Beruflich Dokumente
Kultur Dokumente
Submitted by:
Palmer J.D., Suitor R.L., Hubbert J.R., Green C.
Faculty Advisor: Dr. Mark Halpin
Department of Electrical and Computer Engineering
Mississippi State University
Box 9571
Mississippi State, Mississippi 39762
Email:{jdp1@ece.msstate.edu, rls18@ra.msstate.edu,
jrh23@ra.msstate.edu, grnbean@netdoor.com}
AC INDUCTION MOTOR DRIVE 2 of 39
Executive Summary
The induction motor has often been described as the workhorse for the power
industry. This is due to its broad list of capabilities, and its operating cost.
However, in order to efficiently run an induction motor, the output
characteristics need to be controllable. This calls for some sort of device that
enables the user to vary the input to the motor, so that it will operate at a
desired speed and torque. These devices are known as motor drives.
In designing the motor drive, various areas of power and energy conversions
were researched. Information was gathered on motors, electronic circuits,
and control systems. Manufacturers' designs were studied, as well as some
individual work. Once the design was configured, it was tested on computer
simulation programs in the Electrical Engineering department at Mississippi
State University. These tests provided for an efficient overview of the design,
and made it possible to correct errors in the design, as well as in the
projected cost of the project.
Once the final design was determined, a plan for the actual construction of
the drive was needed. Knowing the necessary parts and estimated size of
the drive, a container for the drive was designed. This was done to protect
the drive from outside interference that could cause physical damage to the
circuitry.
In the past, the need for motor drives placed an overwhelming burden on
manufacturers. Now, not only can drives be made, but they also can be
made to perform in almost any fashion. The problem is that they are fairly
expensive, and must be bought from companies that have their own set of
requirements for each drive. This drive was formed around a design that
would be more affordable than the typical drive, and could perform to the
limits of the motor, without causing damage to it. This increase in the motor's
capabilities allows for a more functional system, thus increasing the number
of ways a particular process can be done, without having to change
equipment.
TABLE OF CONTENTS
ABSTRACT .............................................................................................1
1. INTRODUCTION ....................................................................................1
2. PROBLEM .............................................................................................1
3. OBJECTIVES ..........................................................................................3
3.1. Operating Speed, Derating Factor, and Efficiency ....................
3.2. Torque and V/Hz Ratio .................................................................
3.3. Protection and Packaging ............................................................
4. APPROACH ............................................................................................
4.1. AC Drive For Induction Motor Application .................................
4.2. Rectifier Design ......................................................................
4.3. DC Link (Intermediate Circuit) ....................................................
4.4. Inverter Circuit ..............................................................................
4.4-1. PWM Functionality ............................................................
4.4-2. PWM Circuitry ....................................................................
4.4-3. Electrically Isolation With Inverter Section .....................
4.4-4. Optocoupler Circuit ...........................................................
4.4-5. MOSFET Circuitry ..............................................................
4.5 Power Supply Circuit ....................................................................
4.5-1. Overvoltage Protection .....................................................
4.5-2. Undervoltage protection ...................................................
5. TEST SPECIFICATIONS ........................................................................
5.1. PSpice............................................................................................
5.2. Matlab ............................................................................................
6. TEST CERTIFICATIONS ........................................................................
6.1. Real Time Test Certification ......................................................
6.2. Voltage Ripple of Power Supply Circuit ...................................
7. SUMMARY ..............................................................................................
8. FUTURE WORK .....................................................................................
9. ACKNOWLEDGMENTS .........................................................................
10. REFERENCES.......................................................................................
ABSTRACT
This design project focuses on the power electronics involved in varying the
speed of a motor through a Variable Frequency Drive (VFD). This process
involves converting an AC signal into a smooth DC signal and then making
that DC signal represents a simulated AC signal. By using this simulated AC
signal we can vary its frequency thus changing the speed of an induction
motor.
