Section 1 ROL6 Intro PDF

Section 1
INTRODUCTION
TO
SWITCHED RELUCTANCE
MOTOR DRIVE
TECHNOLOGY
LETOURNEAU TECHNOLOGIES, INC.

Copyright 2008
SECTION 1: Page 2 of 34
INTRODUCTION TO SR TECHNOLOGY

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Introduction To Switched Reluctance

Motor Drive Technology
Basic Motor Design
Torque Production
Basic Motor Rotation
Motor Designs
IGBT Switches
Motor Rotation Sequence
Current Control
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The Latest Advances In Industrial IGBT Module Technology
3.0 General Considerations for IGBT Modules
4.0 Using IGBT Modules

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INTRODUCTION TO SWITCHED RELUCTANCE MOTOR DRIVE TECHNOLOGY BASIC MOTOR DESIGN

LeTourneau Technologies has implemented a new and unique generation of motors and motor drives for
mobile mining equipment, called switched-reluctance. The switched-reluctance motor (SRM) utilizes
electro-magnetic principles to produce torque on the rotor of the motor.
The SR motor is a member of the family variable reluctance motors. (Fundamental torque-producing
mechanism). Members of this family of motors include stepper motors.
Reluctance is defined as the resistance of a material to a magnetic field.
The SR motor is operated by switching phases on and off with respect to the rotor angle hence
switched reluctance motor.
SR Motor Core
A switched reluctance motor has a rotor that has no magnets or windings of any kind and is effectively a
piece of shaped iron, creating an arrangement of salient poles (poles that stick out). The rotor can have
various numbers of poles.
The switched reluctance stator is similar to an AC motor stator with multiple salient poles. Each of the
poles contains a separate winding with no overlap between windings, similar to a field of a DC motor.
Some of the outstanding benefits of SR technology include:
The motor is more robust than an AC or DC motor, since there are no coils on any of the moving parts
of the motor.
The rotor inertia is much lower than a DC rotor, giving benefits to gearing life, especially if there is
frequent stopping and starting.
No commutator maintenance - there are no brushes or brush rigging.
Stators are very similar to DC motor field poles.

- Simple to wind and install
- No overlapped phase coils
Smaller than DC motors with comparable horsepower.
Simple and robust electronic controls compared to variable frequency AC.

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High level of fault tolerance.
Continuous low speed torque output of a conventional DC motor
High Speed - high speeds can be achieved, limited only by bearing and electromagnetic timing
constraints.
Low Speed - can operate at low speed providing full-rated torque down to zero speed (for a short
time).
System is four-quadrant and can run forward or backward as either a motor or generator simply by
changing the timing of energizing the coils. The direction of current in the coils does not change.
Can run without rotor position sensor

- Position detection via phase inductance
The idea of an SR motor is not new as the basic idea was developed in the mid 1800s.
1842 locomotive powered by SR motor

Wooden frame (not very stiff!)
Mechanical commutator
No free-wheel diodes (sparks!)
Development overtaken by conventional (analytically linear) motors
Brushed DC Machine
AC Synchronous Machine (inside-out DC)
Teslas Induction Machine

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1842 SR Motor Drive

The technology was finally developed and put to use in the 1970s due to the following advancements
that enabled the control of an SR motor:
Computers to allow design of non-linear systems

Signal-level control
Economic (solid-state) power electronics
The success of switched-reluctance technology has been made possible by today's digital control
techniques. The transistor switches used to energize the stator coils are called IGBTs (insulated gate bipolar transistors). IGBTs are now available in the current and voltage ratings needed for high horsepower
applications. The availability of these devices also paved the way for todays proliferation of AC drives.
However, unlike the AC drives, the SR drive has a motor coil in line with each IGBT. This system
impedance gives more capability to control any type of system fault. Therefore, the shoot-through fault
possible in AC systems is not present, resulting in a much more robust drive. Also, the generally lower
switching frequencies in a SR system result in a more efficient drive.
Various designs of SR motors are possible from a thin pancake to a longer sausage.

