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AC INDUCTION MOTOR DRIVE

design document for

AC DRIVE FOR INDUCTION


MOTOR APPLICATION
Submitted to:

Professor Joseph Picone


ECE 4522: Senior Design II
Department of Electrical and Computer Engineering
Mississippi State University
Mississippi State, Mississippi 39762

April 24, 2001

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}
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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.

The motor drive designed here is a three-phase induction motor controller. It


operates on an input of 220 volts at 60 Hertz. This is a NEMA (National
Electrical Manufacturers Association) standard for three-phase motors. The
drive consists of three main parts. The first is a converter. This takes the
input AC voltage and converts it to a DC voltage. Next is the filter. This is to
insure a clean DC signal to the motor. Last is the inverter. This is a series of
transistors that switch on and off in a sequence such that the output signal is
pulsing at a particular frequency. The inverter is the main operating part of
the drive. Once the signal can be manipulated to a desired frequency, the
motor can be run at any desired speed (without overloading the motor).

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.

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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 .....................................................................................

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9. ACKNOWLEDGMENTS .........................................................................
10. REFERENCES.......................................................................................

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AC INDUCTION MOTOR DRIVE

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 main advantage of variable frequency drives is reliability. Without a


reliable drive, a system can become unstable and cause many problems. It is
repeatedly found that users of variable frequency drives are placing reliability
on top of their wish list [2]. This project is filled with a lot of valuable
information that covers many concepts in electrical engineering.

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.

The topology of drives has undergone constant change in order to fully


optimize device capabilities. Some of the first topologies were the Current
Source Inverters (CSI), which was later augmented with the Voltage Source
Inverter (VSI), based on application [1]. This control platform has made its
way to the most reliable type of inverter, the Pulse Width Modulation (PWM)
topology. The PWM technique is the type of inverter topology that is used in
this project because of its efficiency and reliability.

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.

The invention of the three-phase induction motor really made automation


possible. These machines may be used as generators or motors, just as DC
machines and synchronous machines. However, due to poor performance,
AC INDUCTION MOTOR DRIVE 6 of 39

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.

An induction motor is an AC machine in which alternating current is supplied


directly to the stator armature windings and to the rotor windings by induction
from the stator. This induction is similar to a transformer action, and has thus
caused the induction motor to be nicknamed a rotating transformer. These
motors come in two main types, a wound rotor and a squirrel-cage rotor, with
the latter being the most common. In the squirrel-cage type, conducting bars
are embedded in slots in the rotor magnetic core, and these bars are short-
circuited at each end by conducting end rings. These bars and rings are
shaped similar to a squirrel cage, hence the name.

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.

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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

1. Motor will operate to 50% of normal operating speed.

2. Motor will operate at no less than 90% derating factor.

3. Motor will operate at no less than nominal efficiency.

4. Maintain a constant V/Hz ratio.

5. Maintain +/- 5% rated output torque.

6. Reduction of common mode noise signals.

7. Increased protection with dynamic braking system.

8. Decreased volume of drive packaging.

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3.1 Operating Speed, Derating Factor, and Efficiency

In industry today, the induction motor is used in many applications.


These motors have to be able to operate at different speeds depending
on the application. When the motor is subject to variable loads, the motor
needs to be able to adjust. Although it is not safe to have the motor
operate at speeds higher than normal operating speeds, it is convenient
to allow the motor to adjust to the different loads applied. With these
different operating speeds comes the possibility of an unbalanced
voltage, which, in turn, produces a derating factor and poor efficiency.
This derating factor is a factor that the rated horsepower is multiplied by in
the case of unbalanced voltages. It is necessary to keep this factor as
high as possible. In order to correct these problems, AC motor drives are
used. These drives allow the motor to operate at the desired speed,
which keeps the voltage somewhat balanced. This balanced voltage
leads to a good derating factor and an increased motor efficiency.

3.2 Torque and V/Hz ratio


Although the motor operates at various speeds, the torque on the motor
should remain constant. The drive detects any change in speed, and
adjusts to maintain the desired constant torque. The constant torque is
sufficient to the life of the motor. Varying the torque puts much stress on
the motor shafts, and this stress can reduce the lifetime of motors.

The voltage/frequency ratio is very important for a number of reasons.


Remember that we need to be concerned with many characteristics when
dealing with AC and inductors. We not only have to be aware of voltage,
current, and resistance, but we must also recognize the importance of
reactance, hysteresis, and eddy currents [4].

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.

