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Product Training

Drive Inverter MOVIDRIVE


Basic of Drive Systems
I2
Preface

These documents have been prepared to supplement the information provided in the training. However, the
combination of exercises followed by proposed solutions means that they are also suitable for private study.

These documents supplement the documentation available from SEW. They have been prepared as conscientiously
as possible. We do not accept any liability for mistakes. Equally, we cannot accept liability for any damage or follow-
on damage resulting from mistakes.

Please do not hesitate to contact the authors if you have any questions or suggestions.

Persons responsible: DriveAcademy Product Training +49 7251 75-3911

Meaning of icons used in the workbook:

Operating instructions

Important information

Special tip

Procedure for diagnostics and troubleshooting

Practical exercise

Reference to additional documentation

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Content

1. Basics of Drive Systems 1


1.1 Comparison of Different Drives 2
1.2 Characteristic Curves for Different Drive Systems 3

2. Basics of Asynchronous Motors 4


2.1 Design and Theory of Operation of an AC Asynchronous Motor 4
2.2 Working Principles of an Asynchronous Motor 5
2.3 Torque Characteristic Curves of an AC Asynchronous Motor Run on the Mains 8
2.4 Nameplate 9
2.5 Important Relationships for an AC Asynchronous Motor 10
2.6 Features of an AC Asynchronous Motor in Mains Operation 11

3. Basics of Frequency Inverters 12


3.1 Power Section of a Frequency/Drive Inverter 12
3.1.1 Supply System Rectifier 13
3.1.2 DC Link Circuit 13
3.1.3 Inverter 13
3.1.4 IGBT 15
3.2 Functional Description of the Frequency Inverter Principle 16
3.3 Use and Function of the Brake Chopper 17
3.4 4-Quadrant Operation 17
3.5 Power Recovery 19

4. Basics of Asynchronous Motors Connected to Drive Inverters 21


4.1 Introduction to the V/f Characteristic Curve 21
4.1.1 Overview of V/f Characteristic Curves 21
4.1.2 Influence of the Frequency on Rated Torque and Breakdown Torque 23
4.2 50 Hz Characteristic Curve with fmax = 70 Hz 24
4.3 87 Hz Characteristic Curve with D Connection 26
4.4 Features of an AC Asynchronous Motor in Inverter Operation 29
4.5 Speed Control 30

5. Control Modes 31
5.1 Non-Field-Oriented Systems 31
5.2 Field-Oriented Inverter Systems 31
5.3 Voltage-Frequency Controlled Field Orientation for Asynchronous Motors 32
5.4 Current-Controlled Field Orientation 32
5.5 V/f without Speed Feedback 33
5.6 V/f with Speed Feedback 34
5.7 VFC without Speed Feedback 36
5.8 VFC with Speed Feedback 38
5.9 CFC with Speed Feedback for Asynchronous Motors 39
5.10 CFC with Resolver for Synchronous Servomotors 42
5.11 Differences Between Voltage/Frequency and Field-Oriented Systems 44
5.11.1 Voltage/Frequency-Controlled, Field-Oriented Systems 44
5.11.2 Voltage/Frequency-Controlled Systems 45
5.11.3 Field-Oriented Drive Systems 46
5.11.4 Current-Controlled, Field-Oriented Systems 46
5.11.5 Torque Rise Times 47

6. Notice 48

Indexverzeichnis 49

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1. Basics of Drive Systems


Objective: The participant is familiar with the different drive systems.
He or she is aware of the demands placed on a drive system by various applications.

The combination of frequency inverters and AC drives has steadily pushed the inverter-fed DC motors
out of the market. This was made possible due to the development of more powerful microprocessors
and power transistors.
At SEW-EURODRIVE, we differentiate between frequency inverters and drive inverters. In principle,
both devices are frequency inverters, but MOVIDRIVE is referred to as a drive inverter. The reason for
this differentiation is the high level of functionality that is implemented in the system. In contrast to the
MOVITRAC31C frequency inverter series, the MOVIDRIVE drive inverters work with field-oriented
control modes. In this way, AC asynchronous motors can achieve levels of dynamic performance and
control quality that were previously only possible using or DC motors servo drives.
In addition, several drive inverters can also be networked using a system bus that is available as
standard. This capability enables fast data exchange between the units.
The integrated IPOSPLUS positioning and sequence control program enables you to control
sequences of motion directly on the inverter, in close proximity to the motor.

The following documentation only deals with the DC link circuit inverter type (U-inverter). This
group is the most important for the power range from 0.5 kW to 100 kW.

2 1. Frequency/drive inverter
3
1
2. AC motor
(here: asynchronous motor)
3. With or without speed feedback after
selection of the control mode

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1.1 Comparison of Different Drives

Property AC asynchronous AC asynchronous Servomotor


motor motor with servo
with frequency with drive inverter controller
inverter
System V/f control Field-oriented: Field-oriented
- Voltage controlled
- Current-controlled
Maintenance on None None None
motor
Weight/power* 100% ~100-150% ~170%
Control range 1:20 open-loop 1:100 open-loop 1:3000
1:200 closed-loop 1:800 closed-loop *2

1:5000 *1 *2
Temporary load 1.5 * MN 1.6 * MN 3 * M0
capacity
3 * MN to 2/3 frated or to
3 * MN
from n=0 to nmax
Wear Low Low Low
Dynamics * 100% ~400% ~500%
SEW amplifier 0.37kW - 45kW 1.5kW - 90kW 0.30kW -
11/30kW
Price System-dependent

*1 Current or torque-controlled field orientation with high resolution sin/cos encoder


*2 Full torque to standstill (intermittent overload up to three times the rated value)

* The properties Weight/power and Dynamics are always dependent on the motor design,
especially for the DC motor, e.g. enclosure

The reference value is the maximum power that can be drawn from a corresponding motor. Based on
its dimensions and weight, the field-oriented control mode, for example, can be used to make
significantly better advantage of the asynchronous motor. In this way, the Weight/power factor also
increases in this case compared with the same factor for the V/f control mode.

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1.2 Characteristic Curves for Different Drive Systems

A complete drive comprises the prime mover (motor) and the driven machine.
The electric motor, which creates a torque that changes depending on the speed, is usually
depicted using a speed/torque curve.
The driven machine resists this motor torque M with a load torque at the same speed.

The following diagrams depict the different speed/torque characteristic curves of driven machines.
These characteristics influence the drive selection.

M n
P
The following applies: 9550 , with P [kW], M [Nm], n [min-1]

1 Md = constant Md ~ n Md ~ n
Md ~ n
P = constant P~n P ~ n P ~ n
P Md
P Md
Md
Md
P P

GRD010.DRW

Winding drives, Hoists, Calender with viscous Pumps,


spindle drives, conveyor belts, friction, fans,
for: rolling mills, eddy-current brakes centrifuges
facing, planing machines,
rotary cutting processing machines

Md = Continuous torque

If you make a distinction between the motor torque and the load torque, a higher motor torque, with
regard to the power, accelerates the drive system and a lower motor torque decelerates it.

