the most commonly
used controllers and has proven to work well with motors that range in size from 0.5 HP to 500 HP.
Most of PWM VFDs are rated for 230V or 460V, 3-Phase operation, and provide output frequencies
in the range of 0.5 to 120 Hz.
ADVANTAGES
No motor cogging
Efficiencies from 92% to 96%
Excellent input power factor due to fixed DC bus voltage
Low initial cost
Can be used with applications requiring multiple motors
DISADVANTAGES
Non-Regenerative operation
High-frequency switching may cause motor heating and insulation breakdown.
Current Source Inverter (CSI) or AC-DC-AC Synchroconverter generally used for AC synchronous
motor drives and is also used in marine electrical propulsion.It’s converter and inverter rely on natural
turn-off (line commutation) for the thyristors by the 3-phase AC voltages at either end of the converter.
between the rectification and inversion stage, a current smoothing reactor coil forming the DC link.
Inverter
Current Switching Sequence
The combination of the controlled rectifier and DC link is considered to be a current source for the
inverter, whose task is then to the sequentially direct block of the current into the motor windings, as
shown in below diagram
The size of the DC current is set bt the controlled switching of the rectifier thyristors.The input current
remains constant but this input current is adjustable.Motor supply frequency (and therefore its speed)
is set by the rate of inverter switching. The six inverter thyristors provide 6 current pulses per cycle
(known as a 6-pulse converter).
In layman language, we can say that the current source (controlled rectification stage) provides the
required motor torque and the inverter stage controls the required speed. The output voltage of the
inverter is independent of the load. The magnitude and nature of the load current depend on the nature
of load impedance.
note:- In order to maintain the correct voltage to frequency (Volt/Hertz), the voltage must be regulated
by the correct sequencing of the SCRs.
ADVANTAGES
Regenerative power capability
Simple circuitry
Reliability (Current Limiting Operation)
Clean current waveform
High efficiency
inherent short circuit protection
DISADVANTAGES
low-speed motor cogging (shaftpulshing / jerky motion)
power factor decreases with decreasing speed
require isolation transformer on the input side
larger physical size of the drive due to internal power components
Large power harmonic generation sent back into power source
Dependent on motor load
CIRCUIT
DIAGRAM OF VARIABLE VOLTAGE INVERTER
The basically variable voltage inverter uses a group of SCRs with chopper circuit to convert incoming
AC voltage into DC and to create six-step waveform. These SCRs provide a means of controlling the
value of the rectified DC voltage from 0 to approximately 620V DC. The L choke and C capacitor of
the DC link section conditioned the converted DC voltage. The inverter section consists of six
switching devices such as thyristors, bipolar transistors, MOSFETs, and IGBTs. Control logic uses a
microprocessor to switch the transistors on and off providing a variable voltage and frequency to the
motor.
This type of switching is often referred to as six-step because it takes six 60° steps to complete one
360° cycle. Although the motor prefers a smooth sine wave, a six-step output can be satisfactorily used.
vvi-waveform
The main disadvantage is torque pulsation which occurs each time a switching device, such as a bipolar
transistor, is switched. The
pulsations can be noticeable at low speeds as speed variations in the motor. These speed variations are
sometimes referred to as cogging. The non-sinusoidal current waveform causes extra heating in the
motor requiring a motor derating.
Figure shows a diagram of the voltage and current waveform for theVVI inverter. From this diagram
notice that the voltage is developed in six steps and that the resulting current looks like an ac sine
wave.
ADVANTAGES
Simple Circuitry
Can be used with applications requiring multiple motors
Not dependent on load
DISADVANTAGES
Large power harmonic generation into power source
Motor cogging when PWM output is below 6 Hz
Non-Regenerative operation
Low power factor