DESIGN OF 3PHASE AC DRIVE FOR DRIVING AND REAL

TIME CONTROLLING.
ABSTRACT:
In older drives transistorized control drives were employed for this frequency
modulation. With the advantage of IGBTs, where they can be operated at
much higher
frequency compared to transistors, they are replacing transistors in AC
drives. Hence
IGBT is the main switching device in AC drives. These can be termed as
Variable
Frequency Drives (VFDs).
In industries when driving mechanical load with given torque slip
characteristics, the
speed can be controlled by controlling either its synchronous speed or the
rotors Slip.
3-phase induction motors are commonly employed in adjustable speed
drives. They
admirably suited to fulfill the demand of loads requiring substantially a
constant speed.
The most effective adjustable frequency drives use state-art technology
Pulse Width
Modulation combined with variable frequency drive (VFD) and superior
flexibility. The
combination of IGBT and surface mounted device technology has allowed
more
compact unless complex design with reduced cost compare to constant
speed drives.

IMPORTANCE:
In industries when driving mechanical load with given torque slip
characteristics, the
speed can be controlled by controlling either its synchronous speed or the
rotors Slip.
3-phase induction motors are commonly employed in adjustable speed
drives. They
admirably suited to fulfill the demand of loads requiring substantially a
constant speed.
The most effective adjustable frequency drives use state-of-the-art
technology pulse
width modulation combined with variable frequency drive (VFD) and superior
flexibility.

The combination of IGBT and surface mounted device technology has

allowed more
compact unless complex design with reduced cost compare to constant
speed drives.

INTRODUCTION:
AC motors have advantages compare to DC motors such as maintenance
free as there are
no brushes and commutators. For the given power rating AC motors have
compact in size
compared to their DC counterparts. DC motors power losses are more
compare to AC
motor. Due to these primary advantages AC motor are slowly progressed into
variable
speed application viz. machine tool application, elevators, cranes, pumps
and so on.
Speed of Ac motor (rotor of the motor) can be controlled by varying the
frequency of power applied to the motor. In older drives transistorized control
drives
were employed for this frequency modulation. With the advantage of IGBTs,
where they
can be operated at much higher frequency compared to transistors, they are
replacing
transistors in AC drives. Hence IGBT is the main switching device in AC
drives.These
can be termed as Variable Frequency Drives (VFDs).
In any VFD there are 2 sections:

1) Control section
2) Power section

VFDs can be either analog drives or digital drives and VFD operates as
closed loop
velocity control system, where rotor speed is controlled with set speed.
The basic difference between analog and digital drives is the control section
i.e.,
controlled with analog circuits or a microprocessor or microcontroller.
The control section mainly consists of set-point processing (the speed setpoint),
speed amplifier, current amplifier, triggering circuits and pulse transformer.
Apart
from these circuits over-voltage, protection circuit, under-voltage protection
circuit, overcurrent
limitation, temperature limitation circuits will also be there. The power circuit
mainly contains high-frequency switching device (IGBT).
In general in the power section of AC drive, 3-phase AC supply is first

converted into DC by a 3-phase converter and then it is smoothed with a

choke,
4
and the smoothed DC smoothed supply is again converted into AC supply by
a
IGBT power bridge. The drive is interfaced to AC servomotor which is
controlling
axis feed (linear motion of a machine tool). Actually the drive is a part of CNC
control system, which is a closed loop position control system which has
outer
position feedback loop. The CNC controls the position of axis feeds, driven by
AC. This AC drive system forms the inner speed feedback loop. For speed
feedback signal tachogenerators
are used. With these details a more simpler, efficient and flexible design can
be simulated.
BLOCK DIAGRAM:

THEORETICAL ANALYSIS:
1)IMPORTANCE OF SPEED CONTROL:

Speed control systems allow to set easily and adjust the speed of a motor.
The control
system consists of a speed feed back system, a motor, a drive and a speed
setting device.
The motor for the motor for the speed control system is either a Brushless dc
motor or a
standard AC motor. The purpose of a motor speed controller is to take a
signal
representing that demanded speed, and to drive a motor at speed. The
controller may or
may not actually measure the speed of the motor, if it does it is called a feed
back speed controller or closed loop speed controller if it is not, it is called a
open loop
speed controller. Feed back speed control is better, but more complicated
and may not be
required for a simple robust design.

2)SPEED CONTROL OF AC MOTORS:

A 3-phase AC motor is practically a constant-speed machine, more or less

like a DC
shunt motor. The speed regulation of an AC motor is usually less than 5% at
fullLoad. However, there is one difference of practical importance between the
two. Where
as DC shunt motor can be made to run at any speed within wide limits, with
good
efficiency and speed regulation, merely by manipulating a simple field
rheostat, the
same is not possible with AC motor. In their case, speed reduction is
accompanied by a
corresponding loss of efficiency and good speed regulation.