1. INTRODUCTION
The need for efficient drives has grown exponentially over the past decade.
The growth in industrial motor drives over the past 10 years has exceeded
25%, a rate far exceeding the previous 30 years [1]. This unprecedented
growth of drives results from the increased demand for efficient, reliable
process control, flexibility, and process improvement.
2. PROBLEM
Since the development of the power industry, people have come to rely on
electrical motors to lessen the amount of manual labor required to do most
every job. This has become an important factor in today's industries. Now,
instead of having someone assigned to each stage of a product's
development, some sort of machine has been designed to take his/her place.
This implementation of machines allows for several aspects of manufacturing
to become more efficient. In return this allows more profit to be made by the
manufacturer.
induction generators have not been very popular. Induction motors have been
labeled the "workhorse of the power industry" due to its vast number of uses
and popularity.
This motor has the advantages of low cost and low maintenance. The
biggest disadvantage has been its difficulty in controlling the motor speed in
an efficient manner. In the past, if a three-phase induction motor with variable
speed was needed, a wound rotor induction motor with a potentiometer was
used. The use of resistance or reactance in the rotor really kills operating
efficiency. This configuration added expense and increased the motor's
maintenance cost.
Thus has arisen the concept of variable speed drives. These drives allow the
user to change the speed of the motor under different operating conditions
with efficiency. This process provides a more sound manufacturing process.
This concept produces the basis for our project. In order to change the speed
of a squirrel-cage motor, a drive must be designed to meet the motor's
capability, and be able to operate it smoothly and efficiently. The drive is
composed of three main parts: the rectifier, the DC filter, and the inverter.
The rectifier rectifies the applied AC signal to DC. The filter smoothes out the
inverted DC signal. The typical motor drive inverter switches much faster than
60 Hz, but the switching is controlled such that the fundamental component of
the output voltage is 60 Hz or whatever frequency you want. Because the
speed of the DC pulses are controlled, the frequency of the signal can be
varied, thus allowing a change in the motor's speed, while maintaining a
constant torque. A block diagram of a variable frequency drive is represented
in Figure 2.1.
Once the drive is successfully implemented, the user can control the
operation of the motor. This allows any single motor to now have a broader
list of capabilities. With this, a manufacturer can not only decrease the cost of
manual labor, but also be able to operate at the most efficient speed for any
particular type of production. This makes for a better manufacturing process,
and in return greater profit.
3. OBJECTIVES
Suppose that we could increase the voltage applied to the motor without
adjusting the frequency of the applied voltage. This increased voltage
would create magnetic flux, which in turn would saturate the iron
components of the motor. Also, this flux would increase iron losses in the
form of hysteresis and eddy currents. This could in turn increase the
stator current and possibly damage the motor windings as a result.
4. APROACH
Design of a Variable Speed Drive for Induction Motor Application will be done
using a pulse width modulation technique. The design will be broken down
into 3 parts the AC to DC rectifier, DC Link, and PWM. PWM is the most
intense and hardest part of the design and will require the most effort.
The diodes in our circuit need to be sized due to Peak Inverse Voltage (PIV).
The PIV is calculated by:
Our diodes are rated at 1000[V] and 10[A]. These ratings are far above the
average value of the pulsating DC voltage and also far above our average
current flow. The reason we chose such high ratings is to compensate for
high motor startup currents and voltages.
The function of the DC Link is to smooth the output of the rectifier. This
intermediate circuit acts as a low pass filter. The circuit for the DC link is
shown in Figure 4.2.
Through research the current drawn in the motor determines the value of the
capacitance. Every amp of current requires 50 to 100 microfarads of
capacitance.
Some general comments can be made about the trend in applying these
drives. For retrofit applications, PWM is preferred over CSI, which requires a
better match between the inverter and the motor. CSIs produce torque
pulsations at low speed along with the fact that they are heavy and large. In
sizes below a few hundred horsepower there is an increasing trend to use
PWM [3]. CSI is used mainly for large motor applications, rather than small
motor applications.
