4/30/2012 1

Variable Speed Drives

Presented by: Nguyen Huu Loi
4/30/2012 2
PART 1
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ENERGY:

The motor changes electric energy into mechanical work which, once adapted to the
production needs, becomes the effective work.

The sizing of the mechanical system and of the motor will be performed from those data
about the effective work, in order to:

Ensure the energy transfer,

Limit mechanical and electrical losses.


WORK:

Work is the product of a force by a distance covered under the effect of that force. It is
expressed in joules and is independent from time.

As far as an angular motion is concerned, it is the work of a force torque whose action is
equal to 2F1 x r. This action which is commonly called torque, is expressed in
Newton-meters.
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WORK
Linear motion
A B
F
Work = force x distance
W(J) = F(N) x I(m)
Angular Motion
u
r
F
A
B
u
r
B
A
F
1


F
1
Work = force x distance
W = 2F1

x ru

W(J) = C(Nm) x u(rd)
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POWER - TORQUE - SPEED
Transportation of 50 kg in one go Transportation of 5 kg in 10 times

WORK WORK
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FOR AN ANGULAR MOTION:
Hence:
P(w) = T(Nm) x e(rd/s)
POWER
t
W
=
t
T
t
W
P
u
= =
e =
u
t
and:
angular speed in
radians/second
Power is defined by WORK divided by the total time spent to perform the task.
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The mechanical power required by the application represents the
ability of the motor to provide a work in a given time.

The rated power corresponds to the work provided in one
second by the motor in permanent normal state. It is expressed
in WATT.
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THE RESISTANT TORQUE

It is opposed to the motion whatever the direction of the rotation.
The machine is driven by the motor.

There are several types of resistant torques:

- Constant resistant torque: Tr = constant

- Resistant torque proportional to speed: Tr = ke

- Resistant torque proportional to square speed: Tr = ke
2


- Resistant torque inversely proportional to speed:

- Pull-up torque or starting overtorque

- Some machines have a high variation of torque


THE TRAILING (OVERHAULING) TORQUE

This makes the motion easier whatever the direction of the rotation.

The machine drives the motor.

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POWER:

Power is proportional to speed.

P = Tre , Tr = constant P = ke

MACHINES:

Conveyor belts
Conveyors, Hoisting & Lift
(80% of the cases)
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A
MACHINES WITH CONSTANT RESISTANT TORQUE
Tr = constant
Speed
Tr
0
Torque
Graph
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POWER:

The power changes according to the square speed.

P = Tre , Tr = ke P = ke
2


MACHINES: Rare cases (some worm conveyors based on the
principle of Archimedean screw and spiral pumps).
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B
MACHINES WITH RESISTANT TORQUE PROPORTIONAL TO
SPEED
Tr = ke
Speed
Torque
0
Tr
Graph
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POWER:

The power changes according to the cube of the speed.

P = Tre , Tr = ke
2
P = ke
3

MACHINES:

Centrifugal pumps
Ventilators

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C
MACHINES WITH RESISTANT TORQUE PROPORTIONAL TO
SQUARE SPEED TR = Ke
2

Speed
Torque
0
Tr
Graph
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POWER:

The power is constant:

P = Tre , P = k

MACHINES:

Machines tools broaches (cutter bar or bit)
Windings and unwinding machines
e
=
k
Tr
Textile machines
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D
MACHINES WITH RESISTANT TORQUE INVERSELY
PROPORTIONAL TO SPEED
e
=
k
Tr
Torque
Speed
Maximum
speed
Minimum
speed
Minimum
torque
0
Maximum
torque
Tr
Graph
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E
PULL-UP TORQUE OR STARTING OVERTORQUE
Torque
Speed
Tr = constant
Tr = ke
Tr = ke
2

0
Tp
PULL-UP TORQUE
e
=
k
Tr
Graph
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PART 2
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- Reduction of Mechanical Stress
Importance of Speed Control
Speed
Time DEC ACC
Lift & Elevator
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-Reduction of Current peaks, voltage drops
and protection motor
Importance of Speed Control
I/In
N/Ns
0
1
2
3
This curve will
change
according to
the load
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- Process Regulation
Importance of Speed Control
Conveyor
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- Power Saving
Importance of Speed Control
HVAC System
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Methods of Varying Motor Speed
Mechanical method
Clutch
Variable Gear Reducers
Electrical method
Variable transformers
Steps resistors
Motor Winding
Electronic motor drives

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Where it is commonly used ?
Constant Torque loads,
Hoisting & Lift
Conveyors
Crushers
Variable Torque loads
Pumps
Fans
Beam Winders

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M
Line
Frequency
drive
3 Phase
Motor
AC
DC
PWM
PWM - Pulse Width Modulated wave
Basic Theory
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Fv - Frequency Variable
Fc - Frequency Carrier
Fv
Fc
PWM wave
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TECHNOLOGY

TYPICAL POWER DIAGRAM
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We have the definition to calculate the speed of the motor bases on the frequency and
number poles of the rotor:

The function of the inverter is changing the speed of the motor and keeping the moment of
the motor is a constant at any speed. In order to do so, the flux must be a constant
according to the formula below:

T = K u I cos = constant

We can see that the moment is propositional to the current of the motor and it will be a
constant like:
T = constant if u = constant
=
60f
Ns
p
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In an asynchronous motor, the stator create a flux:
u = L I
At the voltage U, and frequency is f.
The Ohm law is: U = Z I
The impedance of the solenoid (without resistance) is : Z = L e
So : U = L e I

e is represented by: e = 2 t f

We have the current of the motor :

The flux is finally calculated :

In order to keep the flux in constant, i.e moment is contant, the ratio must be a constant at any speed of the
motor.
Conclusion: with the inverter, the voltage and frequency are changed propositionally.
f L
I =
u
2

t

u =
1
2 t

U
f
u = cst
U
F
= cst
U
F
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PART 3
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CENTRIFUGAL LOADS
70% OF ALL CONSUMED ELECTRICAL ENERGY
IS:
PUMPS
FANS
BLOWERS
COMPRESSORS
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Pumping is an art of moving liquid and gasses
Pumps and Fans are designed to make water or air flow
and most of them are categorized as Variable Torque Load
In Variable Torque Load the torque required to drive the load
changes according to the speed.As the speed of the load is
reduced the torque required to drive it is decreased as a squared
of the speed
Variable Torque Profile
0
0.2
0.4
0.6
0.8
1
%

T
o
r
q
u
e

0 0.2 0.4 0.6 0.8 1
% Speed
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Pump & Fans Princilple
CONSTRUCTION :
ROTATING IMPELLER INSIDE OF A SPECIALLY SHAPED
SHELL
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PRINCIPLE :
THE FLUID IS DRAWN IN AT THE AXIS AND
ACCELERATED ALONG THE VANES OF THE IMPELLER
Pump & Fans Princilple
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PRINCIPLE :
THE FLUID IS MOVING FASTER AT THE TIPS OF THE
IMPELLER, INCREASING BOTH ITS FLOW AND
PRESSURE
Pump & Fans Princilple
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PRINCIPLE :
THE DIFFERENCE IN PRESSURE IS ALSO THE FORCE
THAT DRAWS MORE FLUID INTO THE AXIS
Pump & Fans Princilple
Typical Pump Curve
0
20
40
60
80
100
120
140
160
0 200 400 600 800 1000 1200 1400 1600
Flow
P
r
e
s
s
u
r
e




Reminder
60
50
40
30
Point A
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TYPICAL OUTPUT CONTROLS
THROTTLE VALVES
OUTLET DAMPERS
INLET VANES
MECHANICAL SPEED
CHANGES
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A SCARY ANALOGY
CONTROLLING A SYSTEM
LIKE THIS IS LIKE DRIVING A
CAR WITH YOUR FOOT TO THE
FLOOR ON THE
ACCELERATOR WHILE
CONTROLLING THE SPEED
WITH A BRAKE.
Variable Torque Loads

Fans and Pumps are designed to make air or water flow.As
the rate of flow increases, the air or water is has greater
change in speed put into it by the fan or pump,increasing
it inertia.

The effect that reduced speed has on variable torque
fan or pump are summarized by set of rules known as the
AFFINITY LAW .

VSD Relation to Energy Savings
0
0.2
0.4
0.6
0.8
1
0 0.2 0.4 0.6 0.8 1
% Speed
F
l
o
w

Affinity Law
- Flow produced by the device is proportional to the motor speed
1st Law
0
0.2
0.4
0.6
0.8
1
0 0.2 0.4 0.6 0.8 1
% Speed
P
r
e
s
s
u
r
e

- Pressured produced by the device is proportional to the motor speed squared.
Affinity Law
2nd Law
0
0.2
0.4
0.6
0.8
1
0 0.2 0.4 0.6 0.8 1
% Speed
P
o
w
e
r

- Power produced by the device is proportional to the motor speed cubed
Affinity Law
3rd Law
0
0.2
0.4
0.6
0.8
1
0 0.2 0.4 0.6 0.8 1
% Speed
%

F
l
o
w
,
P
r
e
s
s
u
r
e
,
H
P

Flow
Pressure
Horse Power
Affinity Law
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THROTTLE VALVE vs VSD
0
20
40
60
80
100
120
THROTTLE VALVE
VFD
P
E
R
C
E
N
T

P
O
W
E
R

PERCENT FLOW
100 40
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INLET VANES vs VSD
0
20
40
60
80
100
120
INLET VANES
VFD
P
E
R
C
E
N
T

P
O
W
E
R

PERCENT FLOW
100
Cost to run a motor at 100% speed:

(Power) x (Time) x ($/VND/KWhr)

Cost to run a motor with variable speed drive

(%speed) for (%time) is to:
(Power) x (%speed)
3
x (%time) x ($/VND/KWhr)

Savings

Cost w/o Drive - Cost w/ Drive

Formula :
Example:

-Consider a 50 Hp (37.3 KW) drive at 2000 VND/KWhr
running at 250 days a year for 10 hrs per day (2500 hrs).


Cost to run the motor at 100% speed

= (37.3 KW) x (2500 hrs) x (2000 VND/KWhr)

= 186.5 MVND

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Annual Duty Cycle using Drives
100
80
60
40
20
0
%Speed
625 hrs.
625 hrs.
1250 hrs.
100% speed for 25% time
= (37.3KW) x (1.0)
3
x (625) x (2000 VND/KWhr)
= 57.625 MVND
80% speed for 50% time
= (37.2KW) x (0.8)
3
x (1250) x (2000 VND/KWhr)
= 47.616 MVND
60% speed for 25% time
= (37.2KW) x (0.6)
3
x (625) x (2000 VND/KWhr)
= 10.044 MVND
Estimated yearly cost of saving based on use

= 186.5 115.285
Total cost based on duty cycle

= 57.625 + 47.616 + 10.044
= 115.285 MVND
= 71.215 MVND
= 4.522 USD
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PART 4
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Flux Vector Control
Constant Speed
Reference
Set point
Rotary Encoder
Motor
Tacho & Pulse generator
feedback option card
ATV58
Drive
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Motor 1
Motor 2
Motor Switching option
2 Motor performing different
function
Parameter Switching
option card
ATV 58
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Pressure
Sensor
Pump
PI Regulation
Constant Pressure
Gauge
ATV58
Drive
Reference
Set point
Pipe Line
ATV38
Drive
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Automatic catch on the fly with speed retrieval
When the mains supply returns, the product
carries out a speed search and
re-accelerates on the ACC ramp
N
ATV58 & ATV18
acceleration ramp
speed retrieval
without speed retrieval
U
Operating
voltage
t
t
Power Interruption
Operating
speed
ATV58
Drive
ATV38
Drive
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A very complete
basic product
Operator terminal
on the drive or on the enclosure door
5 languages
downloading of 4 files

PC software under Windows 95
Disk upload / down load

Programming terminal
adjust config storage

Program and mornitor by
PowerSuite Software


Catalogued option cards to
suit your needs
I/O extension
multiparameter
pump switching
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Built-in Modbus RS485
communication port
Remotable display unit
ATV58 X 4
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Built-in Modbus RS485
communication port

One dialogue multi-drive
Control by PC or PLC
ATV58
PC
HMI
PLC
X 4
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Fast communication cards
FIPIO ; Modbus + Interbus-S
Profibus DP
AS-I
Device-Net
Can Open
Unitelway
Ethernet
ATV58
Communication
option card
PLC
PC
PLC
ATV31
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Pump Switching Option
Flow Rate
Number of Pumps
PV
PV
PV
PV
P1 P1 P1
P2 P2
P3
PV
P1
P2 P3
Pressure Measurement
ATV 58
Sensor
Power Line
Motor
Starter
Gauge
Flow
Motor
Starter
Motor
Starter
Motor Switching
option card
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Any Questions?