The driving motor is predominantly responsible for:

Startup
Rated operation
Speed control
Braking

Note on project planning:

To select the correct drive size, the load and acceleration torque required by the motor must be
compared with the available motor torque.
To do so, you have to consult the motors torque characteristic curves, which are available in the
respective motor catalogs.

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2. Basics of Asynchronous Motors


Objective: The participant is familiar with the most important physical relationships and features of an
asynchronous motor.
He or she knows how an asynchronous motor functions during supply system operation.

2.1 Design and Theory of Operation of an AC Asynchronous Motor

Design An AC asynchronous motor consists of the main components stator and rotor.

Stator The stator consists of a housing, stator core and stator


winding. The stator winding is distributed over the entire
area and, in contrast to a DC motor, does not have any
salient poles. The winding is housed in the grooves of the
laminated iron stator core.

Winding The winding is made up of three sections which are offset by 120, 60, 30
etc. depending on the number of poles. The starting ends of the windings
have the designations U1, V1 and W1. The other ends have the
designations U2, V2 and W2. The windings can be connected in a star or
delta connection.

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Rotor Only squirrel-cage rotors are considered here. The rotor is the rotating
part of the motor. It is located in the stator and designed with two rings
and short-circuit bars made of aluminum, copper, brass or bronze. The
rings and bars create a squirrel-cage winding. An air gap is created in the
motor between the stator and the rotor. This air gap is an essential
feature in the theory of operation and working principle of the motor.

2.2 Working Principles of an Asynchronous Motor

Note 1 If an electric conductor is moved in a permanent


magnetic field at speed v, with the magnetic field
N
lines cutting the conductor at right angles, a
voltage Uind is induced in the conductor.
The induction voltage can be increased by using
- higher speeds, more conductor loops or by
generating a higher magnetic field.
v However, the basic requirement of induction is
movement of the conductor in the magnetic field
or a fundamental change of the magnetic field
+ compared with the conductor.
A force F on the charge carriers in the conductor
pushes these carriers (electrons) in one
V direction. This causes an excess of charge
S carriers (negative terminal) at one point in the
conductor and a lack of charge carriers (positive
terminal) in another. This charge carrier
displacement or potential difference can now be
measured as voltage.

Note 2 Each current-carrying conductor is surrounded


by a magnetic field. The magnetic field always
moves in a clockwise direction around the
conductor, looking in the direction in which the
current flows.
Several conductor loops are grouped together to
form a coil. The magnetic field lines within this
coil generate a magnetic field (principle of the
relay or contactor coil).
Using a magnetic material as the coil or winding
form can increase the strength of the magnetic
field.

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Effect of notes 1 and 2 on the behavior of an asynchronous motor:

The stator In principle, the stator of the asynchronous motor consists of three coils that are wound around a
ferromagnetic transformer stator core.
The coil ends can be connected in STAR or DELTA connection.
When the device is switched on (power supply operation, e.g. in star connection), an inrush
current I flows through the coils. A magnetic field is created in each coil.
When all three magnetic fields are added together, a magnetic field is generated in the stator. This
magnetic field rotates continuously at 50 Hz (3000 rpm).

The rotor The rotor of the asynchronous motor is designed as a cylindrical cage (squirrel cage rotor).
Individual bars are embedded in slots in the rotor iron and short-circuited at each end by conducting
rings.
When the motor is switched on (mechanical speed = 0 1/min), the magnetic field of each bar
changes to 3000 1/min, i.e. a maximum rate change.
In this case, the maximum voltage is induced in each bar. A short-circuit current flows directly over
the short-circuit ring through the rotor bars. Each current-carrying conductor is surrounded by a
magnetic field.
When the individual fields of the rotor are added together, the rotors magnetic field results.

Stator magnetic field

Rotor magnetic field


50Hz

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The motor After the magnetization phase, the motor has two magnetic fields. The stator field acts across the
air gap and couples to the rotor. The stator field is faster initially and it pulls the rotor field up to its
speed. The rotor then begins to turn. In this way, the relative rate of change between the rotor and
stator decreases. Less voltage is induced, less short-circuit current flows, the rotor field becomes
weaker.
When the rotor speed is equal to the stator frequency, the relative rate of change = 0. As a result,
the rotor slows as the magnetic force no longer has an effect. A relationship is created between the
rotor speed and stator frequency, depending on the load on the motors output shaft. This
relationship is known as slip. Slip is required to generate torque in the asynchronous motor.
Induced voltage is greatest when the rotor is at a standstill. As an asynchronous motor is essentially
a transformer with a shorted winding in the secondary circuit, this also explains the high current
consumption when the motor is at a standstill. (Maximum induction voltage Maximum secondary
short-circuit current, therefore maximum current consumption in the primary circuit.)

Stator Leakage Leakage Rotor


resistance inductance 1 inductance 2 resistance

Short-circuit
Air gap
Magnetizing
Primary side inductance

The stator resistance represents the ohmic losses of the copper windings. The leakage inductance
represents the magnetic losses in the rotors iron core. The main inductance magnetizes the motor.
The magnetic flux is transformed into the rotor across the air gap. The rotor also has magnetic and
ohmic losses because it is a real electrical conductor (aluminum), a conductor loop.

Magnetic The motor is designed for a fixed voltage/frequency ratio (V/f-ratio). This ratio is determined by the
field supply system at the place of installation. If this voltage/frequency ratio exceeds this determined
Air gap value (voltage is too high in relation to the frequency), the motor is overmagnetized. If the frequency
is too high in relation to the voltage, the motor is undermagnetized.
If the motor is undermagnetized, it is weakened and can no longer output the rated torque. In this
case, it would be possible to overload the motor.
If the motor is overmagnetized during normal operation, it will overload, which causes the motor to
overheat. Both over and undermagnetization can cause irreparable thermal damage to the motor.
The magnetic field rotates in the air gap. It is induced by the stator coils. A rotating field system with
a symmetrically rotating magnetic field is created by using the three phases (three windings). The
resulting magnetic field creates the voltage in the rotor to generate rotational movement. With
power supply operation, a constant magnetic field is created depending on the coils and the coil
resistances. It also results in a load-dependent magnetic field in the rotor. The stator field and rotor
field are coupled across the air gap.
This voltage/frequency ratio can be influenced by using a frequency inverter.

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2.3 Torque Characteristic Curves of an AC Asynchronous Motor Run on the Mains

MA is the start-up torque of the motor when rated voltage and rated frequency are applied at a standstill.
MK is the breakdown torque. It is the highest torque rating that the motor can output when the rated
voltage and rated frequency are applied.
MN is the rated torque of the motor. It develops when the motor is run at the rated frequency, rated
voltage and rated load.
The nominal data is listed on the nameplate of the motor. This data specifies the optimum operating
point of the motor for power supply operation.

