YASKAWA Frequently Asked Questions Date: 15.Sept.

01 Page 1 of 1

Braking Calculation 01

Dynamic Braking Calculation

In some applications the motor works in regenerative mode during deceleration, i.e. the kinetic energy of the machine is fed back into the inverter. This causes a rise of the DC bus voltage. If the fed back energy is too much, the inverter may trip with an overvoltage fault (OV). In this case a DB resistor or a combination of a braking unit and a DB resistor must be used to dissipate the energy as heat. Typical applications where DB resistors must be used are hoist applications like cranes and elevators and applications where the machines inertia is very high like winder, washing machines and so on. General way of DB resistor and braking unit dimensioning 1. Calculation of the maximum braking torque MBmax. The maximum braking torque depends on the speed at deceleration start n1, the speed at deceleration end n2, the desired deceleration time tB and the total inertia of the system Jtot (sum of all inertias regarded to the motor shaft). J (n1 n 2 ) MB max = tot Mload 9.55 t B 2. Calculation of the maximum braking power PBmax. M (n1 n 2 ) PB max = B max 9.55 3. Calculation of the maximum electrical braking power Pel. The braking power calculated in step 2 results of the energy that is fed back from the mechanical system. Because of losses in the motor and the inverter not the whole energy comes back to the DC bus, i.e. the energy that has to be dissipated in the braking resistor as heat is lower than that which comes back from the mechanical system. If a gear is installed some losses in the gear will occur additionally.

Pel = PB max k PrMot (1 Gear ) PB max

The reduction factor k depends on the rated motor power PrMot. Typical reduction factors are shown the following table. Motor Power to 1.5 kW 2.2 kW to 4 kW 5.5 kW to 11 kW 15 kW to 45 kW up from 45 kW Factor k 0.25 0.20 0.15 0.08 0.05

If the gear efficiency Gear is unknown, a value of 1 can be taken. In this case the resulting electrical braking power value will be more on the safe side. 4. Calculation of the maximum allowable braking resistor value RB. The maximum braking resistor value can be calculated as follows: U 2 RB B Pel The selected resistance value should not be higher than this calculated value. UB is the DC bus voltage level at which the braking chopper is switched on. For the internal braking chopper it depends on the power supply voltage and the input voltage setting (constant E1-01 at G5, F7 and G7; see table below). When an external braking chopper is used, it can be selected by jumper setting (for details refer the braking chopper manual).

YASKAWA Frequently Asked Questions Date: 15.Sept.01 Page 2 of 2

Braking Calculation 01

Dynamic Braking Calculation

400V class E1-01 < 400V E1-01 >400V 660V DC +-3% 763V DC +-3% 682V DC +-3% 788V DC +-3%

Inverter Type G5 F7, G7

200V class 380V DC +-3% 387V DC +-3%

Internal braking chopper turn ON level

Note: Make sure that the selected resistance value is not below the minimum connectable resistor value of the braking chopper. Otherwise the braking current will be too high which may result in braking chopper damage. 5. Selecting the braking chopper To select the braking chopper the following data have to be known: - The duty cycle ED - The braking current IB - The braking time tB - The overload curve for the braking chopper The duty cycle ED is the ratio between the braking time tB and the cycle timeT.
speed

n1

n2
time

tB T

t ED = B T

The braking current IB can be calculated using the braking start voltage UB and the selected braking resistor value RBsel. UB IB = RBsel Assuming that the braking torque is constant, the braking power is proportional to the speed. The speed is lowered linearly by the inverter, i.e. the braking power is also lowered linearly (see figure below).
Motor Speed n1

Tdecel

n2

Load Power PBave PBmax

YASKAWA Frequently Asked Questions Date: 15.Sept.01 Page 3 of 3

Braking Calculation 01

Dynamic Braking Calculation

Hence for the selection of the braking chopper the average braking power value PelAve can be used. It is calculated as follows: P PelAve = el 2 Now the braking time tch, that is relevant for selecting the braking chopper is lower than the real braking time tB. It can be calculated as follows: P R P t ch = t B elAve = t B Bsel 2 elAve PelMax VB Using the values for the braking current IB, the time tch and the duty cycle ED together with the braking chopper overload curves the proper braking chopper can be selected.