3.3 Protection and Packaging


Protection is a major issue to the consumer. Dynamic braking is an
important protection scheme. When the voltage is below the threshold
voltage, the dynamic brake is inactive, but when the voltage is above the
threshold voltage and below the overvoltage trip level, a resistive load is
placed across the dc bus to reduce the excess voltage. The cost of an AC
motor drive can and will be very expensive, but the expense cannot be
compared to replacing broken motors due to the various speed changes.

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With the increase of industrial use of motor drives, packaging becomes a


major issue. The volume of the drive needs to be reduced in order to
allow all drives necessary to a production line inside the enclosure. In
most cases, drives are not really exposed to bad weather. Actually, in
most cases, the drive is mounted in an enclosure and secured from any
harm; therefore, plastic has been chosen to enclose the drive.

4. APROACH

4.1. AC DRIVE FOR INDUCTION MOTOR APPLICATION

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.

4.2. RECTIFIER DESIGN

Rectification is the process of converting an alternating (AC) voltage into one


that is limited to one polarity. There are two classifications of rectification
half-wave and full-wave. Half-wave rectification is the simpler of the two. The
half-wave rectifier is sometimes called an uncontrolled rectifier. The final
output of a half-wave rectifier circuit sometimes produces an unacceptable
ripple. This ripple can be taken care of with a DC Link circuit, which
smoothes its output. The second type of rectification, the full-wave rectifier,
can also remove a large portion of this ripple. The full-wave rectifier is more
expensive and complex than the half-wave rectifier. Since the half-wave
rectifier is cheaper and the ripple problem can be solved with an intermediate
circuit; we have chose this design for our application.

This uncontrolled rectifier consists of six diodes. A diode permits current to


flow in one direction only. The current flows from the anode to cathode. In an
attempt to send current from the cathode to the anode the diode will block the
current flow. When AC voltage is applied to a diode it becomes a pulsating
DC voltage. The design for our rectifier circuit is in Figure 4.1.

Figure 4.1. Rectifier Circuit Design

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When a three-phase AC voltage is applied to an uncontrolled three-phase


rectifier the DC voltage will still pulsate. Our uncontrolled three-phase rectifier
consists of two groups of diodes. One group contains diodes D1, D2, and D3;
and the other diodes D4, D5, and D6. Each diode is conducting 1/3*T. This
is equivalent to 120 degrees. The two groups of diodes are conducting in
turns. The interval between the two groups is 1/6*T. This is equivalent to 60
degrees. The group of diodes D1, D2, and D3 is conducting the most positive
voltage. On the same hand, D4, D5, and D6 are conducting the most
negative voltage. The output of the rectifier is the difference between the
voltages of the two-diode groups.

The diodes in our circuit need to be sized due to Peak Inverse Voltage (PIV).
The PIV is calculated by:

3 VLN 2 3 120 2 294[V ]

Taking 3 raised to changes the voltage from line to neutral to line-to-line


voltage and this voltage is in RMS. We need to figure the peak voltage. To
change from RMS to Peak voltage you simply multiply by the square root of 2.
Our diodes also needed to be rated for current flow. This can be figured by
the simple equation below:

I P / V (.75HP * 746) / 208V ) 560 / 208 2.69[ A]

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.

4.3. DC LINK (INTERDEMIATE CIRCUIT)

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.

Figure 4.2. DC Link Circuitry

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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.

4.4. INVERTER CIRCUIT

The inverter circuit is used to produce a simulated AC circuit. This circuit is


the main part to control the speed of a motor. Three types of inverter circuits
were looked at in determining which would be best for our application. The
three are variable frequency square-wave (VSI), variable-frequency CSI, and
variable frequency PWM. The VSI drive controls the DC voltage using
converter thrysistors, which in turn control the inverter output voltage. The
load draws whatever current it needs. This inverter doesnt use high
frequency switching. The CSI drive controls the current to the motor to
maintain the required voltage and frequency with a more complex inverter
section. The PWM drives uses a simple diode bridge converter, which
minimizes the lower order harmonics and doesnt generate commutation
notches but has a complex inverter section, which must control both the
output voltage and frequency. It uses higher frequency switching devices on
the output than both VSI and CSI and is more reliable [7]. In PWM frequency
converters the task of the converter is to produce a symmetrical, 3-phase
voltage whose magnitude and frequency can be controlled. PWM inverters
have a good power factor (due to diode front end). Where lots of smaller
drives are applied with expected low speed operations, PWM drives will
significantly improve power factor and could reduce the cost of harmonic
filtered capacitor banks [5]. Comparison of these variable-frequency inverters
can be seen in Table 4.1.