The relationships between the motor torque or current consumption and the speed are defined by
characteristic curves. The different rotor designs or windings result in specific characteristic curves.

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2.4 Nameplate

DT 71D4 / BMG / TH / HR / AV1H / IS

Integrated plug connector


Hiperface absolute encoder
Manual release for brake
TH/TF Temperature sensor
BR/BMG brake
DT/DV Foot-mounted motor
71mm Height
4 pole

The designation could looks as follows for a gearmotor:

K67 DT 71D4 / BMG / TH / HR / AV1H / IS


Helical bevel gear unit

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2.5 Important Relationships for an AC Asynchronous Motor

Stator f 60 f = Frequency
speed n sync p = Number of pole pairs
p

Rotor f (1 s) f = Frequency
speed n 60 p = Number of pole pairs
p s = Slip

Slip n sync n
s
n sync

Slip n s n sync n
speed

Slip ns p
frequency fs
60

The slip speed of the motor is specified on the nameplate, in the motor data sheet or in the motor
catalog.

Voltage U= 2 km f kM = Machine constant


f= Frequency
= Magnetic flux

The relationship between the magnetic flux and the current is important for the torque that the motor
can output. If the flux and current remain constant, the torque is also constant.

This results in the requirement:

U
cons tan t 4.44 k M
f

However, since kM is also a constant factor, this leads to the following direct relationship:

U
M M cons tan t
f

Torque for an AC asynchronous motor

M I

In the rated slip range, the torque is virtually proportional to the current and the magnetic flux.

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The speed of an asynchronous motor can be controlled by:

Changing the slip


- Dropping resistors in slip-ring motors
- Return of energy from the rotor into the supply system
- Change terminal voltage
Changing the number of pole pairs Pole-changing motor
Changing the applied frequency Drive of frequency inverter

2.6 Features of an AC Asynchronous Motor in Mains Operation

An AC asynchronous motor is very robust, practically maintenance-free and is the most cost-effective
solution when compared to other electric motors. The operating characteristics in mains operation,
depending on the rated power PN and the number of pole pairs, are:
High starting current IA (3.5...7 x IN)
High run-up torque MA (2...3 x MN)
Load-dependent speed n (slip values: 2...8 % or 30...120 rpm speed drop at MN, relating to 1500
rpm 4-pole motor)
Permitted torque overload capacity between 1.6 and 1.8 x MN. At higher load, the danger of the
motor stalling increases, the motor speed collapses and the maximum temperature limit will be
reached in a short time (10 ... 30 s)
Limited starting frequency (thermally permitted number of switch-ons per hour) is dependent on the
mass moment of inertia
Stalling torque Mstall 2.2...3 x MN

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3. Basics of Frequency Inverters


Objective: The participant gets to know the principle design and function of the SEW frequency/drive
inverters.

He or she is familiar with the options for realizing 4-quadrant operation.

SEW-EURODRIVE basically manufactures frequency or drive inverters with DC link circuits; that is, the
energy is stored in a capacitor. However, there are also inverter systems that work with a so called
current source DC link. These systems store energy through inductance.
The following section refers to inverter systems with capacative energy storage.

3.1 Power Section of a Frequency/Drive Inverter

Three-phase mains input DC link IGBT inverter


uncontrolled rectifier
B6 circuit

T1 T2 T3

L1 1
C
L2 2

L3 3
T4 T5 T6

eLEIST_1.DRW/OE

4 5 6

Three-phase asynchronous
motor

Mains connection: Terminal 1, 2, 3, phase sequence does not have to be taken into account.
Motor connection: Terminal 4, 5, 6, note direction of rotation. The motors direction of rotation can
be altered by changing the phases.

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3.1.1 Supply System Rectifier

The supply system rectifier comprises a non-controlled, three-phase bridge connection. The rectifier
converts the mains AC voltage into a (pulsatin) DC voltage. This is then smoothed by the DC link
capacitor.

=
6 UStr = 6 230V 563V
_ _
U = 1,35 * UNetz U = 1,35 * 400V = 540V
L1
L2 , U
L3

3.1.2 DC Link Circuit

Low- Modern three-phase inverters are not fitted with DC link capacitors.
capacity DC
link This fact enables lower in-rush currents and more favorable mains perturbation values to be achieved.
Such inverters can be recognized by the fact that their mains input current is lower than the output
current.

Advantage: No charging connection required and smaller units are possible due to the low DC link
capacity.

Disadvantage: Lower energy buffer for power supply fluctuations and faster cut-out speeds for short-
term system voltage drops.

3.1.3 Inverter

The inverter comprises three bridge branches each consisting of two transistors and two diodes. It
converts DC link voltage into three-phase pulsating output voltage.

Creating sine-evaluated control voltages for the inverter valves

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US Umsc haltpunkt IZ

t
T1 T2 T3

U1 UZ

t
U2 T4 T5 T6

t U12

U3
U2
t
U12
UZ U1 U3

t
Grundschwingung

Control To create sine-evaluated control voltages for inverter valves, a variable sinusoidal reference voltage is
voltage compared with a triangular auxiliary voltage for each inverter line. This is a digital process. The different
sinusoidal reference signals are stored in a table memory (EEPROM) and are read out and processed
by the microcontroller depending on the setpoint. The transistors of the inverter are switched on or off at
the points where the triangular voltage meets the sinusoidal reference voltage. If the triangular voltage
is higher than the sinusoidal voltage, the output pulse is negative (-UZ/2). If it is lower, the pulse is
positive (+UZ/2). In this way, in each bridge branch, either the upper or lower transistor is activated.
Depending on the switching status of the individual bridge branches, either the positive or negative pole
of the DC link voltage is applied at the windings. The effective total voltage results when the individual
voltages applied at the windings are superimposed.

Free- As high induction voltages occur in the inductive output load at the point of switchover, freewheeling
wheeling diodes are connected in parallel to each transistor. Driving voltages occur in the winding inductances
diodes caused by self-induction when a switch is opened. These voltages force the motor currents to continue
to flow in the same direction over the freewheeling diodes. Without these diodes, the switching
elements would be destroyed due to the high inductive voltages in the winding inductances. The
reactive power required for the motor is also covered by the freewheeling diodes.

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Course of the current that develops in the motor inductances:

Soll-Strom

Obere Toleranz

Untere Toleranz

+Uz

-Uz

3.1.4 IGBT

The inverter is fitted with IGBTs (Isolated Gate Bipolar Transistors). These transistors standardize two
transistor technologies. The IGBT is a combination of bipolar transistor technology and field-effect
transistor technology. The idea behind this concept was to use the advantages of the two systems
whilst removing any disadvantages.

