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2914233
SATHYABAMA UNIVERSITY
(Established under Section 3 of UGC Act 1956)
APRIL 2013
SATHYABAMA UNIVERSITY
(Established Under section 3 of the UGC Act, 1956)
Accredited with B++ Grade by NAAC
JEPPIAAR NAGAR, CHENNAI - 600 119
This is to certify that this Project Report is the bonafide work of Mr. SIDHARTHA SHANKAR
RAY ( Reg.No 2914233) who carried out the project entitled “MICROCONTROLLER BASED
SPEED CONTROL OF INDUCTION MOTOR USING V/F CONTROL” under our supervision
from NOVEMBER 2012 to March 2013.
INTERNAL GUIDE
Mr.S.JAYAPRAKASH
CHAPTER-1
1.1 Introduction...................................................................................1
1.1.1 General..................................................................................1
1.1.2 Overview Of The Thesis........................................................1
1.1.3 Objective Of The Thesis........................................................1
1.1.4 Organisation Of The Thesis...................................................2
CHAPTER-2
2.1 Objective.......................................................................................3
2.4 Pi Control......................................................................................6
2.4.4 Output....................................................................................10
CHAPTER-3
3.1 General............................................................................................17
3.3.1.5 Microcontroller.....................................................................27
3.3.2.3.2 Optoisolator.....................................................................31
CHAPTER -4
4.4.4 Hardware.....................................................................................52
4.5 Advantages.......................................................................................... 53
4.6 Application............................................................................................54
CHAPTER-5
5.1 Summary.............................................................................................55
5.2 Conclusion............................................................................................56
LIST OF FIGURES
An induction motor can run only at its rated speed when it is connected
directly to the main supply. This is felt the most in applications where inp ut
power is directly proportional to the cube of motor speed. So we can reduce
the speed of the motor upto 20% and save the power upto 50%. As the
semiconductor fabrication technology has advanced than previous both the
size and price have gone than before. Due to this the usage of motor has
already been reduced where as it can be replaced by VFD(variable frequency
drive). The VFD not only controls the motor speed, but can improve the
motor's dynamic and steady state characteristics as well. In addition, th e
VFD can reduce the system’s average energy consumption.
Generally we use open loop control for controlling the speed of a motor but
for VF controlling we use the closed loop control. It is also simple to
implement and cost effective. The on-chip hardware PW M modules, making
them on-chip hardware PWM modules, making them suitable for 3 -phase
motor control applications.
VF CONTROL:
The base speed of the induction motor is directly proportional to the supply
frequency and the number of poles of the motor. Since the number of poles is
fixed by design, the best way to vary the speed of the induction motor is by
varying the supply frequency. The torque is directly proportional to the ratio
of the applied voltage and the frequency. This is exactly what V F control tries
to achieve.
ACKNOWLEDGEMENT
I SIDHARTHA SHANKAR RAY hereby declare that the project titled “MICROCONTROLLER
BASED SPEED CONTROL OF INDUCTION MOTOR USING V/F CONTROL”was done by me
under the guidance of Mr.S.JAYAPRAKASH is submitted in partial fulfillment of the
requirements for the award of the degree in BACHELOR OF ENGINEERING.
DATE:
1.1 INTRODUCTION
1.1.1 GENERAL
Industrial drive applications are generally classified into constant speed and variable
speed drives.Traditionally AC machines have been used in constant speed ap-
plications,whereas DC machines were preferred for variable speed drives. DC
machines have the disadvantages of higher cost and maintenance problems with
commutators and brushes. Commutators and brushes do not permit a machine to
operate in dirty and explosive environment. An AC machine overcomes the drawback of
DC machines. Although currently, the majority of variable speed drive applications use
DC machines, they are progressively being replaced by AC drives. While there are
different methods of speed control of induction motor,Variable Voltage Variable
Frequency (VVVF) or V/F is the most common method of speed control. This method is
most suitable for applications without position control requirements or the need for high
accuracy of speed control. Examples of these applications include heating, air
conditioning, fans and blowers.
2
CHAPTER-2
2.1 OBJECTIVE:
The base speed of the induction motor is directly proportional to the supply frequency
and the number of poles of the motor. Since the number of poles is fixed by design, the
best way to vary the speed of the induction motor is by varying the supply frequency.
By varying the supply frequency alone is not suitable for speed variation efficiently –
why-
V ∝ φ x 2πf
φ ∝ V/f
3
The torque developed by the motor is directly proportional to the magnetic fields
produced by the stator. So, the voltage applied to the stator is directly proportional to
the product of stator flux and angular velocity. This makes the flux produced by the
stator proportional to the ratio of applied voltage and frequency of supply. By varying the
frequency, the speed of the motor can be varied. Therefore, by varying the voltage and
frequency by the same ratio, flux and hence, the torque can be kept constant
throughout the speed range.
Fig
2.1: Graph showing V/F Control
4
1. SPWM Controller
2. Analogue
3. Digital
4. Digital –Re configurable
5. POWER Circuit
6. AC-DC Rectifier
7. DC-AC Inverter
8. Motor
FIG 2.2: VARIABLE FREQUENCY DRIVE
2.4 PI CONTROL :
The model used in b) P-control will be used again. The only thing to be changed, is the
content of the controller block i.e. the block "Controller - PI-controller" see figure 1
below.
Fig 2.3: House model with PI-controller
where
e ="error"
KP = Proportional gain
τI ="Integrationtime"[s]
τN = "Reset time" [s]
NB: There is - in the real life - some confusion in the use of these two definitions.
If the error is negative (t > tset) then u would be negative and the radiator heat negative!
Which is not possible, therefore we have included a "Saturation" block in the actuator
block, see figure 3. The settings of this block is Max = Q_R and Min = 0.
9
2.4.4 OUTPUT:
Running the model - with almost arbitrary PI-parameters - gives this output:
This is the the steady-state "off-set" is almost zero! Which is the main benefit of the
ingetration part of the PI-controller.
10
Specification
FSBB20ch60b
3phase,200v
1.8amp
3 phase source case induction motor
It is an advanced smart power module (SPMTM) that Fairchildhas newly developed and
designed to provide very compactand high performance ac motor drives mainly
targeting lowpowerinverter-driven application like air conditioner and washing machine.
It combines optimized circuit protection and drivematched to low-loss IGBTs. System
reliability is furtherenhanced by the integrated under-voltage lock-out and
shortcircuitprotection. The high speed built-in HVIC provides optocoupler-less single-
supply IGBT gate driving capability that furtherreduce the overall size of the inverter
system design. Eachphase current of inverter can be monitored separately due tothe
divided negative dc terminals.
Fig 2.9 GENERAL VIEW OF SPM MODULE
11
13
The x-axis shows slip speed, the y-axis shows torque and current, the characteristics
shown in Fig 2.1 are drawn with rated voltage and frequency suppliedto the stator.
During startup the motor typically draws up to seven times the ratedcurrent. This high
current is result losses in the stator and rotor windings, and lossesin the bearings due to
the friction.At startup the motor delivers 1.5 times the rated torque of the motor. This
starting torque is also called locked rotor torque .As the speed increases, the
currentdrawn by the motor reduces slightly. At the base speed the motor draws the
rated current and delivers the rated torque .At base speed if the load on the motor shaft
is increased beyond its ratedtorque, the speed starts dropping and slip increases.
The disadvantages like motor draws high current during start up, torqueis highly non
linear as speed varies. These drawbacks can be overcome by using V/F control.
14
2.9 V/F CONTROL THEORY:
The base speed of the induction motor is directly proportional to the supply frequency
and the number of poles of the motor. Since the number of poles is fixed by design, the
best way to vary the speed of the induction motor is by varying the supply frequency.
The torque developed by the induction motors is directly proportional to the ratio of the
applied voltage and the frequency of supply. By varying the voltage and the frequency,
but keeping their ratio constant, throughout the speed range. This exactly what v/f
control tries to achieve.
Scalar control, as the name indicates, is due to magnitude variation of control variables
only and disregards the coupling effect in the machine. For example, the voltage of a
machine can be controlled to control the flux, and frequency or slip can be controlled to
control the torque. However, flux and torque are also the function of frequency and
voltage, respectively.
15
TABLE 2.1 COMPARISON BETWEEN PROPOSED AND EXISTING METHOD
16
CHAPTER-3
3.1 GENERAL:
They are-
The Figure shows the simulation diagram of open loop V/F control of
three-phase induction motor. It consists DC source, three -phase PWM inverter and
three phase induction motor. Dc source is connected to the dc side of the converter.
In this reference speed is set. From that reference speed frequency is determined
using the formula . V/F function block determines the amplitude corresponding to that
frequency. This frequency and amplitude are used to update the PWM duty cycle.
MOSFET based converter gives the supply of the induction motor. Connecting the
scope through bus selector shows speed of the induction motor.
3.2.1.1 Block diagram of open loop control:
Fig.3.1: Block diagram of open loop control
The Figure shows the simulated speed waveform of open loop V/F
control of three-phase induction motor. Reference speed is set at 1460 RPM. Speed
reaches the steady state at 0.3 second.
The Figure shows the gate pulses for PWM inverter consists of three
legs, one for each phase. The gating signals for the three phase inverters have a phase
difference of 120°. The first pulse is given to the positive switch of phase A, the pulse is
given to the positive switch of phase B the third to the positive switch of
phase C.
Fig. 3.3: Output Gate Pulses
Fig. 3.4: Output line voltage waveform
The Figure shows the simulated line-to-line voltage waveform of open loop V/F control
of three-phase induction motor. It is observed that the voltage waveform is almost
sinusoidal.
It consists DC source, three -phase PWM inverter and three phase induction motor as
open loop in addition to that it has PI controller,limiter. Connecting the scope through
bus selector .Now the simulation circuit is run with closed loop control shows speed of
the induction motor.
3.2.2.1 Block diagram of closed loop control:
I. The execution of closed loop control is executed very similar to the open loop
control.
II. In extra the PI controller is added here for controlling the error wave.
The Figure shows the simulated speed waveform of closed loop V/F
control of three-phase induction motor. Reference speed is set at 1460 RPM. It
reaches the steady state at 0.1 second.
The Figure shows the simulated line-to-line voltage waveform of closed loop V/F control
of three-phase induction motor. It is observed that the voltage waveform is almost
sinusoidal.
In this method, several pulses per half cycle are used as in case of multiple pulse width
modulation. Instead of maintaining the width of all pulses the same as in the case of
multiple pulse modulation, the width of each pulses is varied proportional to the
amplitude of a sine wave evaluated at the center of the same pulses. By comparing a
sinusoidal reference signal with a triangular carrier wave frequency, fc, the gating signal
are generated.
The PWM control has the following advantages,
(1) The output voltage control can be obtained without any additional components
(2) With this type of control, lower order harmonics can be eliminated of minimized
along with its output voltage control. The filtering requirements are minimized
as higher order harmonics can be filtered easily.
3.3.1.3 Driver circuit:
The driver circuit is the circuit which controls the PWM waves and
thereby controls the speed of the motor. The driver circuits of AND gates, optoisolators,
camparators, not gates, Smart Power Module (SPM), current sensors etc.
This circuit takes the input power and gives the required power after
regulating this. This circuit regulates the voltage and gives the output of 5V which is the
operating voltage for the microcontroller.
3.3.1.5 Microcontroller:
Below all the driver circuit, Smart Power Module (SPM) and
microcontroller is discussed elaborately with their full circuit diagram.
3.3.2 Hardware circuit diagram:
Each PWM pulse is passed through an U1 4081 AND gate. The PWM signal
and the signal C1 (current from the capacitor which is connected through 5V) is applied
to the AND gate and the output of the AND gate is fed to the optoisolator.
3.3.2.3.2 OPTOISOLATOR:
This isolator isolates the high voltage and low voltage sides of the driver
circuit. It also filters the signals. 6 PWM pulses are obtained from the 6 isolators as
shown in the above diagram.
The output signals of the optocoupler is given to the NOT gate to invert the
signal. Actually when the signal is passed through the optocoupler it gets inverted. So,
again it has to be inverted which is done by the NOT gate.
Here an extra PWM i.e. PWMIS is also used to stimulate all the pulses so
that we get a constant flow of PWM pulses. PWMIS signal stimulates all the PWM
waves to keep a constant value of them.
I. All the signals (RTOP, RBOT etc.) are fed to the FSBB20CH60 module.
II. There is a current resistance (IRES) signal which is also fed to the
FSBB20CH60 module.
III. Finally the output (three phase signals- R, Y, B) are obtained through three
INOUT devices.
IV. There are a few diodes and capacitors are connected with the SPM module for
filtering the signal.
V. A protection circuit is also included to process the higher values without affecting
the circuit.
PIN 1 -Reset
PIN 17 - K1 signal
4.1 GENERAL:
To analyze the speeds of the motor and to control the speeds a few
readings are taken both in open loop and closed loop control. Simulation has become a
very powerful tool on the industry application as well as in academics, nowadays. It is
now essential for an electrical engineer to understand the concept of simulation and
learn its use in various applications. Simulation is one of the best ways to study the
system or circuit behavior without damaging it .The tools for doing the simulation in
various fields are available in the market for engineering professionals. Many industries
are spending a considerable amount of time and money in doing simulation before
manufacturing their product. In most of the research and development (R&D) work, the
simulation plays a very important role. Without simulation it is quiet impossible to
proceed further deails.
2 0.77 40 1186
3 0.57 30 883
4 0.38 20 590
5 0.70 10 305
So, here both the frequency and modulation Index is increased and
the graph comes linearly.
Fig 4.2: Actual speed vs Modulation Index graph
Here the Kp and Ki value is kept constant. The Kp and Ki values are 0.1 and 0.02
respectively. The dc voltage is also kept as constant at 200V.
Here the values of actual speed are accurately same as the set
speed due the operation of closed loop.
Also the frequency values are increased from 0 to 50.Finally the V/F ratio is determined.
(1.36+1.45+1.40+1.08+1.26)/5 = 1.31
4.3.4 Simulation results of closed loop control:
I. To analyze the full operation of the hardware the driving of the motor must to be
understood well first.
II. The above block diagram explains the operation of driving the motor.
III. The input supply is applied to the autotransformer. The autotransformer is the
device which takes the input supply and give as the output voltage as the wish of
the operator. So we can vary the output voltage of the autotransformer as our
wish. That is the reason it is called variac otherwise.
IV. Now, we can gradually increase the output voltage of the autotransformer which
is applied to IGBT power module and thereby goes to the motor.
V. We can keep the output voltage at any values like 100V, 150V etc. But here we
are keeping the output voltage in such a value that it produces 200V after
converted to dc.
VI. The isolation transformer connected with the autotransformer is used to isolate
VII. The high disturbance from the current.
VIII. The single phase bridge rectifier is connected with the isolation transformer.
IX. So, the output of the isolation transformer is converted to DC voltage by the
single phase bridge rectifier.
X. Now, the converted voltage is constant 200V. This is applied to the smart power
module which is also consists of the IGBT devices.
XI. Now, finally the output current from the SPM is applied to the motor to run the
motor and also to control the speed of the motor.
XII. The current is applied to the motor through the current sensors for getting the
current readings of the current waves.
XIII. Fig- shows the current waveform which is given to the motor.
I. The operating voltage of the microcontroller is 5V, which is supplied from the input
voltage source. That voltage is regulated by a voltage regulation circuit.
II. Here we are using 3 switches for the entire operation.
a) Increment switch,
b) Decrement switch and
c) Reset switch.
III. The increment and decrement switch is for increasing and decreasing the values of
the frequency, modulation index, set speeds etc.
IV. Now, the microcontroller DSPIC30F4011 is operated at 5V and it generates 6 PWM
pulses.
V. This PWM pulses directly goes to the 3 phase inverter module (smart power
module- SPM) and thereby applied to the motor.
VI. Now, if the modulation index is varied the ON time and OFF time of the PWM pulses
are also varied.
VII. But if the frequency is varied then also the speed of the motor is varied.
VIII. So, by varying the modulation index and the frequency the PWM pulses are varied
and thereby the speed of the motor is varied.
IX. A LCD display is given where the inputs and the outputs are visualized.
X. From table no. 4.1 we can see that in open loop the frequency can be varied by
using the increment or decrement switches and the DC voltage is kept constant at
200V. So, with that the modulation index is also varied and as the result the actual
motor speed is varied.
XI. From table no. 4.2 we can see that in closed loop the set frequency we are giving is
the same what we are getting as motor actual speed.
XII. From table no. 4.3 we can see that by changing both the voltage and the frequency
the speed of the motor is varied. So, the V/F ratio drives the motor speed. The mean
value of the V/F ratios we taken over the operation is 1.31.
4.4.4 Hardware:
4.5 ADVANTAGES:
Easy programming,
Rugged,
Bidirectional operation.
4.6 APPLICATION:
From small appliances to the largest of mine mill drivers and compressors
Centrifugal pump
This chapter describes the hardware implementation of the V/F control of an induction
motor using microcontroller.It includes the development of hardware for microcontroller
circuit, SPWM pulses generation, optocoupler circuit was explained. For SPWM pulses,
the sine wave is generated from PIC microcontroller (DSPIC30F4011) and ramp wave
is generated through ramp generator The output of the controller is given to the
optocoupler circuit which is used for protection and isolation purpose, in case of
commutation failure and short circuit due to the improper trigger. From the optocoupler
circuit the pulses are given to the appropriate switches of the MOSFETs inverter fed
induction motor.
The use of a Variable Speed Drive for a speed control application usually offers an
energy efficient and environmentally friendly solution. The best opportunities for
energy savings, with subsequent economic savings, arise through the laws which
govern the operation of centrifugal fans and pumps. Simple and straight forward VSD’s,
such as the PWM inverter drives, are available for applications where the speed control
accuracy is not critical. This compact inverter had its hardware reduced to a minimum
through the use of bridge inverter. The variable speed drive with variable frequency
control method will offer new, low-cost solutions for light commercial and consumer
applications. The frequency range of the constructed circuit is 10 Hz to 50 Hz at
constant voltage for changing the speed of induction motor between theoretical limits of
300 rpm to 1460 rpm if 50 Hz, single-phase AC
motors are used.
The speed of a 3-phase induction motor in open loop and closed loop, supply voltage
and frequency need to be varied with constant ratio to each other. A low cost solution
of this control can be implemented in a DSPIC microcontroller. This requires six PWMs
to control a 3-phase inverter bridge. Many DSPICmicro microcontrollers have two
hardware PWMs.
5.2 CONCLUSION:
The speed of three-phase induction motor is being controlled by varying supply voltage
and frequency with constant (V/F) ratio. It is simple, economic to easier to design and
implement in open loop. But the drawbacks of open loop is it doesn’t correct the change
in output also it doesn’t reach the steady state quickly.
These drawbacks can be overcome by modifying an open loop into a closed loop
system. In this project only open loop was implemented in hardware.The project can be
extended in future to control the speed of induction motor in closed loop.