Parameter PWM Square Wave CSI


Input power factor + - --
Torque pulsations ++ - -
Multi-motor capability + + -
Regeneration - - ++
Short-circuit protection - - ++
Open-circuit protection + + -
Ability to handle undersized motor + + -
Ability to handle oversized motor - - -
Efficiency at low speeds - + +
Size and weight + + --
Ride-through capability + - -
Complex Control Circuit + - -
Size and Weight + - -
Table 4.1. Comparison of inverter reliability [3].

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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.

4.4-1. PWM Functionality

The functionality of PWM is as follows:

Produce a Sine and Saw tooth wave.


Send 2 waveforms to a high-speed comparator.
Output is a modulated pulse.
Pulses are fed into the gate of the MOSFETs.
Saw tooth wave determines switching frequency
By varying the frequency of the PWM signal, the frequency of the
resulting sinusoid can be varied.

Figure 4.3. PWM Functionality Graphically.

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4.4-2. PWM CIRCUITARY

The PWM circuitry is shown in Figure 4.3.

Figure 4.3. PWM Circuitry.

4.4-3. ELECTRICALLY ISOLATION WITHIN INVERTER SECTION

Often, there is a need for electrical isolation between logic-level control


signals and drive circuits. There are a few basic ways to provide electrical
isolation to these drive circuits. A few of these ways are with optocouplers,
fiber optics, and by transformers. Optocouplers consists of a light-emitting
diode, an output transistor, and a build-in trigger. When a positive signal is
applied to the optocoupler the diode will light up causing the output transistor
to cut on. At the transistor cut-on, an arbitrary voltage is fed from the output
of the optocoupler.

An alternative to this is fiber optic cables. These cables can be used to


provide high electrical isolation. Transformers can also be used to isolate
drive circuits. The high side and low side of transformers are not physically
connected therefore isolation is present here. The most economically
solution to this isolation problem in our project was to use the ability of
optocouplers.

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4.4-4. OPTOCOUPLER CIRCUIT

In our optocoupler-isolated drive circuit; the optocoupler itself is the interface


between the output of the control circuit and the input of the isolated drive
circuit. The input side of the optocoupler is directly connected to the control
circuit of the PWM and the output side of the optocoupler is connected to the
isolated drive circuit of the MOSFETs. The optocoupler circuit is shown in
Figure 4.4 and Figure 4.5.

Figure 4.4. Optocoupler isolation circuit.

Figure 4.5. Optocoupler isolation circuit.

The FDA215 chip is the optocoupler consisting of a diode and solar cell. This
chip provides isolation between the PWM circuit and the MOSFETs.

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4.4-5. MOSFET CIRCUITARY

The MOSFET circuitry is shown below in Figure 4.5.

Figure 4.5. MOSFET Circuit.

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.

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4.5 POWER SUPPLY

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

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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

4.5-1. Overvoltage Protection

The power supply circuit is equipped with overvoltage protection. By


controlling the voltages on the secondary side of the transformer in figure 4.5-
2 we can protect the power supply circuit as well as the rectifier and inverter
inside the drive. The overvoltage protection works very simple just using a
fuse, SCR, and a zener diode. The schematic for the overvoltage circuit can
be seen in figure 4.5-3.

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.

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Figure 4.5-3

Zener conducts at 28
Volts

Voltage triggers SCR

ISC

4.5-2. Undervoltage protection

The power supply is also equipped with an undervoltage protection system.


The schematic for the undervoltage protection circuit can be seen in figure
4.5-4.

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.

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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.

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Figure 4.5-5

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4.6. ONE PHASE OF VFD

One phase of our variable frequency drive is below in Figure 4.6.

Figure 4.6. One phase of VFD.

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

An AC motor drive can be a complicated piece of equipment. Therefore,


some computer simulation tools were needed to verify its operation. The first
program used was PSpice. This is an electronic circuit simulation program.
Various components can be used in the circuits entered into the program, and
a very efficient model can be attained. Next, Matlab was used to calculate
some of the formulas used in the circuit design, and to attain graphs of some
of the output.

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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

PSpice is an electronic circuit simulation program. The components used in


the drive are stored in a library of parts in the program. The circuit can be
designed as schematic and simulated using models of the required inputs.
The output of the system can be monitored graphically; so various circuits can
be tested until the correct one is found.