The FDA215 chip is the optocoupler consisting of a diode and solar cell. This
chip provides isolation between the PWM circuit and the MOSFETs.
The output of the PWM is connected into the optocoupler and then directly
into the MOSFET circuit. When the signal of the PWM goes high this turns on
the transistors and when the signal of the PWM goes low the transistors are
turned off. The output of the MOSFET circuitry produces the simulated sine
wave that is fed directly into the input of the motor.
In order for the Induction Motor Drive to be complete, the design must
incorporate a power supply circuit equipped with both overvoltage and
undervoltage protection circuits. The power supplys main purpose is to
supply the pwm circuits with a small dual polarity dc voltage. Since
environments that usually accommodate drives have AC three phase
voltages, special attention must be given to the supply voltages of the
discrete components of the drive control circuits.
One way of solving this problem is to use a small transformer to step down
the motors supply voltage to a smaller voltage that can then be rectified and
stabilized to provide a constant dc voltage source for the control circuits. In
such cases, any time ac voltages are rectified to provide dc voltages, special
attention must be given to control excessive ripple voltage levels. In such
cases, capacitors and voltage regulators provide sufficient ripple reduction.
The proposed circuit for the power supply can be found illustrated in figure
4.5-1. The figure shows how the power supply fits into the entire circuit
design.
Figure 4.5-1
Also a more up close view of the power supply circuit can be found in figure
4.5-2. This figure shows just the power supply circuit.
Figure 4.5-2
The process in which the overvoltage circuit works is shown in figure 4.5-3.
The zener diode will conduct and allow current to pass through it. There will
also be a voltage drop across the zener and resistor. Once there is a voltage
present the SCR gate will have that same voltage on it, and allow current to
pass from the anode to the cathode of the SCR.
Once current moves through the SCR, this will be direct path to ground and it
will blow the fuse. After this the circuit will be broken and the power supply
will be interrupted from the supply voltage of the transformer and will not
operate until the fuse is replaced.
Figure 4.5-3
Zener conducts at 28
Volts
ISC
From the figure you can see how the undervoltage circuit works. Just like in
the overvoltage circuit the zener diode conducts at the minimum voltage you
would like the power supply circuit to receive. The current passed by the
zener allows the transistor to be biased when the reset button is pushed.
Since the transistor inside the optocoupler stays biased the circuit remains
operational without the reset button pushed. The other half of optocoupler
controls the triac, which switched the ac power on and off.
Figure 4.5-4
I1
Transistor is biased
I2
Zener conducts at 21
Volts
The entire circuit for the power supply with the overvoltage and undervoltage
protection can be found in figure 4.5-5.
Figure 4.5-5
Each phase of our drive acts the same way and is essentially the same
circuit. The only difference between each phase is that an oscillator is used
to delay each phase by 5.556 [ms]. This 5.556 [ms] is equivalent to a 120-
degree phase shift.
5. TEST SPECIFICATION
Requirement PSpice
Output frequency
Output voltage
Efficiency
Cost
Packaging
Table 5.1. Summary of the proposed tests to evaluate the motor drive using
programs like PSpice and Matlab.
5.1 PSpice
5.2 Matlab
Matlab is a useful tool in calculating most all types of math functions. In our
case, it will be used to determine the system model, and its outputs. This
program also is used to produce graphs of the output of the system, the
efficiency, and some cost data.
6. TEST CERTIFICATION
It can be seen that the rectifier produces a straight, DC signal. This signal will
be supplied to the transistors in the inverter circuit. The sawtooth generator
and sinusoidal input are operable, but the values are arbitrary until the
MOSFET circuit is implemented. The value of the output of the comparator
must be at least twice that of the value required to drive the transistors.