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Range of SR Motor Types

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Commercial SR Motor

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TORQUE PRODUCTION
As a stator pole winding is energized, a magnetic force is generated and the rotor pole is forced into
alignment with that stator pole.
Basic Torque Production

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Consider a simple single-phase motor

Phase current sets up a magnetic flux in the
stator
Magnetic attraction will try to turn rotor to its
fully aligned position
Clockwise torque will be produced (green
arrows)
This is principle of a variable reluctance motor
Phase torque is zero at fully aligned position

Rotor position shown gives minimum magnetic
circuit reluctance
Phase inductance is at its maximum
This position is often called top dead center
(TDC)
Phase torque is also zero at fully un-aligned

position
Rotor position shown gives maximum magnetic
circuit reluctance
Phase inductance is at its minimum
This position is often called bottom dead
center (BDC)

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Torque can be reversed without changing

polarity of current
If phase current still flows in the interval after
TDC, and before BDC is again reached,
counter-clockwise torque will be produced
(Orange arrows)
If the rotor is still rotating clockwise the torque
is braking the load.
Positive or Negative torque is obtainable simply
by changing the timing of winding excitation
Operation as a switched reluctance motor

Energizing at the correct angle
Assume Clockwise rotation
Rotor is shown at BDC
Get clockwise torque once rotor as turned past
BDC
If the phase is switched on before BDC the
rotor will see counter-clockwise or braking
torque
Ideally switch on at BDC (not before) in order
to maximize motoring torque.
De-energizing at the correct angle
When TDC is reached the instantaneous
torque falls to zero.
Get counter-clockwise or braking torque when
the rotor turns past TDC unless the phase
current is switched off.
Ideally switch off at TDC to maximize motoring
torque.

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Inductance vs. Rotor Position
Propel Torque vs Rotor Position

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Braking Torque vs. Rotor Position
Maximum Torque Position point on rotor pole close to point on stator pole

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Maximum Torque Position multi pole motor 18/12
BASIC MOTOR ROTATION

The following pages show examples of motoring and braking sequences in a simple SR motor. The
following graphic shows the definitions for CW (clockwise) and CCW (counterclockwise) as used in the
descriptions.
CW (clockwise) Rotation
CCW (counterclockwise) Rotation

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For motoring torque the phases are energized over the increasing inductance region.
Example of motoring sequence:
1) CW rotation, No torque
2) CW rotation , No torque
4) CW rotation, CW torque

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8) CW rotation, no torque

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An SR motor can also be operated as a brake or electrical generator.
Exact opposite of motoring operation

Braking torque is produced when rotor and stator poles are being pulled apart by the rotating
inertia of the rotor when inductance is falling.
Switch phase current ON at TDC (ideally)
Switch phase current OFF at BDC (ideally)

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Example of braking sequence:
2) CW rotation , No torque
4) CW rotation, CCW torque

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Flux flow in Basic SR Motor

The coils are wound so that one is N and one is S. Flux will flow from N to S across the rotor when the
rotor is aligned with the poles. The flux returns via the one piece lamination structure of the stator.

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MOTOR DESIGNS
Some Basic SR Pole Configurations

A wide number of SR motor designs are possible depending on the requirements of the application. A
small sample of the various combinations of rotors and stators that can be used as is shown in the
drawing above. In all cases (except for the simple 1 phase design) the stator will have a greater number
of poles than the rotor.
Some Basic SR Phase Configurations

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Various phase combinations are also possible. In this case Phase refers to the number of groups stator
poles that are energized at the same time.
A single phase motor as used in the previous example only produces torque half the time. It requires
special arrangements to ensure starting such as a parking magnet but it is a good design for high speed
applications such as fans or vacuum cleaners.
Poly phase motors are useful for industrial applications and can be 2, 3 or 4 phases. The poly phase
motors allow starting and produce smoother torque. The phases are energized so that they overlap.
For the examples shown previously the assumption was used that the phase currents could be turned on
and off instantaneously. In practice this is not true and the control circuits have to do more work to
compensate.
The time for the rise and fall of current and magnetic flux are limited by the design of a given motor. The
control system must be calibrated to a specific motor type.
This means that when the coil is first energized there will be a slight delay before the current and
magnetic flux reach their operating values. When the coil is de-energized the flux and current will persist
for a period of time.
This effect is minimal at low speeds. The delays become more significant as the speed rises. The control
system will vary the turn on and turn off angles in order to maintain the best torque and efficiency.
IGBT SWITCHES
The current to the stator coils is controlled by using IGBTs. The IGBT transistor has two states ON or
OFF like a switch. The IGBT switches cannot be operated partially on or partially off or they will be
severely damaged (nearly immediate failure).
IGBT Schematic
IGBT Simple Schematic
IGBT with Diode typical for

this application
IGBT diode protection

The internal diode on each IGBT switch serves two purposes. When the IGBT switch is on, the diode is
used to protect the switch against reverse voltages. When the IGBT switch is off, the diode on the unused
IGBT switch becomes a freewheel diode providing a path for the dissipation of the residual inductive load.

