كلية الهندسة – جامعة سوهاج
قســـم الهندســــة الكهربائيـــة
Ass. Prof. Khairy Sayed
Introduction
Requirements of speed control
Methods of speed control of induction motor
Advantages and disadvantages
Components of VFD
Applications of VFD
Controllers for VFD
A three phase induction motor is basically a
constant speed motor
It is widely used in industry due to low cost,
simplicity, easy maintenance and rugged
The speed control of induction motor is done
at a cost of decrease in efficiency and low
power factor
Changing the
Speed regulation
speed as
due to load on
desired by the
the shaft
process
Energy Saving
Speed control Low Speed
(Manually or Starting
automatically) Soft Starting)
Stator voltage control
Stator frequency control
Rotor resistance control
Stator current control
V/f control
INDUCTION MOTOR BASICS
Basic parts of three-phase induction motor :
Three-phase
windings Rotor windings
Three-
phase • Stator
supply
• Rotor
Air gap
Stator Rotor
• Air gap
m T
s
Three-phase
windings Rotor windings
Three-
phase
supply
Stator Air gap Rotor
m T
s
The stator winding are supplied with balanced three-
phase AC voltage. This creates a rotating magnetic
field which in turn induces a current in the rotor.
The rotor also creates a magnetic field and starts to
follow the stator due to magnetic attraction.
The rotor will turn slower than the stator field, and this
is referred to as ‘slip.’ If the rotor were to turn at the
same speed as the stator, no current would be induced,
thus no torque. The difference in speed ranges from
0.5-5% depending on the motor winding.
The speed of rotation of field is called the synchronous speed s , which
is defined by :
ωs is syncronous speed [rad/sec]
2 Ns is syncronous speed [rpm]
s or p is numbers of poles
p ω is the supply frequency [rad/sec]
f is the supply frequency [Hz]
120 f Nm is motor speed
Ns
p
The rotor speed or motor speed is : m s (1 S )
m NS Nm
S S S
Where S is slip, as defined as : Or
S NS
1. Controlled Starting Current (smooth)
2. Reduced Power Line Disturbances
3. Lower Power Demand on Start
4. Controlled Acceleration -- An Adjustable
Speed AC Drive starts at zero speed and
accelerates smoothly
5. Adjustable Operating Speed
6. Adjustable Torque Limit
7. Controlled Stopping
8. Energy Savings
9. Reverse Operation
10. Elimination of Mechanical Drive
Components -
11. AC drives are lighter in weight as compared
to DC drive for the same rating.
12. Ac drive requires low maintenance
13. AC drive are less expensive
14. Reduces thermal and mechanical stresses
on the motor
15. Dynamic response of VSDs compare to dc
drives leading to better control
16. Increase of power factor
Power converters are more complex
Power converters for AC drives are
expensive
Power converters generate harmonics in the
supply system
VFD Applications
Filling Compressors Conveyors Food
Fans Pumps Printing Packaging
And more!
What is a VFD?
Variable Frequency Drive (VFD), also known as:
• Variable Speed Drive (VSD)
• AC Drive or adjustable speed drive (ASD)
A VFD can be used to control both the speed and torque of a
standard induction 3 phase AC motor.
• It varies both the frequency and current of the AC waveform
being delivered to the motor saving costs of electricity.
Basic components of VFD
•Basic components of a VFD:
•Input section, draws AC electric power from the utility.
•Rectifier section, converts the AC into DC power.
•Inverter section, converts DC back into a controllable
AC waveform.
In the example below, a 100-horsepower pump with 10-percent
reduction in speed yields a 27-percent reduction in annual
operating cost.
100 HP MOTOR OPERATING COST/YEAR
100% SPEED 27,139$
90% SPEED 19,811$
Energy SAVINGS 7,328$
In fact, a 20-percent
reduction in motor speed Approximately 40% of all electricity used
produces a 50-percent in industry is consumed by pump and fan
energy savings. systems.2 Therefore, commercial and
municipal facilities running pumps, fans,
and blowers can gain 30% to 35% cost
reductions with VFDs
Consider this typical example of a 100 HP motor with a VFD
operating a pump at 60% speed. This is how cost savings are
calculated:
Fixed-Speed Motor running at 100% flow volume manipulated
with a valve
100 HP X 100/95 efficiency X .746 (HP conversion to kW) X .16
$/kWh X 12 hours/day X 360 days/year = $54,280 per year in
energy costs.
VFD-Controlled Motor
100 HP X .63 (break HP) X 100/95 efficiency X .746 (HP
conversion to kW) X .16 $/kWh X 12 hours/day X 360 days/year =
$11,720 in energy costs.
