control techniques flux vector drive manual
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control techniques flux vector drive manualHowever, it still relies on the basic volts per hertz core for controlling the motor. These combined techniques control not only the magnitude of motor flux but also its orientation, thus the flux vector name. Volts per hertz variable frequency drives control only the magnitude. Open loop is actually a misnomer because it’s actually a closed loop sys tem, but the feedback loop comes from within the variable frequency drive itself instead of an external encoder. For this reason there is a trend to refer to open-loop VFDs as sensor less vector VFDs. The block diagram of a sensorless flux vector control VFD is shown as: Its operation can be summarized as follows: This is used to estimate the amount of slip, providing better speed control under load.The most common encoders deliver 1,024 pulses per revolution.Do you have it? best regard.To tell an old story, when I worked for a positive displacement pump company we sold packages with variable frequency drives. A salesman. Outstanding control performance. Superior Adaptability. Optimize EMC design, immunity for high interference environment.User can forbid the overwriting of the uploaded parameters. Horizontal or other installation are forbidden. The cooling medium is air. Free from direct sunlight, dust, corrosive gas, combustible gas, oil mist, steam, and water drop. Learn More. Please upgrade your browser to improve your experience. This is enabled by motor equivalent circuit data of the motor. Motor parameters are entered in the drive followed by an auto tune function.Sensor less vector can be used for most applications, however when speed and dynamic torque control at very low speeds are required then must consider the application closely prior to selection of the of the system This is the flux producing current (magnetising Current). This along with motor parameters (equivalent circuit data) cab be used to provide sensor less vector control of cage induction motors.http://energyprobg.com/userfiles/drager-pa-91-plus-manual.xml
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One component defines the magnetic flux of the motor, the other the torque. The control system of the drive calculates the corresponding current component references from the flux and torque references given by the drive's speed control. Typically proportional-integral (PI) controllers are used to keep the measured current components at their reference values.Components of the (d,q) system current vector allow conventional control such as proportional and integral, or PI, control, as with a DC motor.Vector control implementations usually assume ungrounded motor with balanced three-phase currents such that only two motor current phases need to be sensed. Also, backward two-to-three phase, ( Transformed to a coordinate system rotating in rotor reference frame, rotor position is derived by integrating the speed by means of speed measurement sensor.While PI controllers can be used to control these currents, bang-bang type current control provides better dynamic performance.A decoupling term is sometimes added to the controller output to improve control performance to mitigate cross coupling or big and rapid changes in speed, current and flux linkage. PI-controller also sometimes need low-pass filtering at the input or output to prevent the current ripple due to transistor switching from being amplified excessively and destabilizing the control. However, such filtering also limits the dynamic control system performance. High switching frequency (typically more than 10 kHz) is typically required to minimize filtering requirements for high-performance drives such as servo drives.Thus large errors due to for example rotor temperature changes often are encountered. Also the current sensors need not be the best in the market. Thus the cost of the processor and other control hardware is lower making it suitable for applications where the ultimate performance of DTC is not required.Retrieved May 23, 2012. Retrieved June 3, 2012. Retrieved June 4, 2012.http://turbobg.com/fckeditorfiles/drager-oxylog-3000-user-manual.xml By using this site, you agree to the Terms of Use and Privacy Policy. The UNI3405 applies power to the motor at frequencies varied by the user. The motor speed is a result of the output frequency of the drive and slip due to the mechanical load. The drive can improve the performance of the motor by applying slip compensation.This mode should used for multi-motor applications. Typically 100 torque at 4Hz. Typically 100 torque at 1Hz. The UNI3405 directly controls the speed of the motor using the feedback device to ensure the rotor speed is exactly as demanded. Motor flux is accurately controlled at all times to provide full torque all the way down to zero speed. Typically 175 torque at 0rpm. The Unidrive directly controls the speed of the motor using the feedback device to ensure the rotor speed is exactly as demanded. Flux control is not required because the motor is self excited by the permanent magnets which form part of the rotor. Absolute position information is required from the feedback device to ensure the output voltage is accurately matched to the back EMF of the motor. Typically 175 torque at 0rpm Regen operation allows bi-directional power flow to and from the AC supply. This provides far greater efficiency levels in applications which would otherwise dissipate large amounts of energy in the form of heat in a braking resistor. The harmonic content of the input current is negligible due to the sinusoidal nature of the waveform when compared to a conventional bridge rectifier or thyristor front end. Request a Quote! (800) 691-8511. With some products, Velocity mode operation can include capacity