The transistor is controlled via a high-resistance gate (MOS technology) like a field effect transistor.
This enables the transistor to be controlled using a low amount of power.
The current path (collector-emitter path) is designed using bipolar technology. Therefore, the CE path is
subject to very low resistance when it is fully activated. Lower forward losses lead to lower power loss in
the transistor. The IGBT is a metal oxide silicon (MOS) component and very sensitive to static charges
and discharges (ESD).

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3.2 Functional Description of the Frequency Inverter Principle

Communications eGRD008.DRW

Inputs/Outputs Control electronics


Monitoring & Control
Setpoint values

A B C
1 4
2 B6
5
M
3 6 3~
PE

asynchronous
Rectifier DC link Inverter
motor

A B C

V mains 1,35 * V +V
V mains Z
VZ

The input voltage (A) is rectified by the rectifier and stabilized using a capacitor ( DC link circuit).

The inverter converts the DC link voltage into a pulsating, cyclic form. The procedure is based on the
sine-evaluated pulse width modulation (sine PWM).

The form of the pulsed output voltage is dependent on the required output frequency. The Fourier
analysis shows that the pulsed output voltage of the inverter has the same effect on the asynchronous
motor as a sinusoidal voltage of the same amplitude and frequency.

All these aspects are regulated by the control electronics. Modern frequency inverters, like those from
SEW, are controlled fully digitally. The motors rotating field, communication, setpoint processing and
sine-evaluated PWMs are created and processed digitally.

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3.3 Use and Function of the Brake Chopper

Three-phase mains input DC link IGBT inverter


uncontrolled rectifier
B6 circuit

T1 T2 T3

L1 1
C
L2 2

L3 3
T4 T5 T6

eLEIST_1.DRW/OE

4 5 6

Three-phase asynchronous
motor

4Q A brake chopper, in conjunction with a braking resistor, enables 4 quadrant operation for a drive
operation system with an inverter; that is, the motor can be operated and decelerated in both directions.

The kinetic energy available in a driveline after it has been accelerated is stored in the DC link capacity
during the deceleration procedure and then converted to thermal energy.

3.4 4-Quadrant Operation

M
energy flow
II. quadrant I. quadrant
nmot generator mode motor mode energy flow
nmot
M M

Counter-clockwise clockwise
(braking) (driving)
n
energy flow motor mode generator mode
nmot energy flow
nmot
M M
Counter-clockwise clockwise
(driving) (braking)
III. quadrant IV. quadrant

This perspective refers to the driving motor, not the load that the motor has to drive or decelerate.

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Driving diagram
v

t
Braking diagram

Pbrake

Error Lim it DC Link

BRC ON

BRC OFF

Vz

t
P at braking resistor
Pv

eGRD011.DRW

If a drive system is decelerated using a current speed v, the kinetic energy stored in the system must be
fed back and converted. During the deceleration process, this braking power flows into the DC link via
the inverters output stage in the form of a regenerative current. The DC link voltage increases during
this process. When the UZ reaches a specific point (BRC ON), the braking resistor is activated. DC link
energy is reduced via the resistor and the voltage decreases until it reaches the specified switch-off
threshold. The kinetic energy is then converted into thermal energy, except for a small amount.

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3.5 Power Recovery

Power recovery is the term used for returning energy to the supply system during multi-quadrant
operation. Instead of converting the energy, which the regenerative drive feeds back to the inverter, to
heat, the power is fed back phase-synchronously to the supply system using a power inverter. This is
only possible by changing the direction of the energy flow. The braking resistor must be replaced by a
regenerative power supply module. The DC link of one or more units must be coupled with this module.
When the DC link voltage increases to a specified value, the DC voltage in the DC link is fed back into
the supply system amplitude and phase-synchronously using a power inverter.

Regenerative power supply unit Inverter unit


Inverter

Rectifier Inverter

L1
L2 Vz M
L3

eNetzRSp/04.10.01

The regenerative power supply unit and frequency inverter are separated in the MOVIDRIVE inverter
range.
The regenerative power supply unit supplies the DC link with energy for motor operation. Up to six
inverters (MOVIDRIVE) can be connected to one regenerative power supply module without a
damping module.
The inverter itself is not connected to the supply system. The DC link of the inverter is supplied directly
with the voltage Uz of the regenerative power supply module. This takes place via a rectifier in the
power supply system.
When the motor is run using regenerative operation, power recovery takes place via an inverter that is
connected in an inverse-parallel connection to the rectifier. The rectifier works phase-synchronously to
the supply system. In this way, when t = 0 the phase in the three-phase system with the highest voltage
value is detected. Energy is now fed back to the supply system phase-synchronously. The system
commutates to the next phase when the voltage of this phase exceeds the voltage of the initial phase.

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Comparison of power recovery and brake chopper operation

You must decide which procedure is most suitable for a particular application by considering the
properties of the two components.

Power recovery Brake chopper + braking resistor

Accommodation Separate regenerative power supply Brake chopper integrated in


module inverter, braking resistor must
be installed externally.
Effect on ambient Max. permitted operating Heat generation through BR
temperature temperature
Wiring Medium Low
Costs Medium Low
Energy balance Electrical energy remains virtually Electrical energy is converted to
unchanged thermal energy
Expenditure for Line filter Shielded cables required to BR
EMC
Commutation to Line choke required Not applicable
supply system
Use When: One braking resistor per inverter
- Power demands are high pro
- A BR cannot be used

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4. Basics of Asynchronous Motors Connected to Drive Inverters


Objective: The participant is familiar with the behavior of an asynchronous motor when it is connected to a
drive inverter.
This section creates the theoretical basis to avoid errors during project planning or startup.

V/f mode The voltage/frequency mode (V/f mode) is the most well-known method for adjusting the speed of an
asynchronous motor infinitely using a frequency inverter. A very simple characteristic curve (V/f curve),
based on the physics of the motor, is used to select the motor phase voltage for the corresponding
frequency of the three-phase voltage system. This ensures that the motor is neither undermangnetized
nor overmagnetized.

In principle, a similar curve exists for field-oriented systems. This curve is derived from the physics of
the motor and stored in a motor model. Therefore, some research and development is required for field-
oriented systems to modify and adapt the simple V/f characteristic curve for this motor model to
ensure that the curve is fully compatible with the motor.

As a result, the principle of the V/f characteristic curve must first be explained to be able to understand
the relationship between the individual components when the field-oriented systems are considered
later on.

4.1 Introduction to the V/f Characteristic Curve

As we have seen, an AC asynchronous motor provides a constant torque if it is receives a constant


magnetic flux and a constant current.

This is achieved by
1. A constant V/f ratio (constant flow)
2. As constant a load as possible (this is not usually the case)

The flux is constant when the voltage / frequency ratio remains constant (V/f = constant).

Example: Motor data 230/400 V 50 Hz star connection,


Voltage 400 V, f = 50 Hz V/f = 8

Therefore, if the motor is operated at 5 Hz, a voltage of 40 V must be set (ideal value; losses are not
taken into account here).