However, the data shows that the modulated signal can be attained using the
class D amplifier, and could be produced for whatever requirements are
necessary. Thus, the design is overall operable, and only lacks the building
of the MOSFET circuit that is necessary for the desired motor.
Data was collected from the rectifier circuit and is shown in Figures 6.2 and
6.3. The test circuit used to measure this output is shown in Figure 6.1.
The input signal shown is simply a sinusoidal AC input. This signal results in
a converted DC output signal, shown in figure 6.2.
This saw tooth waveform is feed into an input sine wave and the output is
represented as a modulated signal. Our modulated signal is shown in Figure
6.4.
There are two modulated signals represented above. For one phase of our
MOSFET circuit we have two transistors. Each of these pulses feeds one of
these transistors. As you can see, the transistors are not given a high signal
at the same time. If they did turn on at the same time shorted out and would
not work.
The output of the PWM is fed into the MOSFET circuit. This circuits output is
the input into the motor. The output signal of this circuit is a simulated sine
circuit. The output of this simulated sine circuit is shown in Figures 6.5 and
6.6. In Figure 6.5 the output was done without the capacitance in the DC link
(Intermediate Circuit). This is shown to show the affects of the ripple in from
the DC bus. Figure 6.6 shows the output sine wave with the affects of the DC
Link. As you can see below, the DC Link improves the sine wave drastically.
The ripple voltage of the power supply was simulated using pspice and the
hardware was also tested by applying different loads and measuring the
voltage ripple.
Figure 6.2-1 shows the simulated voltage ripple of the power supply circuit
with no voltage regulation and maximum load. Ripple voltage was obtained
to be 16.34 volts.
Figure 6.2-2 shows the simulated voltage ripple of the power supply circuit
with no voltage regulation and a load of 50 mA. Ripple voltage was obtained
to be 992 mV.
Figure 6.2-3 shows the actual ripple voltage including noise of the power
supply with no load applied.
Figure 6.2-4 shows the actual ripple voltage including noise of the power
supply with 1 amp of load applied.
Figure 6.2-5 shows a series of tests using different loads. The ripple voltage
measurements are those with no voltage regulation.
Figure 6.2-6 shows the ripple voltage measured for different loads with
voltage regulation.
Figure 6.2-7 is a graph comparing the ripple voltage of the power supply
without voltage regulation and with voltage regulation.
Figure 6.2-1
Figure 6.2-2
Figure 6.2-3
Figure 6.2-4
Load (Amps) Ripple Voltage (Vr) Load (Amps) Ripple Voltage (Vr)
0.000 0.068 0.000 0.0330
0.023 0.320 0.025 0.0330
0.028 0.356 0.031 0.0410
0.031 0.392 0.041 0.0390
0.036 0.432 0.050 0.0480
0.050 0.580 0.061 0.0500
0.083 0.880 0.081 0.0480
0.127 1.260 0.122 0.0460
0.266 2.280 0.243 0.0524
0.299 2.500 0.271 0.0600
0.344 2.880 0.305 0.0690
0.401 3.280 0.349 0.0690
0.483 3.760 0.409 0.0668
0.603 4.400 0.492 0.0655
0.805 5.280 0.620 0.0720
0.831 5.440 0.832 0.0760
1.211 6.480 1.200 0.1024
Figure 6.2-7
8.0 0.1500
6.480
6.0
0.1000
Volts
4.0 0.1024
0.0500
2.0
0.0 0.0000
0.00 0.50 1.00 1.50
Amps
7. SUMMARY
Reliable cost efficient variable frequency drives are very useful in almost all
industrial environments. In the past if you needed a three-phase induction
motor with variable speed, you had to use a wound-rotor induction motor with
a potentiometer. This configuration entailed added expense and increased
maintenance [4]. Fortunately, we now have VFDs that not only are used to
vary the speed of motors but can also vary its torque, start motors slower, and
smoother, and increase the motors efficiency. Our design brings an attempt
to incorporate a more reliable cost efficient drive into the industrial world.
The most important aspect of our design other than the reliability of the
overall system is to maintain a constant V/Hz ratio. This means that a motor
turning at 1800 RPM, operating from 208 V at 60 Hz would have to operate
from 104 V at 30 Hz to attain a speed of 900 RPM because these values do
not change the V/Hz ratio from its original value [4]. If the constant V/Hz ratio
is not achieved you will create a magnetic flux, which in turn would saturate
the iron components of the motor. Also, this flux would increase iron losses in
the form of hysteresis and eddy currents. This could in turn increase the
stator current and possibly damage the motor windings as a result.
8. FUTURE WORK
There were several obstacles encountered during the design and fabrication
process of this project. The main obstacle was our overall lack of knowledge
of power electronics. Through research and advice from others we were able
to overcome many questions that stood in the way to the completion of our
project. The first main obstacle that we had to overcome was a referencing
problem that we had between our PWM signal and MOSFET circuit. The idea
of why we needed isolation between these circuits was at first hard to
overcome, but with persistence and hard work we were able to come up with
a solution to this problem. Another problem that gave us a lot of headaches
was a frequency issue. Our PWM frequency was too high for the operational
range of our optocoupler. Our optocoupler was staying on at all times
therefore never switching on and off our transistors. A quick fix to this was
changing the RC network on our PWM to lower the frequency of this signal.
The switching frequency is determined by 1/RC. The smaller value the
resistance is, the faster the switching frequency will be. Along the same line
of thought, the larger the resistance value is the slower the switching
frequency will be. To make the PWM signal slower all that we needed to do
was to increase the value of the resistor in the PWM circuit. After raising this
resistance value, we were finally able to turn our transistors on and off.
During the duration of this design our group has learned a great deal about
power electronics, grounding issues, motor operation, and above all
In the future we would like to improve our drive in the following ways:
9. ACKNOWLEDGEMENTS
We would like to thank Dr. Mark Halpin for his valuable insight into our
project. Instead of just telling us what to do with various problems in our
project, he has gave us suggestions and made us figure out solutions
ourselves. This has helped us gain an overall better understanding of our
project and has also helped in developing teamwork skills that will prove to be
valuable in each of our professional careers. We would also like to think Dr.
Ray Winton, Geoffrey Carter, and Evan Burnett for their help with the power
electronics part of our project. Dr. Winton has helped us solve various
electronic problems that we encountered. Mr. Carters funding and support
on key issues proved to be invaluable in the completion of our project. Also
thanks to Dr. Joseph Picone for the time and effort he put forth critiquing our
design project.
Also, I would like to thank Mark Smith of the Stuart C. Irby Co. Mark helped
me early on by donating reading material and old drive components to study.
I would like to thank my Dad, Bill Long. He also gave me reading material
about drives. I would also like to acknowledge Todd Peacock of the Heart
Monitor Group. Todd has a lot of knowledge about electronic circuits and was
willing to lend a helpful hand. I also returned the favor whenever he asked
me a question about something he was unsure of. This leads to a point I
would like to make about senior design. I think that this years group of senior
design II students worked well with each other. Even though we all had
different projects, everybody helped one another when they could.
References
[3] Fox, Gordon, Electric Drive Practice, MGraw-Hill Book Company Inc.,
New York, 1928.
[5] Yamayee, Zia A., Julan L. Bala, Jr., Electromechanical Energy Devices
and Power Systems, John Wiley and Sons, New York, Chichester,
Brisbane, Toronto, Singapore, 1994.
[6] Pedersen, John K., Prasad Enjeti, Frede Blaabjerg, Adjustable Speed AC
Motor Drives: Application Problems and Solutions, Tutorial Workbook,
EPE97, p.198, 1997.
[7] Zeng, Z., E. Ritchie, Selection of Suitable Generic Drive Type to suit the
Application, AAU/IET Report, p.29, I14 97S 0085, 1997.