ABB Industry Oy basic3e.ppt 1

Evolution of DrivesD

r

i

v

e

C

o

n

t

r

o

l

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

T

e

l

e

m

e

c

h

a

n

i

q

u

e

A

l

t

i

v

a

r

6

6

C

o

n

t

r

o

l

T

e

c

h

n

i

q

u

e

s

C

D

E

A

l

l

e

n

-

B

r

a

d

l

e

y

1

3

3

6

P

l

u

s

S

i

e

m

e

n

s

M

a

s

t

e

r

D

r

i

v

e

M

i

t

s

u

b

i

s

h

i

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