AC

MOTORS

AC

MOTORS

DC
AGRICULTURE TRACTION

DC

AC

MOTORS

AC

MOTORS

DC
MEDICAL LABS Etc DOMESTICS (HOUSES)

DC
Etc

Etc

AUTOMOBILE S

PROCESS INDUSTRY

Etc AVIATIONS Etc

DC

DC

DC
MOTORS

DC

A C MOTORS A C MOTORS A C

AC

MOTORS

WE KNOW THAT MOTOR ROTATES AT SOME SPEED

WE CANT LET THE MOTOR TO RUN AS PER ITS WISH

IT HAS TO RUN AT SOME SPEED AS PER OUR REQUIREMENT & NECESSITY & TO ACHIEVE SOME PURPOSE

WHEN THERE IS

REQUIREMENT & NECESSITY & PURPOSE

COMES TO PICTURE

THE TERM

CONTROL

POLES

VOLTAGE

RESITANCE

FREQUENCY

Variable-frequency drive (VFD) is a system for controlling the rotational speed of an AC electric motor by controlling the frequency of the electrical power supplied to the motor. Variable-frequency drives are also known as Adjustable-frequency drives (AFD)

Variable-speed drives (VSD)

Inverter drives. Since the voltage is varied along with frequency, these are sometimes also called VVVF (variable voltage variable frequency) drives. VFD Applications Ventilations systems for large buildings, Motors of Blowers & Fans , Pumps, Conveyor, Machine tool drives , Tractions, Lifts etc

Operating principle: ( SPEED CONTROL) The synchronous speed of an AC motor is determined by the frequency of the AC supply and the number of poles in the stator winding, according to the relation:

Where f = AC power frequency (hertz) p = Number of poles (an even number) s = slip.

Block diagram of VFD control

Parts and Operations of a Drive

1. Rectifier 2. Soft Charge Circuit

3. Intermediate Circuit (DC Link)

4. Brake Circuit 5. Inverter 6. Pulse Width Modulation 7. Control & Regulation Section
ACTUAL PANEL ENERGY SAVINGS

V / HZ RATIO

DRAWBACKS

Rectifier
The 3-phase AC voltage goes into the rectifier section which is made up of a group of gated diodes (silicon rectifiers or SCRs). In most VFDs, these diodes are in a group of 6 as diagramed . One VFD manufacturer has stressed that there should be more sets of diodes, 12, 18, even 24. <REASON> The D1 & D2 convert L1 power to DC D3 & D4 convert L2 power to DC D5 & D6 convert L3 power to DC A volt ohmmeter or VOM ( MOV ) can be used to measure this DC voltage. In this type of circuit, the DC voltage is 1.35 times the AC line voltage. If 240 Vac is coming in, 324 Vdc can be obtained. If 380 Vac is coming in, 513 Vdc can be obtained. If 460 Vac is the line voltage, 621 Vdc can be obtained. If 575 Vac is the line voltage, 776 Vdc can be obtained. Note: Because of line (power coming in) and load (power to the motor) changes, the DC Voltage level is constantly moving above and below this expected value.

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Soft Charge Circuit

On larger drives, (22 450kW or 30 600Hp), inrush current will be 3 to 8 times so there is a necessity to restrict this inrush current , if not it will damage VFD circuit or line fuses would be blown every time the VFD s operated. < HOW> In rectifier circuit with a L C filter when initial current is way beyond the normal, because it is forced to charge empty filter capacitors - these look like a short circuit until a respectable voltage has been reached.

Hence soft charge circuit is used to power up the drive , & the inrush of current is restricted . Operation Initially SCRs in the main rectifier section remain off. Rectifier section in the soft charge circuit starts applying DC power through the current resistors charging up the capacitors in the DC Link. When these capacitors are charged to the DC voltage of minimum value, the control section starts the firing of the SCRs in the main rectifier. The soft charge circuit on some of the VFDs has a resistors to limit starting current & to vary the charging time of the capacitors.

This current resistor even has its own safety, a thermal switch, which shorts out if the current rush is too high in the soft charge circuit & blows the fuses on the soft charge circuit preventing the drive from starting.
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Intermediate Circuit (DC Link)

The Intermediate Circuit also known as a DC Link section. There are 2 major components to the DC Link section, capacitors and coils.

In the diagram only one capacitor is shown but it is always a series of capacitors & this intermediate section always uses DC coils also known as DC Line Reactors or DC chokes.
These capacitor & coils as essential to reduce harmonic noise (interference) by 40% and to filter rippled DC voltage of rectifier to a relatively constant voltage.