for regeneration. For torque mode center winders and a fixed input reference, torque remains constant giving a taper tension effect unless the machine operator increases the torque set-point as diameter increases. Some drives such as the Carotron ELITE PRO, digital DC drive, include CTCW firmware. TORQUE mode operation usually requires encoder feedback. Even evaluation of an inverter drive’s torque regulation ability is not a straightforward task. Do not assume that an inverter and motor operating in “torque” mode will produce a linear and proportional output torque versus reference.How well it does this depends on what feedback signal is used to represent the motor speed. Refer to the Section C, “Open Loop and Closed Loop Control”. Common selections for some DC drives are as follows: When a DC motor is rotated, it will generate a voltage level called counter or back emf that is proportional to the speed of rotation. As on all “generators”, the generated output is also affected by the strength of the field magnetic flux. This signal is then introduced to the speed regulation circuit of the drive, the Velocity Loop, to adjust the drive power section to maintain a constant motor voltage. The primary benefit of armature feedback is that (with Carotron DC drives) no additional drive or motor components are required. One problem is, even with constant armature voltage the motor speed may drop several percent when the motor is loaded. This drop is due to “internal resistance” losses in the motor armature and is addressed on DC drives by the addition of a “internal resistance compensation”, IR Comp, pot and signal. Unfortunately, the effect of IR losses is not usually the same over the motor speed range and a specific IR Comp setting works best at a specific motor speed. On the wound electromagnetic field(s) of Shunt Field motors, temperature increase as the motor warms up (immediately after power up) will cause the field winding resistance to increase. This causes a decrease in field current and flux strength which in turn causes a decrease in generated voltage which when used as velocity feedback causes an increase in motor speed as the drive tries to maintain a constant armature voltage feedback.http://fradiomas.com/images/contrex-m-track-manual.pdf A Velocity Mode Center Winder is an example application where low torque and high speed are required on a beginning roll and as diameter increases; rotational speed decrease is accompanied by an increasing torque requirement. Refer to Section H. Constant Horsepower Winders for more detailed description of this type of operation. So, armature feedback operation is less costly but, the potential associated problems may be prohibitive if precise regulation over the motor speed range and drift-free operation is required. The way to eliminate these potential problems is to “close the velocity loop” by use of an external feedback device such as a tachometer or encoder. Use of such a device for feedback is called “closed loop operation”. Most of them supply a DC voltage output but, AC voltage rated units are still available and used. They can be specified with multiple outputs called quadrature outputs and marker pulses which permit them to feed back direction-of-rotation and rotational position information. These are usually “ring and gear” or “Hall sensor and Magnet wheel” arrangements that mount to a “C” face or flange on the motor. All encoders are specified in Pulses-per-Revolution or PPR and may have output ratings from 1PPR to thousands of PPR. Their main claim to fame is that they ignore most external influences and give an accurate and repeatable output as long as they’re operated within their defined ratings. This means that drives using them for feedback also can ignore or compensate for factors including motor losses, line voltage fluctuation, load change and temperature change. Some examples are: Refer to Section H.12, “Constant Horsepower Winders” for more detailed description of this type of operation. Regeneration is an operating mode that is automatically implemented by a REGEN drive’s velocity control section whenever the velocity feedback is greater than the velocity reference. With regenerative drive capacity, a motor can provide motoring (positive) torque or braking (negative) torque, usually in either direction of rotation. This is called “four quadrant” operation. Non-regenerative drives provide only “single quadrant” operation although the addition of reversing contactors with DC drives can allow motoring operation in the third quadrant. With regen operation, self generated power is taken from the motor and fed back to the AC line or energy dissipating “brake resistors” to produce negative or braking torque in the motor. This function is useful when dealing with high inertia or overhauling motor loads. With DC drives, regenerative capability also provides “solid state reversing”. Without regeneration, DC rated contactors must be used for reversing. Frequent reversing, even at low load levels, can cause short mechanical life expectancy on contactors. With a regen drive, only a single contactor is recommended for “fail safe stopping”. Most lower HP rated AC drives also come with the “braking transistor” circuitry required for expanding regen capability with the addition of only the braking resistor. Additionally, some AC drives may include “line regen” capability where the excess motor energy is fed back into the line instead of being dissipated across resistors. DC regenerative drives can typically deliver higher continuous negative torque than an inverter drive using a braking resistor. The inverter braking transistor and resistor continuous wattage ratings will determine the operating duty cycle. Read other useful motor control tutorials and application tips by clicking on “Back to Index” below. Okay, thanks. But newer AC drives using vector control, also known as field oriented control (FOC), have performance similar to DC motor and drive systems. AC motor-drive systems are also free of the maintenance issues that have historically plagued DC motors—namely, brush wear. So, with the advantages gained by using an AC vector drive, when does it make sense to choose a DC motor and drive system over an AC vector drive system? AC vector drives use a complex algorithm to control the torque-producing and magnetizing components of the stator current independently. This allows better speed control over the entire speed range, as well as better torque control, especially at low speeds. Not of the components themselves, but of the power required for the drive. VFDs typically use 3-phase AC supply voltage, which isn’t always available. If the application only has access to single-phase power, then a DC drive is a better option, since the VFD would have to be de-rated in order to ensure that its components could handle the higher current associated with the single-phase input. A DC drive, on the other hand, can operate via internal armature feedback, foregoing the need for an external encoder. Conversely, DC drives are simple to start up, troubleshoot and maintain. Even DC motor brushes have become more robust and are less likely to require maintenance or replacement than they once were. Image credit: Performance Motion Devices, Inc. Image credit: wikipedia.org Slip is essentially energy loss, which is converted to heat that can damage motor and cable insulation. Because of this heat, the motor cannot produce full torque at low (or zero) speed in continuous operation. However, closed-loop vector control of VFDs solves this problem, by allowing the controller to adjust the torque through control of the flux (magnetizing) current. This enables the drive to provide good torque control regardless of speed, including down to zero speed. The primary reason is simple: cost. Vector drives are complex, and thus, more expensive than DC drives. And for true, closed-loop operation of an AC vector drive, the need for an additional encoder further drives up the cost. The material on this site may not be reproduced, distributed, transmitted, cached or otherwise used, except with the prior written permission of WTWH Media. All types control speed by varying current frequency, but one subtype — flux vector drives — uses current-switching techniques to control motor torque as well. The remainder of the current actually generates torque. Unlike other drives, flux vector drives command both current components; flux current is held at the minimum required to induce a magnetic field, while torque-producing current pulsing through the stator is independently adjusted. It requires continuous transformation between one coordinate system and another. During every sampling interval, the three-phase ac system — dependent on time and speed — must be transformed into a rotating two-coordinate system where every current is expressed and controlled as the sum of two vectors. Open-loop types use motor data and current measurements to calculate rotor position.When they are first connected to a new motor, they need to be “told” what they're driving. This entails entering values for full-load amps, no-load amps, base speed, base frequency, motor voltage, and other parameters. Typically the drive also has a tuning procedure, during which it measures the response and electrical characteristics of the motor, saving this data in its memory. Web processes — from fine thread to heavy sheet metal — need tension control. Controls range from leather straps and weights to load cells and servomotors. In the middle of the spectrum are VFDs. The drive is programmed with high and low torque values (for full roll and core) and uses a speed signal to trim the torque reference. Unwinding is similar. If motor speed range falls within 40:1 of base speed, a transducerless drive generally suffices. Higher speed ranges require closed-loop configuration. Summary New product design can be a time-consuming and expensive process, especially if you’re relying on external suppliers for your prototypes. With the right tools and capabilities in-house, however, it is possible not only to accelerate testing and insight gathering, but to lower your operational costs. David Cullen, Director, Application Engineering, 3D Systems Nearly 22 years in 3D printing and additive manufacturing with specialization in advanced applications development and engineering. All rights reserved. No part of this publication may be copied, reproduced, or reduced to any electronic media or machine-readable format without the prior written permission of Avtron Manufacturing, Inc. The information contained in this manual is considered accurate to the best knowledge of the supplier at the time of publication. The manufacturer, however, assumes no liability for errors that may exist. The supplier reserves the right to change data and specifications without notice. Study this information carefully before working on or with the unit. Failure to follow these instructions may lead to personal injury or death or to damage to the drive, motor, or driven equipment. Additional safety instructions specific to the application software can be found in the application documentation. Please study and follow those instructions as well. Conventions Used The following notation conventions are used throughout this manual to indicate information important to personal safety or machine hazards. ! Attention Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Safety Information i General Precautions. Attention Only qualified personnel with the proper skills, instruction, and familiarity with the drive and its applications should install, start up, operate, troubleshoot, and maintain the drive. You must be familiar with the electrical and mechanical components of the system to perform the procedures outlined in this manual. Static precautions are required when servicing or repairing the unit. ! ! ! Attention If an aluminum electrolytic capacitor in the drive fails from a build-up of internal pressure, a safety vent will operate, spraying electrolyte vapor from the capacitor. If a capacitor vents, avoid contact with the liquid, avoid inhaling the vapors, and ventilate the area. If your skin comes in contact with the electrolyte, flush it immediately with cold water. If electrolyte gets in your eyes, immediately remove any contact lenses and flush the open eyes with plenty of clean water. If electrolyte is ingested, dilute it by drinking warm water and seek immediate medical attention. Attention Drives are intended for fixed, permanent connection to earthed three-phase supply mains. Use of EMC filters along with the equipment will increase leakage current in the protective conductor and may affect compatibility with residual-current-operated protective devices. Attention The drive provides solid-state motor overload protection. The level of protection is dependent upon the rating of the unit (given in Table 2-2) as well as the software overload specified by the user. Please refer to the application documentation for instructions on adjusting the overload. Make certain installation and operating specifications are followed. Attention To provide protection against electrical shock, drives must be mounted in an enclosure meeting at least the requirements of Protective Type IP20 (or NEMA equivalent) according to EN60529 and with top surfaces meeting at least the requirements of IP40 (or NEMA equivalent). It is recommended that a key or tool be required to open the enclosure and that enclosure doors be interlocked with the electrical supply disconnect. ! Attention The drive and associated equipment must be properly earth grounded. ! Attention Any site insulation tests must be performed before making electrical connections to the drive. ! Attention The drive is not equipped with a supply-disconnecting device. An external supply-disconnecting device must be provided to isolate incoming electrical supplies during installation and maintenance work. This device should comply with the requirements of EN 60204-1 as well as all applicable national and local regulations. Application Precautions. Attention Emergency stop devices shall be located at each operator control station and at other operating stations where emergency stop may be required. Control inputs and keypad motor-control functions do not generate an emergency stop of the motor and do not remove power that can cause hazardous conditions. Regardless of the operating state, the drive’s motor output terminals may be at dangerous voltage levels whenever input power is applied and the bus is charged. Safety Information iii. Attention Drive functionality depends upon the application software installed. Some application software offers automatic restart functions that allow the unit to reset and resume operation after a fault. These functions must not be enabled when hazardous conditions might arise from such action. Certain features may present additional hazardous situations. Refer to the associated application documentation for further safety information. Service Precautions ! ! ! ! Attention Always disconnect and lock out all electrical supplies before working on the drive or associated equipment. Do this before touching any electrical or mechanical components associated with the drive application. Attention High voltage may be present even when all electrical power supplies are disconnected. After switching off electrical power, wait at least 15 minutes for bus circuit capacitors to discharge before working on the drive or associated equipment. Use an appropriate voltmeter to further verify that capacitors are discharged before beginning work. Do not rely exclusively on the bus voltage indicator. Dangerous voltage levels may remain even when the indicator is off. Attention High voltage may be present at the motor output terminals (U, V, W) whenever input power is applied, regardless of whether the motor is moving or not. Attention Before energizing the motor, verify that there are no loose components associated with the drive train and that motor motion will not result in injury or damage to the equipment. For service beyond that described in this manual, please contact Avtron Manufacturing or your representative. 1.2.1 Intended Audience The manual is intended for anyone who will be installing and servicing the drive. Installation should be performed by qualified electrical personnel to ensure that correct electrical practices and applicable electrical codes are applied. The audience is expected to have a basic knowledge of physical and electrical fundamentals, electrical wiring practices and components, and electrical schematics. No prior experience with the drive is presumed or required. Follow instructions You can prevent injury and damage to the drive or equipment by carefully following the procedures outlined in this manual. Follow regulations All electrical work should conform to the National Electrical Code as well as all state and local government regulations. Please familiarize yourself with these regulations. It gives instructions on unpacking, identifying, storing, and transporting a drive. It also familiarizes the user with the basic features, architecture, and specifications of the drives. 