4.1.1 Overview of V/f Characteristic Curves

Basic The simplest characteristic curve:


setting The maximum voltage (usually = rated motor
range voltage) is achieved / set at the rated frequency.
Two parameters are required so that the inverter
recognizes these values: Motor voltage and rated
frequency (the rated frequency is also referred to as
the base frequency).
The maximum frequency (speed) here is fN.
Constant torque from "0" to fN.

This range is known as the basic setting range.

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Field There are cases where the European motor


weakening frequency of 50 Hz is not applied, for example,
range America has 60 Hz supply systems and
consequently also 60 Hz motors. Therefore, it must
be possible to adapt the base frequency to run the
motors with their rated data. However, if a 50 Hz
motor is run with a 60 Hz characteristic curve, the
available torque is reduced in linear form across the
entire frequency range from 0 to (in this case) 60
Hz.

Constant but reduced ( 50


60
0,83) torque from "0"
to fN (UN50=UN60)

This extended range is known as the field


weakening range.

V/f The maximum speed of the motor must be able to


curve be set beyond the rated speed. This is achieved by
introducing a new parameter: nmax. This is the
most frequently used V/f characteristic curve today.
From 0 to fN (fbase) there is a constant ratio of V
and f (basic setting range), above the value fN
there is a constant voltage and increasing / variable
frequency for higher speeds.

Constant torque from "0" to fN. Beyond this


value, reduced by 1f (voltage characteristic curve).

Which V/f characteristic curve you use depends on the operating situation and application. They
can be set individually on the inverter.

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4.1.2 Influence of the Frequency on Rated Torque and Breakdown Torque

You can see clearly from the curve that the breakdown torque reduces quadratically as the frequency
increases. As a result, the maximum frequency cannot be increased to any speed the user chooses
when operating a standard motor at 50 Hz or 60 Hz. Otherwise, the motor (without pull-out protection)
could simply stall. Real, absolute maximum frequencies are approximately 2 x fNmotor depending on
the drive and the load. The internal current limit is reduced automatically in the field weakening range
for SEW frequency inverters to protect that motor from stalling.

The curve characteristics described above are based on the physics of asynchronous motors. This
means that the basic setting range and field weakening range also have to be taken into account for
field-oriented systems.

The following sections give examples of using different frequencies or speeds in inverter operation.

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4.2 50 Hz Characteristic Curve with fmax = 70 Hz

For the MOVIDIRVE drive inverter, these settings are made using the startup function. Frequencies
are used in this application description so that it is easier to understand in relation to the V/f
characteristic curve description. The speeds are given in brackets for a 4-pole motor.

Several special features have to be considered when selecting the gearmotor and drive inverter to be
used with a hoist. For more information on this topic, please refer to the diverse documentation
available from SEW.

The following example shows the effects and advantages of the 50 Hz characteristic curve with fmax =
70 Hz (2100min-1) for hoist operation. For the MOVIDRIVE drive inverter the rated frequency of the
motor is only entered during startup. All other data is given by entering speeds.

The example shows two possible gearmotor combinations. The demand is, of course, that the output
speed must remain the same. The gear unit reduction ratio is changed in the ratio 70/50 (2100/1500):
25.49 x 70/50 = 35.7 i = 35.95. The power remains unchanged.

50 Hz characteristic curve 70 Hz characteristic curve


Gearmotor in catalog i=25,49 i=35,95
na=55 na=39
R82DT100L4

GRD005.DRW GRD005.DRW

Catalog data (at 50 Hz) P= 3kW

na = 55 min-1 na = 39 min-1
Ma = 520 Nm Ma = 735 Nm
i = 25.49 i = 35.95
Torque at "0" ... 50 Hz 520 Nm 735 Nm
Torque at 70 Hz (371 Nm) 520 Nm
nmax: 55 min-1 at 50 Hz 55 min-1 at 70 Hz

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Advantage of the 50 Hz characteristic curve with fmax = 70 Hz:

M, U

2,50 x M N

M Kipp ~1/f M

M 140

MN
M 100
UN
U
0,72 x M N
M

0 AS/GRD006.DRW
50 70 f [Hz] 0 AS/GRD009.DRW
n [1/min]
fN 39 55

Below 50 Hz, a constant flux and therefore 100 % rated torque (constant) is available for the motor. Due
to the different gear unit reduction ratio, the output torque of the motor is 1.4 times higher in comparison
with the 50 Hz characteristic curve with fmax = 50 Hz. This is a big advantage particularly during
startup.
The 50 Hz characteristic curve with fmax = 70 Hz is therefore suitable because it offers optimum
reserves and the gear unit can be selected accordingly.

This characteristic curve can also be used for trolleys. However, in many cases, the 87 Hz /
characteristic curve has often proved to be a good solution.

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4.3 87 Hz Characteristic Curve with D Connection

One option to increase the motor utilization is to use a delta connection with fbase = 87 Hz. This can
only be realized using the following constellation (or a comparable one):

Supply voltage Motor voltage Inverter output voltage


/
230 V 127 V / 230 V 3 x 230 V
400 V 230 V / 400 V 3 x 400 V
500 V 290 V / 500 V 3 x 500 V

The working principle can be explained using an example.


The inverter has a rated input voltage of 400 V. Here, it is not important whether the supply system is a
single-phase or 3-phase system. The motor is wound for a voltage of 230 V / 400 V /, 50 Hz. The
following settings are made on the inverter on the basis of this data:

Motor voltage = 230 V, rated motor frequency = 50 Hz; Motor is connected in delta.

(At the maximum output voltage, a frequency of 50 Hz x 3 = 87 Hz is output.)


By switching the motor from star to delta connection and changing the motor voltage from 400 V to

230 V during startup, the motor develops 3 times the power at a frequency of
87 Hz. However, due to the increased losses (iron, fan and mechanical losses) and the higher thermal
load that results, SEW recommends that you only make use of the utilization with the listed motor of the
next higher power level.

Example: Motor DT 100 L4 with listed power PN = 3 kW


Voltage = 230 V / 400 V /, current = 11.4 A / 6.6 A /, at 50 Hz

Increased power with connection and fbase = 87 Hz: 3 kW 3 = 5.2 kW (intermittently)


Usable continuous power in S1 operation and setting range 1:10,
4 kW with thermal classification F (150 C).

4 kW because the motor in the next higher power level has 4 kW.
In this way, the motor still has 4/3 = 1.33 times the power compared with the rated power.

Selecting an inverter for delta operation

Due to the increase in current when switching from star to delta connection, an inverter with a higher
power level must also be selected. .
The inverter must be able to output the power with which the motor is operated.

