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AC Drives (VFDs)
See what it costs to hold an Onsite AC Drives seminar (at your facility).
Above is a cross-sectional view a motor rotor and field magnetic core. Looking from
the side would look something like a looking at a can:
We can add magnets (and torque) to our drive system by using a motor with a core
that is either longer, larger in cross-sectional diameter, or some combination of both.
Electro-Magnet
After we apply the electric current, the magnet field grows at a finite rate to a
finite size .
After voltage is applied and full current is reached, which always takes a little
time, the field quits growing and becomes a constant size. If we increase the
applied voltage the field grows and becomes stronger, decrease the voltage
and the field weakens and shrinks.
When we remove electric power to the coil the field does not just disappear. It
just decreases in size until it does disappear. It collapses over time so to speak.
The more current our coil draws (which we can force by increasing the applied
voltage level ) the stronger and larger our magnetic field becomes. I know I said
it twice. It's that important.
Some energy is converted into heat within the iron core. Different materials
convert different amounts of energy. This is also usually considered an energy
loss.
Once a core is magnetized, demagnetization and reverse polarity remagnetization consumes more energy and takes quite a long time, relatively
speaking. (Remember, an existing field has to collapse over time.) The amount
of this loss is proportional to the frequency of polarization reversals. This
happens 120 times per second when operating an AC motor at 60 hertz. We will
touch on the importance of this later. (Are you beginning to see where all this is
going?)
The motor stator shown below is a two-pole motor meaning it is wound with with two field
coils for each phase. In the industry this would be called a "2-pole motor".
For simplicity, only one phase is shown. In reality, a 3-phase, two pole motor requires six
coils, evenly spaced around the core - a minimum of two coils is required, to generate two
electro-magnetic poles, for each of the three phases.
(A 4-pole motor will have four coils per phase or 12 total coils for a 3-phase motor.)
Motors are designed so that the electromagnets are made as strong as possible
with acceptable risk of core saturation. This
will maximize the torque capability of the
motor but also means that during normal
operation every motor may at some point,
operate close to saturation. How close a
motor runs to saturation depends upon the
amount and type of core material used. So
naturally, this point varies from
manufacturer to manufacturer. There really
is a difference in motors and you get what
you pay for.
A Coil-Ectomy
If you could remove the coils from the above motor without breaking a connection, and
lay them side-by-side, this is what you would have. What is shown are three phases:
A, B, and C phase connected together (see the arrow) at a "star" or "Y" point. There
are other motor connection schemes but this is the most typical:
AC Generator
If a magnet is passed along the coils, an electric current is generated in each of the
three phases. In fact, there is little difference between AC generator and motor field
windings.
The faster you move the magnet the higher the AC output frequency. Variable
frequency drives control the frequency electronically. We'll get to more on that later.
When an iron core is placed so a moving magnetic field passes through it, a magnet
field is generated within the iron core. It takes time to generate a field therefore, the
new field reaches peak strength after the peak of the generating field has passed. The
bar (rotor) is "pulled" by the magnetic field thus producing torque.
The magnetic field has to pass through the rotor to generate a rotor field and pull. If
the rotor travels at the same speed as the magnetic field, induction into the rotor will
cease, the magnetic field will disappear and the rotor will loose its pull and slow down.
Pull (torque) is obtained when fields are passed through the rotor in quick succession.
Remember though, it takes a long time to generate a field. If the frequency of fields
passing through the rotor is too low, effectiveness is lost. If the frequency of the
generating field is held constant, and the torque is great enough to move the rotor, the
rotor will reach an equilibrium speed, where at any higher speed induction and torque
are reduced and the rotor slows back down to equilibrium.
More About AC Induction Motors
Typical Rotor (Rotating Part)
"Synchronous RPM" is the RPM the motor would run if the rotor did not slip. All AC
induction motors slip. ("Synchronous motors", a special kind of induction motor, do not
slip- at least least they are not supposed to. More about synchronous motors will have
to be covered in another article.)
A note about nominal RPM ratings:
An AC motor referred to, in the industry, as an 1800 RPM motor will be name-plated
with a speed of something less, usually around 1735 RPM. 1735 RPM is a typical
RPM rating but can be higher or lower but is always less than the synchronous speed
(1800 RPM). The difference between the synchronous and the actual RPM is called
"slip". Adjusting slip is an important technique in AC drive applications. A lot more
about slip will come later.
The following is surprisingly simple but important! Don't let it scare you.
You do not have to memorize it - just understand it.
Calculation of Synchronous Speed
(The "Poles" are the number of electro-magnetic poles wound into the motor. Motors can have any even
number of poles wound into them but a minimum of 2 poles for each of the 3 phases are required. The
most common AC motors are wound with either 2, 4, 6, or 8 poles.)
Looking at the calculation above you can see that a motor name-plated approximately 3450 RPM and
60 HZ is obviously a 2-pole motor with a synchronous speed of 3600 RPM.
Calculation of % Slip
(Typical induction motors slip anywhere from 3% to 5% when they are fully mechanically loaded.)
Why are some motors called "induction motors" and what is induction?
When an electric current is applied to a conductor a magnetic field builds around that
conductor. If another conductor is in close proximity so that the building magnet field
"cuts" through that conductor, a current of equal potential is produced with flow in the
opposite direction of the original current. This conductor is called the secondary circuit
and the principal is called induction.