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

Overview of Rectifier Circuit

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Figure 1. Graph of Rectifier Output with 120V source.

Circuit for comparator.

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Figure 2. Plot of Sawtooth Generator compared to the Sinusoidal input


(Comparator)

Figure 3. Input to Modulator

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Figure 4. Output of Modulator

Figure 4. Output of modulator

Circuit Overview of MOSFET implementation.

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

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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.

6.1. REAL TIME TEST CERTIFICATION

6.1.1. RECTIFIER REAL TIME DATA

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.

Figure 6.1. Test Circuit for Measuring DC Output.

Notes about Rectifier Test Circuit:


Current follows arrow in circuit, if this circuit was actually connected in
lab one would burn up D4 because of the ground.
Diodes conduct on only one direction and when they are not
conducting they have a high resistance (like an open circuit).
When voltage is applied to the circuit with ground the ground will short
out (current follows the path of least resistance) causing a high current
over the maximum rating of the diode.
This will in turn burn up the diode.
Remedy:
o Put the ground on for only positive part of the sine wave (pause
o-scope to obtain our result) and take off the ground before S.C.
occurs and D4 is burned up.

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Figure 6.1. Input Signal.

Figure 6.2. Output Signal.

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The input signal shown is simply a sinusoidal AC input. This signal results in
a converted DC output signal, shown in figure 6.2.

6.1.2. PWM REAL TIME DATA

Pulse Width Modulation consists of comparing a sine and a saw tooth


waveform to obtain a modulated pulse signal. These signals are represented
in the graphs below. Our saw tooth waveform is shown in Figure 6.3.

Figure 6.3. Saw Tooth Waveform.

Figure 6.3. Saw Tooth Waveform.

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.

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Figure 6.4. Modulated Pulse Signal.

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.

6.1.3. MOSFET CIRCUIT REAL TIME DATA

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.

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Figure 6.5. Output signal of MOSFET


circuit without affects of the DC Link.

Figure 6.6. Output of MOSFET


circuit with affects of the DC Link.

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6.2 Voltage Ripple of Power Supply Circuit

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.

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Figure 6.2-1

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Figure 6.2-2

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Figure 6.2-3

Figure 6.2-4

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Figure 6.2-5 Figure 6.2-6

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

Ripple Voltage vs. Load

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

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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

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teamwork. Although every aspect of this project did not go exactly as


planned, we feel that our project was a great learning experience and a great
success. In real life nothing goes exactly as you have planned and our
experience during this experiment is a testament to this. Thru teamwork we
were able to entwine our knowledge and solve a lot of problems. Perhaps we
could have performed in a more efficient manner, but for our level of
experience in power electronics we feel that we have accomplished a great
deal. Lots of the things that we have learned in this experiment will make
each of us better engineers.

In the future we would like to improve our drive in the following ways:

1. Implement an auto-response mechanism that will automatically change


motor speed when changing loads. This would be implemented with a
digital control circuit.
2. A digital display that gives information on speed, current, voltage, and
other valuable data.
3. Implement more safety and protective equipment to the overall system.
4. Produce a drive for different size of motors as well as different types of
motors.
5. Reduce packaging.
6. Design a more cost efficient method.

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

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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.

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References

[1] Williams, B.W., Power Electronics: Devices, Drivers, and Applications,


John Wiley and sons, New York, New York, USA, 1987.

[2] Leonhard, Werner, Control of Electrical Drives, Springer-Verlag, Berlin,


Heidelberg, New York, Tokyo, 1985.

[3] Fox, Gordon, Electric Drive Practice, MGraw-Hill Book Company Inc.,
New York, 1928.

[4] Brumbach, Michael E., Electronic Variable Speed Drives, Delmar,


New York, 1996.

[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.

[8] Blaabjerg, Frede, John K. Pedersen, Paul Thoegersen, Improved


Modulation Techniques for PWM-VSI Drives, IEEE Trans. On Industrial
Electronics, Vol. 44, No.1, February 1997.

[9] Blaabjerg, Frede, John K. Pedersen, Optimized Design of a Complete


Three-phase PWM-VS Inverter, IEEE Trans. On Power Electronics, Vol.
12, No.3, pp.567-577, May 1997.

[10] Bech, Michael M., Frede Blaabjerg, Andrzej M. Trzynadlowski.


Experimental Evaluation of Modern Random PWM Techniques for
Induction Motor Drives, Proceedings of IEMDC 9, pp. TB3-10.1 TB3-
10.3, 1997.

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