DC CHOKE

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Brake Circuit

This Brake Option, also known as Dynamic Braking, is used with devices that need to stop or change directions quickly, such as conveyors, hoists and centrifuges.

On drives that have the brake option, an additional IGBT transistor is used to remove extra power coming back into the drive when the motor, which has a large inertia, is stopping or changing direction.

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Inverter

This section takes the DC voltage from the intermediate section and, with the help of the control section, fires each set of IGBT (or other semi conductor device) and provides AC out put to the motor terminals U,V and W . Firing of the IGBTs provides Pulse Width Modulation (PWM) . For any drive larger than 18.5kW (25Hp), master coils are provided to smooth the waveform going to the motor. The smoother the waveform the less heat is generated at the motor and the longer the motor lasts. This PWM frequency can vary from 3.5KHz to 15 kHz, which means it is audible. It is also known as the Carrier Frequency, which is Variable by most VFD manufacturers. A low carrier frequency can have an annoying noise, but a higher carrier frequency generates more heat in the drive and motor. If the carrier frequency noise is too loud particularly with supply fans, LC filters can be placed between the VFD and motor and the noise stops at this filter.

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Volts/Hertz Ratio
SINCE AIR GAP FLUX V f

CONTROL

Output Voltage

460

230 115 Hz
BACK

15

30

Base Frequency

60

90 Output

Frequency

ENERGY SAVINGS ( WITH CONCERNED APPLICATION )

Motor-driven centrifugal pumps, fans and blowers offer the most dramatic energy-saving opportunities. Blowers operate for extended periods at a reduced load. Since they are not always operating at their full load the amount of energy you can save by reducing the current to them as well as the amount of stress release on your motor is enormous and results in an energy efficient and longer lasting system.

VALVES

ENERGY SAVINGS ( WITH CONCERNED APPLICATION )

% flow

CASE STUDY ENERGY SAVINGS

Airflow Volume (percent of maximum)

Daily Operating Time (hours)

Energy Consumed Using a Damper(kWh/year )

Energy Consumed Using a VFD(kWh/year)

Difference in Energy Consumption (kWh/year)

50% 60% 70% 80% 90% 100%

2 3 6 6 4 3

18 500 29 300 61 700 63 300 44 200 34 200

4 800 9 800 26 800 35 900 32 600 35 200

13 700 19 500 34 900 27 400 11 600 1 000

BYPASS VFD

Total

24

251 200

145 100

106 100

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Additional Benefits of VFDs & Scope In addition to energy savings and better process control, VFDs can provide other benefits: A VFD may be used for control of process temperature, pressure or flow without the use of a separate controller. Suitable sensors and electronics are used to interface the driven equipment with the VFD. Maintenance costs can be lower, since lower operating speeds result in longer life for bearings and motors. Eliminating the throttling valves and dampers also does away with maintaining these devices and all associated controls.

A soft starter for the motor is no longer required.

Accurate Speed Regulation

SENSORS

VFDs with 12 diodes in the rectifier section, known as a 12-pulse drive.

This theoretically cancels the 5th and 7th harmonics and only allows the much smaller 11th and 13 harmonics and higher to interfere.

One manufacturer has aggressive pursued this option, producing 12-pulse drives, and 18-pulse drives.

In order to make the 12-pulse option work correctly, a 30 phase shift transformer must be included.

To reduce noise 12-pulse drive work best, if the 3-phase inputs from the transformer should be perfectly balanced.

In real life, there is almost always a phase imbalance between the 3 inputs. As the imbalance increases, harmonic distortion increases.

BACK

BACK

SENSOR LOCATION

BACK

BACK

VALVES

BACK

CONSTANT RATIO SAVES ENERGY IF NOT MOTOR CURRENT WILL BE UNSTABLE & TORQUE CAN DIMINSH & MOTOR MAY GET DAMAGED

BACK

SOME DISADVANTAGE AT FULL LOAD OPERATION ENERGY SAVED IS NILL

NEED BY PASS CIRCUIT AT FULL LOAD

NOT POSSIBLE TO CONTROL DC DRIVES

VFD S ARE BIT COSTLY

DESIGN & IMPLIMENTATION OF VFD FOR REGENARATIVE SYSTEM IS COMPLICATED DRIVE CIRCUITS NEEDS ADDITIONAL PROTECTION CIRCUITS DUE TO INITAIL CURRENT

APPLICATION VIDEOS

1> OVER ALL WORKING( A & B) 2 > EFFECT OF PWM 3> SOFT START & STOP

4> V F D WITH P.I.D CONTROL ( CONTROLLED AIR FLOW)

5> INDUSTRIAL ENERGY SAVINGS 6> BY PASS PROCESS