2.2 Unpacking After opening the package, you should verify delivery and inspect the drive before installing, storing, or transporting the unit. 2.2.1 Lifting Instructions Smaller drives are mounted on wooden supports and shipped in corrugated boxes, while the large drives are transported on skids. When unpacking a boxed drive, carefully follow the lifting instructions below. ! Attention The drive may weigh a considerable amount. Each person should stand at one end of the drive, facing the other. Product Overview 2-1 2.2.2 Verify delivery Check that you received the drive that was ordered as well as any options or accessories. Minimally, you should have received a drive and two manuals (this installation guide and an application guide). Contact your supplier regarding any discrepancies. 2.2.3 Inspect for damage Inspect the drive for any damage that may have occurred during shipment. Remove the cover, if present, and visually examine the insides for obvious problems. If damage is found, do not operate the drive. Repack and store the drive in its original packaging. 2.2.5 Nameplate Identification Drives are ordered using a model number similar to that shown in Figure 2-1. The model number identifies the drive type (1100, 1105, 1110, or 1130) and its configuration, including voltage, power, overload, control type, braking and packaging options, and application software. The drives combine the latest insulated-gate-bipolar-transistor (IGBT), pulsewidth modulation (PWM), and digital signal processor (DSP) technologies with digitalcurrent-regulator (DCR) or digital-space-vector (DSV) control to deliver optimum motor performance, complete programmability, and simplicity of operation. Variable-frequency drive (VFD) operation is also available for cost-effective control of motor speed in simple applications. The complete family is comprised of the 1100, 1105, 1110, and 1130 series of variablefrequency drives as well as the 1140 variable-voltage drive. These drives share a common architecture that provides a high degree of internal consistency. By combining this core drive topology with unique input sections, the 1000 family furnishes flexible, efficient, and cost-effective solutions to a variety of application needs. Table 2-1 summarizes the various models within the family. The 1140 is described in a separate publication. Units may be configured for constant-torque operation for heavy-duty cyclic loads, variable-torque operation for medium-duty requirements, or extended-torque operation for centrifugal loads such as fans and pumps. The drive operates in a transducerless vector control mode that does not require a feedback device and produces full torque to base speed with full starting torque. For demanding applications, an incremental encoder or resolver interface can be added for precise position, velocity, and torque regulation and improved dynamic performance. Dual- and triple-encoder interfaces are also available for position-following and dual-transducer applications. Variable-frequency control is alternately available for applications that do not require critical velocity or torque control. Product Overview 2-3 Motor-Independent Design The 1000 family drives operate any standard- or inverter-duty AC induction or synchronous motor, making it ideal for retrofits and new applications alike. A unique, proprietary digital current regulator (DCR) tunes the drive continuously in real time, eliminating the usual current-loop tuning process required by conventional drives. Digital space vector (DSV) control can be selected for reduced motor noise and low current ripple. Auto Tuning Once routine electrical connections have been made, simple-to-use auto-tuning features adjust virtually all motor- and load-dependent parameters. No motor maps are required. Simply enter basic motor information from the nameplate, and the advanced setup routines do the rest. The drive is completely tuned within minutes. Control Options Numerous control and interface options are available. The 16 MHz control module provides variable-frequency drive (VFD) control for simple applications. The 20 MHz control module is available in digital-current-regulator (DCR) and digital-space-vector (DSV) versions. Each control module provides digital and analog inputs and outputs as well as asynchronous serial communication capabilities. The 20 MHz, 40 MHz, and 100 MHz modules also provide synchronous serial communication capabilities. Braking Options The 1000 family offers both dynamic and regenerative braking options. A dynamic braking IGBT allows motor braking energy to be dissipated in an external resistor. The dynamic braking IGBT is optional on the 1100 and 1110 drives and included as standard on some 1105 drives. Appropriately sized external braking resistors are required. The 1130 lineregenerative drive provides true four-quadrant control without requiring dynamic braking. All controller settings are made digitally for precision and repeatability. Readouts and fault messages are displayed in readily understandable language. A graphical display option provides on-board oscilloscope-type viewing of drive and system parameters. Multiaxis Operation A built-in high-speed synchronous communication port allows the motion of multiple slave drives to be precisely coordinated. Multiple motors can be operated in parallel from a single drive using optional variable-frequency control. Power Quality A built-in link choke on the 1100, 1105, and 1110 drives provides near-unity overall power factor and low harmonic line currents at all motor speeds. High-power 1100 amd 1105 drives also offer a six-phase (twelve-pulse) configuration for further minimizing line harmonics in critical applications. The 1130 line-regenerative drive provides near-unity power factor for both motoring- and braking-type loads by using an IGBT bridge to control the flow of power into and out of the drive. Protection and Advanced Diagnostics Drives monitor their operating conditions and provide a comprehensive set of overload, short circuit, and other electronic protective features to ensure safe, reliable operation. Faults indications are displayed in plain language.