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IGBTs ON
In the above illustration the IGBTs are on and their respective diodes are solely used as reverse voltage
protection. The diodes on the unused IGBTs are ignored by this circuit.
IGBTs OFF
In the above illustration the IGBTs are off and the diodes in the unused IGBTs now act as freewheel
diodes allowing residual inductive load to dissipate.
Why two IGBT switches are used
As the rotor aligns with the energized stator pole, the stator is de-energized by turning the two IGBT
switches off and another stator is energized by turning on the appropriate IGBT switches. In order for the
rotor to continue its rotation, the original stator pole must de-energize (de-flux) rapidly so that it does not

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impede the rotation of the rotor, this is accomplished by allowing the inductive load to dissipate through
the two IGBT freewheel diodes.
As with any inductive load, the current in the stator coil tends to keep flowing and cannot be stopped
instantly when the IGBT is opened. The IGBT is protected from damage by the parallel diode. When
power is applied by the bus to the coil, the polarity will match the bus as shown in the previous diagram
IGBTs ON.
When both of the IGBT switches are opened (see previous illustration IGBTs OFF), the coil will now
become the source of the energy and the polarity on the coil will be reversed. However this reversed
polarity is now connected to the bus via the freewheel diodes. The 600V bus that is opposite to the
induced coil voltage will cause the current in the coil to decay very quickly to 0V. If only one IGBT switch
were used, the decay would be slow and the rotation speed of the rotor would be limited.
IGBTs Technical Specifications
For more information on IGBTs and how they work, please refer to the attached documents provided by
PowerEx. These documents explain the inner workings of the IGBTs and how the compare to BJTs and
FETs.
IGBT Switches
An individual IGBT die such as is shown in the following pictures is capable of about 75A. Many small
IGBTs are used in parallel in order to get the rated capacity of the IGBT module.
A typical IGBT module design as used in the L/D-950 and newer L-1350 machines is shown below. The
IGBTs are the small silver dies as indicated the arrow.
IGBT Module Package
IGBT Module - with top removed
The early L1350 used a different design IGBT module that is integrated with a heat sink. Many different
types of IGBT module packages are available.

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IGBT Modules
The coils in the SR motor are controlled with two IGBT modules. There is a HIGH SIDE IGBT switch
connected between the + bus and one side of the SR motor coil. There is a LOW SIDE IGBT switch
connected between the bus and the opposite side of the SR motor coil. The converter also consists of
diodes for freewheeling and discharging energy in the coils and bus capacitors for storing energy on the
DC bus.

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IGBT Schematic
Rotation is achieved with the sequential energizing of stator poles. The rotor will follow this sequence,
trying to align with the energized stator pole. However, as alignment is almost achieved, that pole turns
off and the next pole comes on. The switched-reluctance motor makes these torques continuous by
turning on the next pole before the previous one is turned off. This consecutive switching of the stator
pole currents ensures the poles on the rotor are continually being attracted by the magnetic field created
by the stator winding current. The torque is achieved by creating flux, which is a function of the current
through the winding and the characteristics of the iron. Sensor-less technology has been developed via
advanced software algorithms so the position of the rotor can be determined without external sensors.

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MOTOR ROTATION SEQUENCE

Illustration "MOTOR ROTATION AND TRANSISTOR SWITCH SEQUENCE" shows a simplified
sequence of pole energizing and rotor movement. Note that a 6/4 (6 stator poles and 4 rotor poles) SR
motor is shown for simplification.
The highlighted IGBT switches are ON, energizing the attached pole coil.
The rotor is coming into alignment with the energized pole.