This typical 100 HP VFD installation example yields $42,560 a
year in energy savings. The cost of both the drive and the
installation ($19,000 total) is absorbed in less than six months,
due to an average of $3,540 in cost savings per month.
What is a VFD?
A variable frequency drive converts incoming 50/60 Hz utility
power into DC, then converts to a simulated variable voltage,
variable frequency output
AC DC AC
RECTIFIER INVERTER
(AC - DC) (DC - AC)
50/60 Hz Power
50/60 Hz
VFD
To
Motor
Electrical Energy
What is a VFD?
How often you switch from positive
pulses to negative pulses determines
waveform frequency
Positive
+
DC Bus
Voltage
Negative -
DC Bus
RECTIFIER INVERTER
Carrier Frequency
Controller Block
Communication Bus
RS-485, CAN,
Ethernet
Functions: Sensing –
processing – actuating-
Memory – configurable logic
blocks
Controllers (contd’)
The inputs to the controller consists of:
1. Torque, flux, speed, and/or position
commands
2. Their rate of variations to facilitate soft
start, to preserve the mechanical integrity of the
load
3. The actual values of torque, flux, speed, and/or
position for feedback control.
AC drives maintain the (V/f) ratio constant at all speeds. The
phase voltage V, is given by:
V = 4.444 f N ϕm or V/f = 4.444×N ϕm,
where N = number of turns per phase, ϕm = magnetic flux
If the same voltage is applied at the reduced frequency, the
magnetic flux would increase and saturate the magnetic core,
significantly distorting the motor performance.
To avoid saturation, ϕm is kept constant.
The motor torque is the product of stator flux and rotor
current. For maintaining the rated torque at all speeds the
constant flux must be maintained at its rated value, which is
done by keeping the V/f ratio constant.
AC drives change the speed of ac motor by changing voltage
and frequency of the power supplied to the ac motor.
Three-phase Where :
windings Rotor windings
Rs is resistance per-phase of stator winding
Three-
phase Rr is resistance per-phase of rotor winding
supply
Xs is leakage reactance per-phase of the
stator winding
Stator Air gap Rotor
Xr is leakage reactance per-phase of the
m T rotor winding
s
Xm is magnetizing reactance
Is Xs Rs Xr’ Rm is Core losses as a reactance
Im Ir’
Rr’/s
Vs
Xm Rm
Stator Air gap motor
Is Xs Rs Xr’
Im Ir’
Rr’/s
Vs
Xm Rm
Stator Air gap motor
Ps cu 3 I s Rs
2
Stator copper loss :
Pr cu 3 ( I r ) 2 Rr
' '
Rotor copper loss :
2 2
V V
Core losses : Pc 3 m 3 s
Rm Rm
Performance Characteristic of
Induction Motor
- Power developed on air gap (Power from stator to
rotor through air gap) : '
' 2 Rr
Pg 3 ( I r )
S '
- Power developed by motor : R
Pd Pg Pr cu 3 ( I r ) (1 S )
' 2 r
S
or Pd Pg (1 S )
Pd Pd 60
- Torque of motor : Td or Td
m 2 N m
Pg (1 S ) Pg
or
S (1 S ) s
Performance Characteristic of
Induction Motor
Input power of motor : Pi 3Vs I s cos m
Pc Ps cu Pg
Output power of motor : Po Pd Pno load
Po Pd Pnoload
Efficiency :
Pi Pc Ps cu Pg
Performance Characteristic of
Induction Motor
If Pg ( Pc Ps cu )
and Pd Pno load
so, the efficiency can calculated as :
Pd Pg (1 S )
1 S
Pg Pg
Performance Characteristic of
Induction Motor
Generally, value of reactance magnetization Xm >> value Rm (core
losses) and also
X m ( Rs X s )
2 2 2
So, the magnetizing voltage same with the input voltage: Vm Vs
Therefore, the equivalent circuit is ;
Is Xs Ii Rs Xr’
Rs Xr’ Xs Is=Ir’
Im Ir’ Im Ir’
Rr’/s Rr’/s
Vs Vs
Xm Rm Xm
Po
Pi
Stator Air gap motor
Stator Air gap rotor
Performance Characteristic of
Induction Motor
Total Impedance of this circuit is :
Ii Xs Rs Xr’ Is=Ir’
Im Ir’ '
R
X m ( X s X r ) jX m ( Rs r )
'
Rr’/s
Vs S
Xm Po Zi '
Pi Rr
Rs j( X m X s X r )
'
S
Stator Air gap rotor
Vs
Ir
'
The rotor current is : 1
2
Rr'
2
2
Rs X s X r
'
S
Synchronous speed
Slip
Torque
Where E2 is the rotor emf
Ns is the synchronous speed
R2 is the rotor resistance, X2 is the rotor
inductive reactance
Rotor resistance R2 is constant and sX2 is small.
Therefore Tα sE22 where E2 is the rotor induced
emf and E2 α V
Hence Tα V2, thus if the supplied voltage is
decreased, torque and hence the speed
decreasing
This method is easiest and cheapest, still rarely
used because:
A large change in supply voltage is required for relatively
small change in speed
Large change in supply voltage will result in large change in
flux density, hence disturbing the magnetic conditions of
the motor
Stator Voltage Control
Controlling Induction Motor Speed by AC
Variable
Adjusting The Stator Voltage Voltage
IM
Sources Td
Vs
3 Rr' Vs2
Td Td
Rr'
2
S s Rs X s X r'
2
Vs > Vs1 > Vs2
S Tmax
Ii Xs Rs Xr’ Is=Ir’
Tst TL
Im Ir’
Tst1
Rr’/s Tst2
Vs
Po
Pi
2 1
S=1 S=0
air s
Stator
gap
rotor Nm =0 Ns
Synchronous speed of induction motor
Where f=frequency of the supply and
P=number of stator poles
Thus the synchronous speed changes with the
change of supply frequency and hence
running speed also changes
The speed can be controlled above and
below the rated speed
This method offers wide range of speed
control
Frequency Voltage Control
Controlling Induction Motor Speed by
Adjusting The Frequency Stator Voltage
AC
Variable
Voltage
Sources IM
Vs Td
' 2
Td
3R V r s f
2
S s Rs
Rr'
X s X r'
2
S Td
fs2 < fs1 < fs
Tmax
Ii Xs Rs Xr ’ Is=Ir’ Tst2
Im Ir’ Tst1
Tst TL
Vs Rr’/s
f
Po
Pi
Stator Air rotor 2 1 s
gap
S=1 S=0 S=0 S=0
m =0 fs2 fs1 fs
The starting torque of IM is proportional to
square of stator current.
It is independent of supply frequency.
It is independent of rotor resistance.
A constant current for 3 phase IM can be
obtained from 3 phase CSI.
Inductor convert the dc voltage as constant
current source.
CSI regulate the output frequency and hence
torque of induction motor.
V/f=C , where V is the voltage and f is the
frequency, and C is constant.
In V/f control, a constant ration of voltage
to frequency should be maintained.
VSI switches are fired
in such way that the
amplitude of output
voltage waveform will
maintain v/f ratio
Wide range of operation
Speed is accurate
Simple control scheme.
The speed is constant even by varying the load .
Applications
Used in industries for
variable speed
applications.
A slip ring motor or a phase wound motor is
an induction motor which can be started
with full line voltage.
The value of starting current is adjusted by
adding up external resistance to its rotor
circuit.
CONTROLLING INDUCTION MOTOR SPEED USING
ROTOR RESISTANCE
(Rotor Voltage Control)
Wound rotor induction motor applications
Cranes
CONTROLLING INDUCTION MOTOR SPEED USING
ROTOR RESISTANCE
(Rotor Voltage Control)
3 Rr' Vs2
Td
Equation of Speed-Torque :
2
S s Rs
Rr'
X s X r'
2
S
In a wound rotor induction motor, an external 3Vs2 S
three-phase resistor may be connected to its Td
slip rings,
s R 'r
RX
Stator
RX
Rotor
RX
Three-phase
supply
The benefit of improvement in the motor drive industry has touched
varied applications, from heavy and large industrial equipment such as
rolling mills in steel making plants,
The two other drive control platforms, vector control and direct torque control (DTC),
adjust the motor voltage magnitude, angle from reference, and frequency[15] so as to
precisely control the motor's magnetic flux and mechanical torque.
Although space vector pulse-width modulation (SVPWM) is becoming increasingly
popular,[16] sinusoidal PWM (SPWM) is the most straightforward method used to
vary drives' motor voltage (or current) and frequency. With SPWM control (see Fig.
1), quasi-sinusoidal, variable-pulse-width output is constructed from intersections of a
saw-toothed carrier signal with a modulating sinusoidal signal which is variable in
operating frequency as well as in voltage (or current).
Advantages of Vector Control
Excellent control of torque.
Speed is regulated at all speeds.
Feedback is from encoder mounted on the motor shaft and
measured
phase currents.
Requires known (and stable) motor characteristics for good
results.
Vector control can often provide direct reliable position control.
Don’t hesitate to ask any question
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