Example:

The previous motor is operated with a MOVIDRIVE in:

connection, S1 operation with MDF/MDV 60A 0030 (3 kW, output current 7 A)


connection, S1 operation with MDF/MDV 60A 0040 (4 kW, output current 9.5 A)
connection, S3 operation with MDF/MDV 60A 0055 (5,5 kW, output current 12.5 A)

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S3 operation (or other permitted duty types) must be selected carefully during project planning to
ensure that the machine is not subject to thermal overload, especially at low speeds (note setting
range).

Star connection and frated = 50 Hz, motor voltage = 400 V

Frequency inverter Motor M, V, P


I
MN
Vmains V Vphase
P N V mains V,P

0,57 x M N
M
eTP87.DRW_1

0 fN f
3 x fN 2 x fN
eTP87.DRW_3

Inverter with motor in star connection Operating characteristics for type point 50 Hz

The relationships between the frequency, torque, voltage and power can be seen in the above
illustrations. From "0 Hz" to fN, the torque is constant. Above fN the power is constant and the torque
decreases reciprocally as the frequency increases.

Delta connection and motor voltage = 230V (fbase = 87 Hz)

The following requirements must be met initially for delta connection:

The V/f ratio must stay the same


The rated power must be available

It is easiest if we consider the system with 50 Hz again. If the V/f ratio is to remain the same, the
connection must also have the same phase voltage (230V) as the connection when the frequency is
the same.
As U = Ustr for the connection, this is also the voltage that the inverter has to output. Therefore, the
type point is changed internally and automatically from 50 Hz to 87 Hz. In this way, at 230 V is output at
50 Hz and 400 V is output at 87 Hz.
This specification is prepared for the MOVIDRIVE inverter during startup. The user has to enter the
voltage that the inverter should output at 50 Hz (therefore, 230 V). The inverter calculates the 87 Hz
characteristic curve itself.

M, V, P
Frequency inverter Motor
Gain
I MN
I phase
V
3 x P N V main s V,P
Vmains
Vphase
M
PN
M50
eTP87.DRW_2

0 fN 3 x fN 2 x fN f
eTP87.DRW_4

Inverter with motor in delta connection Operating characteristics for type point 87 Hz

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Keeping the same V/f ratio and connection type ensures that the motor can still output its rated power at

50 Hz. However, this output can only be achieved when the current is 3 times higher.

Proof: When the motor is connected in delta and fbase = 87 Hz, the following conditions apply (for an
output frequency of 50 Hz):

The voltage applied at the motor is 230 V, = phase voltage. As the phase voltage at 50 Hz is the same
for star and delta connection, the same current also flows through the windings at the rated load (IStr =
6.6 A).

The following applies: U = UStr = 230 V, I = 3 IStr

The power is calculated from: P50 = 3 U I cos ,

P50 = 3 230 V 3 6,6 A cos = 3 kW or

at 87 Hz: P87 = 3 400 V 3 6,6 A cos = 5.2 kW

This leads to increased current consumption, which must be provided by the inverter also for 50 Hz.

If the output frequency is increased, the power is also increased to 3 times the value for 87 Hz. This
is because the torque remains the same as the V/f ratio in the machine is unaltered. The machine only
enters the field weakening range above this value and the torque decreases.
The phase voltage does increase to 400 V at 87 Hz, but SEW motors are designed to withstand
increased levels of voltage, so this does not cause any disadvantages.

Advantages There are three advantages of increased motor utilization.

1. An existing drive can be operated with a higher setting range and faster speed. As the gear unit has
to transmit more power, you must check to see whether this is possible using the same unit.
2. Higher torque and increased setting range than when fbase = 50 Hz because the gear unit
reduction ratio i is increased.
3. Instead of a 4 kW motor with star connection and fbase = 50 Hz, a gearmotor with 3 kW listed
power and changed i in delta connection with fbase = 87 Hz is used.
Advantage: Smaller motor.

Disad- A disadvantage is that the inverter might have to be changed because it has to output more power. In
vantage our example with a DT 100 L4, a 4 kW inverter is sufficient when the system is operated with 4 kW
power and the corresponding torque, in accordance with the SEW project planning guidelines.
However, note that with other permitted duty types, e.g. S3 operation, the full power/current can be
required, which means that the inverter is operated on the current limit. This may cause the inverter to
switch off and record the fault continuous overload or n-monitoring. You can prevent this by using a
5.5 kW inverter.

Comment This could give the impression that increased motor utilization is the best solution. However, the
majority of drives are run normally. The reasons behind this are: Speed-dependent losses in the gear
unit and noises in the gear unit and motor.

Further restrictions apply to hoist operation. Emergency mode, i.e. motor on the supply system is only
possible with reduced rated power and by changing the connection type from to .

The motors themselves represent an additional limitation. From specific voltage/power ratios, the
motors can no longer be designed due to the wire diameter and number of windings.

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For more details on project planning, refer to the section for project planning for inverter-fed AC drives
in the Drive Engineering Practical Implementation, Vol. 5 documentation.

4.4 Features of an AC Asynchronous Motor in Inverter Operation

Running an AC asynchronous motor on a MOVIDRIVE drive inverter instead of MOVITRAC,


improves and, to a certain extent, extends the features. The following features apply to a
motor/frequency inverter combination with an adjusted power rating and with a drive inverter that is
started and operated in accordance with the instructions.

Current limitation can typically be set up to 1.5 x IN.


Torque can be set by current limitation of the inverter.
Precise torque control when using the current-controlled mode (CFC).
Simple startup functions for all control modes provide ideal conditions for the drive systems.
Control modes can be switched.
Continuous calculation of a motor model for VFC and CFC operating modes.
No load-dependent deviation from speed from nN, in specific setting range, due to high quality of
slip compensation for VFC.
Danger of the motor stalling is avoided by monitoring functions in the frequency inverter.
Starting frequency considerations are no longer relevant in inverter operation, because the motor is
always operated in the stable characteristic range with max. 1.5 x IN.
Setting range of the speed is typically up to about 1...100 in VFC mode and 1...250 in VFC with
speed control depending on the maximum speed and rated motor power. A setting range of 1:3000
is possible for the CFC control mode. (Ventilation conditions at low speeds restrict continuous duty
fan cooled/forced cooling).
Possible disadvantage: Motor may develop increased noise if the maximum frequency is above 50
Hz (due to the fan wheel) and when the PWM frequency is in the audible range.
Positioning operation is possible.
Phase-synchronous operation of several drives is possible.
Extensive control options are available.