Motor Rotation and Transistor Switch Sequence (Sheet 1 of 2)

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As the rotor comes into alignment with the energized pole, it turns OFF, and allows
the coil energy to freewheel back into the bus.
At the same time the next pole in the sequence is energized, continuing the rotor
rotation.
Motor Rotation and Transistor Switch Sequence (Sheet 2 of 2)

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CURRENT CONTROL
At low motor speed the current is controlled by chopping or turning the IGBT on and off in a rapid
controlled manner to maintain the commanded current level.
Slow Speed Motoring Waveform close up showing hysteresis chopping

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As speed increases the current waveform changes from chopping to angle control.
High Speed Motoring Waveform

In the braking mode the stator coils are switched on behind the rotor poles inverted left to right as shown
in "HIGH SPEED BRAKING WAVEFORM.
High Speed Braking Waveform

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Current Waveform Chopping Mode
Current Waveform Angle Control Mode

The changeover from chopping to angle control happens seamlessly during operation of the motor.
Chopping occurs at lower speeds and angle control at higher speeds.

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Changeover from Chopping to Angle Control

The best method for each torque and speed is determined by the characterization of the SR motor.
Characterization is the initial testing of a motor over its entire torque and speed range. The control is
optimized at each point. This is referred to as the characterization curve for a motor. This is based on
the physical motor type. It has to be redone whenever there is a change to the electrical characteristics
of the motor (lam material, lam pole shape, coil type, coil turns, etc. This information is then programmed
into the SR code that is loaded into the drive module.
Example of Typical Characterization Chart

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Section 1

LETOURNEAU TECHNOLOGIES, INC.

LETOURNEAU TECHNOLOGIES, INC.

Introduction To Switched Reluctance

Basic Motor Design

Basic Motor Rotation

Motor Rotation Sequence

Powerex Vendor Documentation

The Latest Advances In Industrial IGBT Module Technology

3.0 General Considerations for IGBT Modules

4.0 Using IGBT Modules

LETOURNEAU TECHNOLOGIES, INC.

LETOURNEAU TECHNOLOGIES, INC.

INTRODUCTION TO SWITCHED RELUCTANCE MOTOR DRIVE TECHNOLOGY BASIC MOTOR DESIGN

No commutator maintenance - there are no brushes or brush rigging.

Stators are very similar to DC motor field poles.

Smaller than DC motors with comparable horsepower.

Simple and robust electronic controls compared to variable frequency AC.

LETOURNEAU TECHNOLOGIES, INC.

High level of fault tolerance.

Continuous low speed torque output of a conventional DC motor

Can run without rotor position sensor

1842 locomotive powered by SR motor

LETOURNEAU TECHNOLOGIES, INC.

1842 SR Motor Drive

Computers to allow design of non-linear systems

LETOURNEAU TECHNOLOGIES, INC.

Range of SR Motor Types

LETOURNEAU TECHNOLOGIES, INC.

LETOURNEAU TECHNOLOGIES, INC.

Basic Torque Production

LETOURNEAU TECHNOLOGIES, INC.

Consider a simple single-phase motor

Phase torque is zero at fully aligned position

Phase torque is also zero at fully un-aligned

LETOURNEAU TECHNOLOGIES, INC.

Torque can be reversed without changing

Operation as a switched reluctance motor

LETOURNEAU TECHNOLOGIES, INC.

Inductance vs. Rotor Position

Propel Torque vs Rotor Position

LETOURNEAU TECHNOLOGIES, INC.

Braking Torque vs. Rotor Position

LETOURNEAU TECHNOLOGIES, INC.

Maximum Torque Position multi pole motor 18/12

BASIC MOTOR ROTATION

CCW (counterclockwise) Rotation

LETOURNEAU TECHNOLOGIES, INC.

LETOURNEAU TECHNOLOGIES, INC.

Example of motoring sequence:

10) CW rotation, No torque

11) CW rotation, CW torque

12) CW rotation, CW torque

LETOURNEAU TECHNOLOGIES, INC.

Example of motoring sequence:

13) CW rotation, CW torque

14) CW rotation, No torque

15) CW rotation, No torque

16) CW rotation, no torque

An SR motor can also be operated as a brake or electrical generator.

Exact opposite of motoring operation

LETOURNEAU TECHNOLOGIES, INC.

Example of braking sequence: