Jan 06, 2016
ABB Industry Oy basic3e.ppt 1
Evolution of DrivesD
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Time1969 research started
1975 PWM based V/f-control (SAMI A)
1985 PWM based flux vector control (SAMI STAR)
1995 DTC control technology (ACS 600)
1993 ACV 700 drive system
1997 ACS 600 for System Solutions
Fully digital
IGBT technology(1990)
ABB Industry Oy basic3e.ppt 2
Variable speed AC driveskW
8000
3000
1500
1000
315
7,52,2
208 220 415 480 575 690380 460 500 660 2400 3300 7000 V
1600024000
32000
12001000 6000
CYCLO
CYCLO
SAMI MEGASTAR
ACS 600
AC-drive features
ABB Industry Oy basic3e.ppt 3
1. High total efficiency (up to 0,94 over 100 kW)2. Low need for maintenance3. Use in critical environments4. Large power and speed ranges5. No acceleration problems6. Optimized drive packages for each need7. Modular construction8. Driving and braking in both directions9. Constructions for in- or out mounting10. High reliability11. Converter-/motor-voltage 0,2 - 3,3 kV12. Converter-/motor-current 3 - 3000 A13. Frequency 0...50...400 Hz14. Cooling: air, water or air/water
Frequency converter with intermediate DC-circuit
ABB Industry Oy basic3e.ppt 4
Intermediate circuitEnergy storage
Line converterRectifier
V1 V3 V5
V2V6V4
C
L +
-
U1V1W1
M 3Ud
Control electronicscontrol/monitoring/communication
L1
L2
L3
Motor converterInverter
Motor
Monitoring
Control
Line
Power semiconductors
ABB Industry Oy basic3e.ppt 5
V
A
Hz
kW
cm2
voltage
current
frequency
power
chip size
year
THYRISTOR
6000
5000
400
104
80
1960
GTO BIPOLAR TRANSISTOR IGBT FET MCT FETh
4500
4000
1000
104
80
1977
1600
1200
2000
103
>10
1985
1000
10
100000
101
5
1980/90
1600
400
20000
103
>10
1991
4500
50
10000
102
5
1995
3500
50
5000
102
2
1993
Pulse width modulation = PWM
ABB Industry Oy basic3e.ppt 6
==Ud
U2UlineM 3
Uline Ud U2 at 1/2 fmax U2 at fmax
Six-step inverter switching
ABB Industry Oy basic3e.ppt 7
V1 V3 V5
V2V6V4
U
V
WUUV
UVW
UWU
120o180o
0o300o
360o
V1V2V3V4V5V6
180o
360o
Sinus-triangle modulation
ABB Industry Oy basic3e.ppt 8
UsinusUtriangle
U1
U2
U3
switching point
U12 =U1-U2
fundamental wave
Scalar control voltage-frequency diagram
ABB Industry Oy basic3e.ppt 10
= N = constant
= ca. 1/f
Field weakeningrangeU = konstant
U
UN
0 fN f
IR-comp
Constant torquerangeU/f = constant orprogrammedapplication
U = voltagef = frequency = fluxI = currentR = stator resistance
= (f/fN)2
Voltage source and current source inverters
ABB Industry Oy basic3e.ppt 11
V1 V3 V5
V2V6V4
C
L +
-
UdL1L2L3
U1V1W1
L
L1L2L3
L
I
I
VSI:Constant DC-bus voltage
CSI:ConstantDC-bus current
V1 V3 V5
V2V6V4
U1V1W1
ABB Industry Oy basic3e.ppt 12
Block Diagram of DTC
~
M3 ~
Inverter
Rectifier
DC bus
Switch
commands
Optimumpulseselector
Line
Torque comparator
comparator Flux
Torquestatus
Flux
Controlsignals position
Adaptive motor model
Switch positions
DC bus voltage
Motor currentMotor current
Torque reference controller
Actual torque
Actual flux
Actual speed
Internal torque reference
Flux reference controller
U
f
U
f Internal fluxreference
PID
Speedcontroller
+ accelerationcompensator
Torque reference
Speed reference
Flux optimizing
Flux braking On/Off
On/Off
status+
-
DTC core
ABB Industry Oy basic3e.ppt 14
Torque Response
With Pulse Encoder:
DTC 1..5 msecFlux Vector 10 - 20 msec
Closed Loop Flux vector
Open Loop DTC
Torque
Without Pulse Encoder:
DTC 1..5 msecV/f Control 100..150 msec
Speed Accuracy Comparison
ABB Industry Oy basic3e.ppt 16
Sensorless DrivesSensorless Drives
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1
3
3
6
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A
2
4
0
A
B
B
A
C
S
6
0
0Motor:nN = 1440 rpmslipN =60 rpm
150 rpm*
750 rpm*
1500 rpm*
2.33%
0.53%
0.20%
9.00%
0.33%
0.10%
6.20%
1.57%
1.05%
1.66%
0.66%
0.50%
4.00%
0.46%
0.25%
3.00%
0.37%
0.19%
*Average values of 4 different tests
ABB Industry Oy basic3e.ppt 18
Multi Motor Applications
z Voltage, Frequency and Number of Pole Pairs have to be the same- Preferably similar type motors are used
z Greater variance allowed if mechanical connection among motorsz Load of all motors have to be the same
- Problems with rolling tables where the load varies among the motors
z Fixed set of motor- Motors cannot be added or removed without new identification run - Less than 20% variance in cumulative nom. current
z User macros allow two motor set-ups
--> Otherwise scalar control
ABB Industry Oy basic3e.ppt 19
DTC Benefits
Fast torque step rise time 10 times faster torque response than any open loop drive No feedback device required for most applications
Dynamic speed accuracy 8 times better dynamic speed accuracy than any open loop drive Better static speed accuracy than any open loop drive Closed loop static speed accuracy is 0.01%
Reliability Calculates motor state every 25 s with a powerful digital signal processor
(DSP) Immediate response to power loss situations and load impacts Adaptive motor model automatically used if feedback device breaks in
closed loop speed control
Low audible noise Each phase voltage constructed by switching between + and - DC voltage Insulated Gate Bipolar Transistors (IGBT) & high switching frequency Optimized switching - no predetermined switching pattern is followed Heating of the motor is lower compared to PWM
ABB Industry Oy basic3e.ppt 20
SummaryClosed loop control Open loop control
Torque Control
Resolution 1:10000 1:10000Non-linearity 1 %* 4 %*Repeatability 0.7 %* 1.0 %*Torque step rise time 1 to 5 ms 1 to 5 ms
Speed Control
Resolution 1:20000 1:20000Speed range 1:6000 1:3000Static accuracy 0.01 % 0.10 %**Dynamic accuracy 0.2 %s 0.4 %s
* Nominal torque** 10 % of nominal slip