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4.5 Speed Control

The properties of an AC asynchronous motor operated on a drive inverter can be improved significantly
using speed control.
Prerequisites for speed control on MOVIDRIVE units:

Control card with speed detection (MDV)


Encoder mounted on motor (resolution 512, 1024, 2048, / TTL, HTL technology or sine/cosine
encoder)
Set the operating mode with speed control
For servo systems: MDS control card with connection to the resolver available as standard on the
motor.
Startup and optimization of the speed controller

The following properties can be improved by using speed control:

The setting range of the speed, here control range, has been increased from 1:200 to at least 1:800
(encoder resolution 1024). (Based on n = 3000 1/min). Up to 1:5000 is possible for CFC control
mode (only with sin/cos encoder).
The load-dependent deviation of the speed (static control accuracy) has been improved from
13 % to < 0.05 % based on nN and a step change in load M = 80 %.
The recovery time for changes in load (control dynamics) is reduced from ca. 0.5 2 s to ca.
0.1 0.3 s for a step change in load M = 80 %. (The time data is dependent on the drive unit).
The torque and its consistency can be significantly increased below fbase as the motor is provided
with the optimum input voltage based on the calculation of the motor model, which means that more
current is available.

In addition to the extension of the control range, which now comes close to the properties of a
controlled DC motor, the increase in torque that can be achieved is also a very interesting aspect. If a
motor is run with the corresponding frequency inverter, it can even reach higher intermittent torque than
is possible with mains operation (up to 3 x Mrated is possible).

Various operating modes and controller settings are required to achieve different operating
characteristics or to realize a number of applications with one device (inverter). The physics of the
asynchronous motor described in section 5 were utilized by the V/f controller systems.
The MOVIDRIVE inverter series has various field-oriented control modes. The design is based again
on the physics of the asynchronous motor has described previously. The operating characteristics of
the motor should be improved significantly by using field-oriented control modes. The performance that
can be achieved by using standard asynchronous motors sets new standards in automation technology.

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5. Control Modes
Objective: The participant learns about the different control modes.

The systems can be divided into non-field-oriented and field-oriented systems with or without speed
control. This section gives the participant a basic overview of the systems.

5.1 Non-Field-Oriented Systems

V/f mode As a non-field-oriented mode, V/f is the common method for motor control. See section 5.1 ff. This
system can be operated as a controlled and/or as a speed-controlled system.
For speed-controlled V/f drives, the speed consistency and the torque rise times are improved
significantly. However, for this type of voltage-controlled drives, a motor model is not used to calculate
the active current, phase voltages, magnetization etc. As a result, the temperature of the motor may be
higher in the lower speed range, for example. It is difficult to realize operating modes, such as torque
control, and they are then very inaccurate.
However, this type of inverter/motor system is suitable for a large number of applications.

5.2 Field-Oriented Inverter Systems

Field orientation means that two existing magnetic fields are oriented against each other.

Field orientation is the same for asynchronous motors and servomotors. However, the physics of the
different motor types plays an important role. Field orientation is already used for servo controllers. In
this case, the resulting stator field is aligned with the permanent-field of the rotor. The orientation data is
supplied to the system via a sensor (resolver).
For the field orientation of asynchronous motors, a greater number of physical parameters must be
taken into account to ensure constant magnetization of the rotor similar to a servomotor.

Field-oriented systems have very good torque rise times and develop a very high dynamic and speed
consistency. Current-controlled field-oriented systems can be used to calculate and apply the current
used to create torque exactly. Synchronous servomotors achieve very high dynamic properties due to
the rotors low internal mass moment of inertia.

Field-oriented systems for asynchronous motors can be divided into systems with and without speed
feedback and current and voltage-controlled field orientation. The difficulty with these systems for
asynchronous motors is to maintain constant magnetization of the rotor in order to create the virtually
the same behavior as for a synchronous servo system based on this magnetization.

As explained in section 3.1, the rotor of the asynchronous motor is not magnetic. Therefore, a
calculation model has to be used. This enables the user to calculate the rotor magnetization exactly on
the basis of a number of system parameters after a brief transient phase once the system has been
switched on. Once the resulting magnetic field is known, it can be oriented with the stator field.

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5.3 Voltage-Frequency Controlled Field Orientation for Asynchronous Motors

VFC SEW-EURODRIVE has developed the VFC (Voltage Flux Control) control mode for this type of field
orientation. This mode is implemented as the standard control mode in the MOVIDRIVE frequency
inverters. The VFC mode can be used as a sensorless mode or as a mode with speed feedback. It
supports standard asynchronous motors. Both variants increase the dynamic properties, ensure the
motor does not get too hot at low speeds and optimize performance as exact motor models and phase
voltages can be calculated.

5.4 Current-Controlled Field Orientation

CFC The CFC (Current Flux Control) control mode has been developed for this type of field orientation. This
mode is available in the MOVIDRIVE frequency inverters when the MDV control card is installed. The
mode must be selected at startup.
The CFC mode requires an incremental encoder (not sensorless) and supports standard
asynchronous motors from SEW-EURODRIVE.
Synchronous servomotors can also be operated in CFC mode, but they must be fitted with a resolver
system. Two control cards are offered. There are differences in the speed feedback evaluation for
asynchronous and synchronous motors.
Both systems provide the same high dynamic properties. However, in comparison with the servo
system, the current-controlled field orientation for asynchronous motors offers a higher power range for
dynamic applications. Servo systems still offer higher dynamic properties due to the low mass moment
of inertia and slim-fit design of the rotor.

The following section gives a brief system overview of the control modes for SEW frequency inverters.
The description starts with V/f control and runs through to current-controlled field orientation for
asynchronous motors.

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5.5 V/f without Speed Feedback

Power section

Current detection
BW

V mains~ M~
BRC

Unit


control
Iact
Three-phase system
PWM-MODULATOR
Vz on
off
Vxset
BRC control t V
Vact
Pulse-
width
modulation t

fset Vact (voltage amplitude)


Iext. Iint.
Motor control
V
Imax
Ia ct Im a x ? Iact Vm ax
Iact
'Boost'
fset , if Iact Im a x 'IxR'
IsI t

until Iact = Im a x
Pull-out protection* V/f fundamental
f
+10V characteristic curve
with 'boos t' + 'IxR'

f set fmax f set


fset m ax f set
max
nset f set

n set t
Ramp generator

By specifying a speed setpoint (here: potentiometer), the assignment of the maximum frequency is
used to determine the corresponding three-phase field setpoint frequency.
The setpoint frequency assigned to the speed setpoint is limited or controlled via the ramp generator.
The pull-out protection device influences the ramp generator. It stops or reduces the frequency once it
has reached the current limit, in order to prevent the asynchronous motor from pulling out.
Voltage is supplied to each new output frequency of the ramp generator via the V/f characteristic curve.
The output frequency of the ramp generator and the voltage level of the V/f curve are input values used
to generate the three-phase voltage system. The pulse width modified voltage pulses for controlling the
inverter in the PWM modulator are created from the setpoint frequency and voltage level via a voltage
phasor. The energy for the drive is taken from the DC link circuit fed by the supply system and is made
available to the motor via the inverter.

