ELECTRIC DRIVES

INTRODUCTION TO ELECTRIC DRIVES

MODULE 1
Dr. Nik Rumzi Nik Idris
Dept. of Energy Conversion, UTM
2006
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Electrical Drives
Drives are systems employed for motion control
Require prime movers
Drives that employ electric motors as
prime movers are known as Electrical Drives
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Electrical Drives
About 50% of electrical energy used for drives
Can be either used for fixed speed or variable speed
75% - constant speed, 25% variable speed (expanding)
MEP 1522 will be covering variable speed drives
Example on VSD application
motor pump
valve
Supply
Constant speed
Variable Speed Drives
Power
In
Power loss
Mainly in valve
Power out
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Example on VSD application
motor pump
valve
Supply
motor
PEC pump
Supply
Constant speed
Variable Speed Drives
Power
In
Power loss
Power out
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Power loss
Mainly in valve
Power out
Power
In
Power loss
Mainly in valve
Power out
motor pump
valve
Supply
motor
PEC pump
Supply
Constant speed
Variable Speed Drives
Example on VSD application
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Power
In
Power loss
Power
In
Power out
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Conventional electric drives (variable speed)
Bulky
Inefficient
inflexible
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Modern electric drives (With power electronic converters)
Small
Efficient
Flexible
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Modern electric drives
Inter-disciplinary
Several research area
Expanding
Machine design
Speed sensorless
Machine Theory
Non-linear control
Real-time control
DSP application
PFC
Speed sensorless
Power electronic converters
Utility interface
Renewable energy
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Components in electric drives
e.g. Single drive - sensorless vector control from Hitachi
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Components in electric drives
e.g. Multidrives system from ABB
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Components in electric drives
Motors
DC motors - permanent magnet wound field
AC motors induction, synchronous (IPMSM, SMPSM),
brushless DC
Applications, cost, environment
Power sources
DC batteries, fuel cell, photovoltaic - unregulated
AC Single- three- phase utility, wind generator - unregulated
Power processor
To provide a regulated power supply
Combination of power electronic converters
More efficient
Flexible
Compact
AC-DC DC-DC DC-AC AC-AC
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Components in electric drives
Control unit
Complexity depends on performance requirement
analog- noisy, inflexible, ideally has infinite bandwidth.
digital immune to noise, configurable, bandwidth is smaller than
the analog controllers
DSP/microprocessor flexible, lower bandwidth - DSPs perform
faster operation than microprocessors (multiplication in single
cycle), can perform complex estimations
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Overview of AC and DC drives
Extracted from Boldea & Nasar
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Overview of AC and DC drives
DC motors: Regular maintenance, heavy, expensive, speed limit
Easy control, decouple control of torque and flux
AC motors: Less maintenance, light, less expensive, high speed
Coupling between torque and flux variable
spatial angle between rotor and stator flux
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Overview of AC and DC drives
Before semiconductor devices were introduced (<1950)
AC motors for fixed speed applications
DC motors for variable speed applications
After semiconductor devices were introduced (1950s)
Variable frequency sources available AC motors in variable
speed applications
Coupling between flux and torque control
Application limited to medium performance applications
fans, blowers, compressors scalar control
High performance applications dominated by DC motors
tractions, elevators, servos, etc
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Overview of AC and DC drives
After vector control drives were introduced (1980s)
AC motors used in high performance applications elevators,
tractions, servos
AC motors favorable than DC motors however control is
complex hence expensive
Cost of microprocessor/semiconductors decreasing predicted
30 years ago AC motors would take over DC motors
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Classification of IM drives (Buja, Kamierkowski, Direct torque control of PWM inverter-fed AC motors - a survey,
IEEE Transactions on Industrial Electronics, 2004.
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Elementary principles of mechanics
M
v
F
m
F
f
)
dt
Mv d
F F
f m
=
Newtons law
Linear motion, constant M
First order differential equation for speed
Second order differential equation for displacement
)
Ma
dt
x d
M
dt
v d
M F F
2
2
f m
= = =
x
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Elementary principles of mechanics
First order differential equation for angular frequency (or velocity)
Second order differential equation for angle (or position)
)
2
2
m
l e
dt
d
J
dt
d
J T T

=

=
With constant J,
Rotational motion
- Normally is the case for electrical drives
)
dt
J d
T T
m
l e

T
e
,
m
T
l
J
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
dt
d
J T T
m
l e

+ =
For constant J,
)
dt
d
J
m

Torque dynamic present during speed transient

)
dt
d
m

Angular acceleration (speed)

The larger the net torque, the faster the acceleration is.
0.19 0.2 0.21 0.22 0.23 0.24 0.25
-200
-100
0
100
200
s
p
e
e
d

(
r
a
d
/
s
)
0.19 0.2 0.21 0.22 0.23 0.24 0.25
0
5
10
15
20
t
o
r
q
u
e

(
N
m
)
Elementary principles of mechanics
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Elementary principles of mechanics
)
dt
v d
M F F
l e
=
Combination of rotational and translational motions
r r

T
e,

T
l
F
l
F
e
v
M
T
e
= r(F
e
), T
l
= r(F
l
), v =r
dt
d
M r T T
2
l e

=
r
2
M - Equivalent moment inertia of the
linearly moving mass
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Elementary principles of mechanics effect of gearing
Motors designed for high speed are smaller in size and volume
Low speed applications use gear to utilize high speed motors
Motor
T
e
Load 1,
T
l1
Load 2,
T
l2
J
1
J
2

m1

m2
n
1
n
2
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Motor
T
e
Load 1,
T
l1
Load 2,
T
l2
J
1
J
2

m1

m2
n
1
n
2
Motor
T
e
J
equ
Equivalent
Load , T
lequ

m
2
2
2 1 equ
J a J J + =
T
lequ
= T
l1
+ a
2
T
l2
a
2
= n
1
/n
2
Elementary principles of mechanics effect of gearing
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Motor steady state torque-speed characteristic
Synchronous mch
Induction mch
Separately / shunt DC mch
Series DC
SPEED
TORQUE
By using power electronic converters, the motor characteristic
can be change at will
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Load steady state torque-speed characteristic
SPEED
TORQUE
Frictional torque (passive load)
Exist in all motor-load drive
system simultaneously
In most cases, only one or two
are dominating
Exists when there is motion
T~ C
Coulomb friction
T~
Viscous friction
T~
2
Friction due to turbulent flow
E
T
L
T
e
Vehicle drive
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Load steady state torque-speed characteristic
Constant torque, e.g. gravitational torque (active load)
SPEED
TORQUE
Gravitational torque
gM
F
L
T
L
= rF
L
= r g M sin E
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Load steady state torque-speed characteristic
Hoist drive
Speed
Torque
Gravitational torque
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Load and motor steady state torque
At constant speed, T
e
= T
l
Steady state speed is at point of intersection between T
e
and T
l
of the
steady state torque characteristics
T
l
T
e
Steady state
speed

r
Torque
Speed

r2

r3

r1
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Torque and speed profile
10 25 45 60 t (ms)
speed
(rad/s)
100
The system is described by: T
e
T
load
= J(d/dt) + B
J = 0.01 kg-m2, B = 0.01 Nm/rads-1 and T
load
= 5 Nm.
What is the torque profile (torque needed to be produced) ?
Speed profile
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Torque and speed profile
10 25 45 60 t (ms)
speed
(rad/s)
100
0 < t <10 ms Te = 0.01(0) + 0.01(0) + 5 Nm = 5 Nm
10ms < t <25 ms Te = 0.01(100/0.015) +0.01(-66.67 + 6666.67t) + 5
= (71 + 66.67t) Nm
25ms < t< 45ms Te = 0.01(0) + 0.01(100) + 5 = 6 Nm
45ms < t < 60ms Te = 0.01(-100/0.015) + 0.01(400 -6666.67t) + 5
= -57.67 66.67t
l e
T B
dt
d
J T + +

=
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Torque and speed profile
10 25 45 60
speed
(rad/s)
100
10 25 45
60
Torque
(Nm)
72.67
71.67
-60.67
-61.67
5
6
t (ms)
t (ms)
Speed profile
torque profile
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Torque and speed profile
10 25 45
60
Torque
(Nm)
70
-65
6
t (ms)
For the same system and with the motor torque profile
given above, what would be the speed profile?
J = 0.001 kg-m2, B = 0.1 Nm/rads-1
and T
load
= 5 Nm.
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Thermal considerations
Unavoidable power losses causes temperature increase
Insulation used in the windings are classified based on the
temperature it can withstand.
Motors must be operated within the allowable maximum temperature
Sources of power losses (hence temperature increase):
- Conductor heat losses (i
2
R)
- Core losses hysteresis and eddy current
- Friction losses bearings, brush windage
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Thermal considerations
Electrical machines can be overloaded as long their temperature
does not exceed the temperature limit
Accurate prediction of temperature distribution in machines is
complex hetrogeneous materials, complex geometrical shapes
Simplified assuming machine as homogeneous body
p
2
p
1
Thermal capacity, C (Ws/
o
C)
Surface A, (m
2
)
Surface temperature, T (
o
C)
Input heat power
(losses)
Emitted heat power
(convection)
Ambient temperature, T
o
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Thermal considerations
Power balance:
2 1
p p
dt
dT
C =
Heat transfer by convection:
) T T ( A p
o 2
E =
C
p
T
C
A
dt
T d
1
= A
E
+
A
Which gives:
)
t

E
= A
/ t h
e 1
A
p
T
A
C
E
= t , where
With AT(0) = 0 and p
1
= p
h
= constant ,
, where E is the coefficient of heat transfer
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Thermal considerations
t
t
T A
t
t
t
A = A
/ t
e ) 0 ( T T
T A
)
t

E
= A
/ t h
e 1
A
p
T
Heating transient
Cooling transient
A
p
h
E
) 0 ( T A
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Thermal considerations
The duration of overloading depends on the modes of operation:
Continuous duty
Short time intermittent duty
Periodic intermittent duty
Continuous duty
Load torque is constant over extended period multiple
Steady state temperature reached
Nominal output power chosen equals or exceeds continuous load
T A
t
A
p
n 1
E
t
p
1n
Losses due to continuous load
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Thermal considerations
Short time intermittent duty
Operation considerably less than time constant, t
Motor allowed to cool before next cycle
Motor can be overloaded until maximum temperature reached
t
1
t
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Thermal considerations
Short time intermittent duty
A
p
s 1
E
max
T A
A
p
n 1
E
t
T A
p
1
p
1n
p
1s
t
1
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Thermal considerations
Short time intermittent duty
t
t
T A
)
t

E
= A
/ t s 1
e 1
A
p
T
max
T A
A
p
n 1
E
)
t

E
=
E
/ t
s 1 n 1 1
e 1
A
p
A
p
)
t
>
/ t
s 1 n 1
1
e 1 p p
1
/ t
n 1
s 1
t e 1
1
p
p
1
t
<

t
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Thermal considerations
Periodic intermittent duty
Load cycles are repeated periodically
Motors are not allowed to completely cooled
Fluctuations in temperature until steady state temperature is reached
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Thermal considerations
Periodic intermittent duty
p1
t
heating coolling
coolling
coolling
heating
heating
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Thermal considerations
Periodic intermittent duty
Example of a simple case p
1
rectangular periodic pattern
p
n
= 100kW, nominal power
M = 800kg
L= 0.92, nominal efficiency
AT

= 50
o
C, steady state temperature rise due to p
n
kW 9 1
1
p p
n 1
=

'
+

'

L
= Also,
C / W 180
50
9000
T
p
A
o
1
= =
A
= E

If we assume motor is solid iron of specific heat c

FE
=0.48 kWs/kg
o
C,
thermal capacity C is given by
C = c
FE
M = 0.48 (800) = 384 kWs/
o
C
Finally t, thermal time constant = 384000/180 = 35 minutes
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Thermal considerations
Periodic intermittent duty
Example of a simple case p
1
rectangular periodic pattern
For a duty cycle of 30% (period of 20 mins), heat losses of twice the nominal,
0 0. 5 1 1. 5 2 2. 5
x 10
4
0
5
10
15
20
25
30
35
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Torque-speed quadrant of operation

T
1
2
3 4
T +ve
+ve
P
m
+ve
T -ve
+ve
P
m
-ve
T -ve
-ve
P
m
+ve
T +ve
-ve
P
m
-ve
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
4-quadrant operation

m
T
e
T
e

m
T
e

m
T
e

T
Direction of positive (forward)
speed is arbitrary chosen
Direction of positive torque will
produce positive (forward) speed
Quadrant 1
Forward motoring
Quadrant 2
Forward braking
Quadrant 3
Reverse motoring
Quadrant 4
Reverse braking
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Ratings of converters and motors
Torque
Speed
Power limit for
continuous torque
Continuous
torque limit
Maximum
speed limit
Power limit for
transient torque
Transient
torque limit
INTRODUCTION TO ELECTRIC DRIVES - MODULE 1
Steady-state stability