SPEED CONTROL METHODS:

Mainly there are three types of speed control methods. They are
1) Speed control by changing the applied voltage.
2) Speed control by changing the applied frequency.
3) Speed control by changing the number of stator poles.

1) SPEED CONTROL BY CHANGING THE APPLIED VOLTAGE:

This method, through the cheapest and the easiest, is rarely used because
I. A largely change in voltage is required for a relatively small change in
speed.
II. This large change in voltage will result in a large change in the flux density
There by seriously disturbing the magnetic conditions of the motor.

2) SPEED CONTROL BY APPLIED FREQUENCY:

This method is also used very rarely. We have seen that the synchronous
speed of an AC
induction motor is given by Ns=120 f/p. Clearly, the synchronous speed of an
AC
induction motor can be changing the supply frequency f. These are directly
proportional
to each other.

3) SPEED CONTROL BY CHANGING THE NUMBER OF STATOR

POLES:
This method is easily applicable to squirrel-cage motor because the squirrelcage rotor
adopts itself to any reasonable number of stator poles. From the above
equation it is
clear that the synchronous speed of an AC induction motor could also be
changed
by changing the number of stator poles. This change of number of poles is
achieved by
having two or more entirely independent stator windings in the slots.
This method has been used for elevator motors, traction motors and also for
small motors
driving machine tools.

DRIVES:
Drives are devices by which the speed of a motor can be controlled. These
are
essential for the CNC machines for precise axis movement and spindle
rotation. The
CNC system controls the drive by supplying them with the required input and
receiving
feedback signals from position feedback transducers. Drives are
7
used in motor speed control for smoother, versatile control and to achieve
specific
torque speed characteristics.

AC DRIVES:
PRINCIPLES OF OPERATION:
Adjustable frequency AC motor drive controllers frequently termed inverters
are
typically more complex than DC controllers since they must perform two
power
section functions that of conversion of the AC line power source to DC and
finally an

inverter change from the DC to a coordinated adjustable frequency and

voltage
output to the AC motor. The appeal of the adjustable frequency drive is
based
upon the simplicity and reliability of the AC drive motor, which has no
brushes,
commutator or other parts that require routine maintenance, which more
than
compensates for the complexity of the AC controller. The robust construction
and low
cost of the AC motor makes it very desirable for a wide range of uses. Also,
the ability
to make an existing standard constant speed AC motor an adjustable speed
device
simply by the addition of an adjustable frequency controller creates a very
strong
incentive for this type of drive

COMPARISON OF AC AND DC DRIVES:

AC and DC drives both continue to offer unique benefits and features that
may make one
type or other better suited for certain applications

AC DRIVES MAY BE BETTER BECAUSE:

They use conventional, low cost, 3-phase AC induction motors for

most applications.AC motors require virtually no maintenance and are
preferred for
applications where the motor is mounted in an area not easily reached for
servicing or replacement.
AC motors are smaller, lighter, more commonly available, and less ex
pensive
than DC motors. AC motors are better suited for high speed operation (over
2500 rpm)
since there are no brushes, and commutation is not a problem.Whenever the
operating
environment is wet, corrosive or explosive and special motor enclosures are
required. Special AC motor enclosure types are more readily available at
lower
prices.Multiple motors in a system must operate simultaneously at a
common
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frequency/speed .It is desirable to use an existing constant speed AC motor
already
mounted and wired on a machine.When the application load varies greatly
and light loads

may be encountered for prolongedperiods. DC motor commutators and

brushes may wear
rapidly under this condition.Low cost electronic motor reversing is required.It
is
important to have a back up (constant speed) if the controller should fail.

DC DRIVES MAY BE BETTER BECAUSE:

DC drives are less complex with a s ingle power conversion from AC to DC.DC
drives
are normally less expensive for most horsepower ratings.DC motors have a
long tradition
of use as adjustable speed machines and a wide range of options have
evolved for this
purpose Cooling blowers and inlet air flanges provide cooling air for a wide
speed range
at constant torque. Accessory mounting flanges and kits for mounting
feedback
tachometers and encoders.
DC regenerative drives are available for applications requiring continuous
regeneration
foroverhauling loads. AC drives with this capability would be more complex
and
expensive.Properly applied brush and commutator maintenance is minimal.
DC motors are capable of providing starting and accelerating torques in
excess of 400%
of rated.

VARIABLE FREQUENCY DRIVE:

A VFD controls the speed, torque and direction of an AC Induction motor. It
takes fixed
voltage and frequency AC input and converts it to a variable voltage and
frequency AC
output . In very small VFDs, a single power pack unit may contain the
converter and
15
inverter. We can divide the world of electronic motor drives into two
categories: AC
and DC. A motor drive controls the speed, torque, direction and resulting
horsepower of a motor. A DC drive typically controls a shunt wound DC
motor, which
has separate armature and field circuits.

DRIVE CHANGE MOTOR SPEED:

A drive provides the frequency and voltage output necessary to change the
speed of a
motor. Shows a basicPWM drive.Basic PWM Drive Components All PWM drives
contain these main parts, with subtle differences in hardware and software

components.Although some drives accept single-phase input power, we'll

focus on
the 3-phase drive. The input section of the drive is theconverter. It contains
six diodes,
arranged in an electrical bridge.
These diodesconvert AC power to DC power. The next section-the DC bus
section-sees
a fixed DCvoltage.The DC Bus section filters and smoothes out the
waveform. The diodes
actually reconstruct the negative halves of the waveform onto the positive
half. In
a 460V unit, we measure an average DC bus voltage of about 650V to 680V.
We can calculate this as line voltage times 1.414. The inductor (L) and the
capacitor (C)work
together to filter out any AC component of the DC waveform. The smoother
the
DC waveform, thecleaner the output waveform from the drive.The DC bus
feeds the
final section of the drive: the inverter. As the name implies, this section
inverts the DC
voltage back to AC. But, it does so in a variable voltage and frequency
output. That
depends on what kind of power devices our drive uses. If we have many SCRbased
drives in our facility, see the Sidebar. Bipolar Transistor technology began
superceding SCRs in drives in the mid-1970s. In the early 1990s, those gave
way to
using Insulated Gate Bipolar Transistor (IGBT) technology, which will form the
basis for our discussion.

SWITCHING BUS WITH IGBTs:

Today's inverters use Insulated Gate Bipolar Transistors (IGBTs)to switch the
DC bus on
and off at specific intervals. In doing so, the inverter actually creates a
variable AC
voltage and frequency output. As shown in Fig, the output of the drive
doesn't
provide an exact replica of the AC input sine waveform. Instead, it
17
provides voltage pulses that are at a constant magnitude. Drive output
waveform is
shown below.
18
The drive's control board signals the power device's c ontrol circuits to turn
"on" the

waveform positive half or negative half of the power device. This alternating
of
positive and negative switches recreates the 3-phase output. The longer the
power
device remains on, the higher the output voltage. The less time the power
device is on, the lower the output voltage (shown in Fig).
Conversely, the longer the power device is off, the lower the output
frequency.Drive
Output Waveform Components
The speed at which power devices switch on and off is the carrier frequency,
also known as the switch frequency. The higher the switch frequency, the
more
resolution each PWM pulse contains. Typical switch frequencies are 3,000 to
4,000
times per second (3 KHz to 4 KHz). (With an older, SCR-based drive, switch
frequencies are 250 to 500 times per second). As you can imagine, the
higher the switch
frequency, the smoother the output waveform and the higher the resolution.
However, higher switch frequencies decrease the efficiency of the drive
because of
increased heat in the power devices.

SHRINKING COST AND SIZE:

Drives vary in the complexity of their des igns, but the designs continue to
improve. Drives come insmaller packages with each generation. The trend is
similar to
that of the personal computer. More features,better performance, and lower
cost with
successive generations. Unlike computers, however, drives have dramatically
improved in their reliability and ease of use. And also unlike computers, the
typical drive
of today doesn't spew gratuitous harmonics into our distribution system-nor
does it affect
our power factor. Drives are increasingly becoming "plug and play." As
electronic power
components improve in reliability and decrease insize, the cost and size of
VFDs will
continue to decrease. While all that is going on, their performance and ease
of use will
only get better.

IGBTs BETTER THAN SCRs:

With the large installed base of SCRs, An SCR (originally referred to as a
thyristor)

contains a control element called a gate. The gate ac ts as the "turn-on"

switch that
allows the device to fully conduct voltage.The device conducts voltage until
the
polarity of the device reverses-and then it automatically "turns off."Special
circuitry, usually requiring another circuit board and associated wiring,
controls this
switching. The SCR's output depends on how soon in the control cycle that
gate turns on.
The IGBT output also depends the length of time the gate is on. However, it
can turn
off anytime in the control cycle, providing a more precise output waveform.
IGBTs also
require a control circuit connected to the gate, but this circuitry is less
complex and
doesn't require a reversal of polarity.