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5.6 V/f with Speed Feedback

Power section

Current detection
BW

Vmains~ M~
BRC

Unit
control


Iact
Vz on
of f Three-phas e s ys tem
t PWM-MODULATOR
BRC Control
Vx set
V => f act
Vact
Pulse-
width
modulation t
fsoll V act (voltage am plitude)
V
Vm ax
fslip

'Boost'
'sxR'
'IxR'
f
Iext. V /f fundam e ntal characte ris tic curve
w ith 'Boost' + 'IxR'
Iint. Iact
M otor control

f s et
I max Speed controller
f s et
Iact Imax ?
Current
lim iter
+10V fset fset
fmax Controller
fslip
fset max f set m ax feed
forward
nset
f set PI - +
Slip
lim itation
- controller +
nset Ramp generator t
fact

A suitable three-phase setpoint frequency is determined by specifying a speed setpoint. The setpoint
frequency assigned to the speed setpoint is limited or controlled via a ramp generator. The actual speed
is adjusted to the speed setpoint via a PI controller. The correcting variable of the speed controller
creates the setpoint slip frequency of the motor. When this value is added to the actual frequency, the
actual setpoint frequency fsoll results for the motor control and the three-phase voltage system.
When the specified current limit is reached, the current limitation restricts the slip controller. 1.5 times
the slip is the maximum correcting variable that can be set. This function ensures stable operation.
In the motor control, the voltage level is determined via the V/f curve for the frequency fsoll. It can be
adapted dynamically depending on the value of fschlupf. The pulse width modified voltage pulses for
controlling the inverter in the PWM modulator are created from the setpoint frequency and voltage level
via a voltage phasor. The energy for the drive is taken from the DC link circuit fed by the supply system
and is made available to the motor via the inverter.

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Brief description of the speed controlled

ENCODER
M~ The speed control function requires the current
actual speed supplied via speed feedback. The
encoder required for this process is usually
designed as an incremental encoder. An
incremental encoder supplies square-wave
encoder signals, which are usually available in 2n
=> fact graduations (standard value 1024).

Speed controller
f s et SPEED CONTROLLER
Input values of the speed controlled generate the
Current
lim iter
desired speed setpoint and the actual speed of
the motor, which is determined from an
C ontroller
fslip incremental encoder signal. The speed
fe ed differential is calculated by subtracting the actual
fo rward speed from the setpoint speed. This value is
transferred to a PI controller, which creates a
fset PI - +
Slip
kind of setpoint slip frequency so that that speed
lim itation
- controller + differential is controlled as near to zero as
possible. If the setpoint changes are large, an
f act acceleration feedforward supports the PI
controller. This allows the control speed to be
increased.

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5.7 VFC without Speed Feedback

Power section

Current detection
BW

Vmains~ M~
BRC

Unit
UPWMact(u,v,w)
control


Iact
Vz on Three-phas e s ys tem
of f
PWM-MODULATOR
t
BRC Control
Vxset
V
Vact
Pulse-
width
modulation t

f act V act (voltage am plitude)


Motor control
fact Vact
Voltage setpoint calculation
f set
f ist f set' Pull-out
Imax
Iext. +
Vact(u,v,w)
protection

iq
Vo l ta g e f slip fslip -
Vact a m p l i tu d e ca l cu l a ti o niq
Iact
ist
ca l cu l a ti o n
Vact
iq
Motor
Flux
Iist I max
model
model
Iact

I max
+10V
nset nmax nset fset
nsetmax nsetmax Iext. Iint.
Vnset nset Zp

nset/V Ramp generator t


-10V

The setpoint speed assigned to the analog setpoint value speed is limited or controlled via a ramp
generator.
The speed of the drive is simulated within the system. To do so, the calculated slip speed (calculated by
detecting the active current; the active current is proportional to the torque and slip) is subtracted from
the PWM frequency (= stator frequency).

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The motor control calculates the exact magnetization using a flow model. This results in a vector of the
magnetic field in the rotor. The motor model calculates the new active current for the current load state
of the motor. The slip and actual frequency required for the voltage amplitude calculation is derived
from this value.
The pull-out protection function corrects the frequency fsoll so that the set current limit cannot be
exceeded. The slip frequency fschlupf corresponding to the motors load state is added to this
frequency. On the basis of this slip compensation, the motor speed results using the required setpoint
speed.
A continuous voltage phasor is generated from the setpoint frequency and the voltage level. This is then
converted to control signals for the output stage in the PWM unit.

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5.8 VFC with Speed Feedback

Power section

Current detection
BW

V mains~ M~
BRC

Unit
Control


Iact Encoder evaluation
Vz on Three-phase system Speed
of f nact
PWM-MODULATOR
t
BRC-Control Vxset
V
Va ct
Puls-
width
modulation t

f act Va ct (vo l ta g e a m p l i tu d e )
Motor control fact V act
Voltage setpoint calculation

Iext. nact
Iint. Iact f ist f synchr on
+
Zp n act
Voltage
V a ct amplitude

Imax
calculation
fslip set fslip set
Iact Imax ?

+10V n set n set


nmax
Zp
Controller
feed
nsetmax nsetmax forward
Vnset nset Slip
-
PI controller
+
limitation nslipset

nset/V Ramp generator t nact


-10V
Speed controller

The setpoint speed assigned to the analog speed setpoint is limited or controlled via a ramp generator.
The speed controller compares the setpoint speed with the actual speed, creates the control differential
and, if there is a deviation, adjusts the setpoint speed using the slip frequency. The actual setpoint
frequency results. The speed controller is identical to the one used with the V/f system.

The torque demand is determined by the output value of the N controller = slip. The motor control
creates the actual frequency from the actual speed and the slip frequency. The magnetization is the
rotor is also calculated. The voltage amplitude for the PWM is determined from the actual frequency
and the slip frequency.
The pulse width modified voltage pulses for controlling the inverter in the PWM modulator are created
from the setpoint frequency and voltage level via a voltage phasor. The energy for the drive is taken
from the DC link circuit fed by the supply system and is made available to the motor via the inverter.

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5.9 CFC with Speed Feedback for Asynchronous Motors

Power section

Current detection
BW

Vmains~ M~
BRC

Unit
control


Iact
Encoder evaluation
Vz on En- Rotor
Speed
of f Three-phase system coder pos ition
t
BRC Control Pulse-
width- PWM-MODULATOR
modulation

V xset
Motor control
Ixset PI
- controller
Current controller Vx set
Ia ct
Iu set Ivset Iwset
Current setpoint calculation
Motor

Iext. model
Iint.
Iu,v,w set
Phase
current id Flux nact
nact
calculation

I max
model Mse t
iq I M s et
Iset > I max ? M

Speed controller

+10V nset nset


nmax Controller
feed
nsetmax nsetm ax forward

nset nset PI +
Current
lim itation
- Controller
Mse t
n set/U Ramp generator t nact
-10V

The setpoint speed resulting from the analog speed setpoint value is limited or controlled via a ramp
generator.
The actual speed is adjusted to the setpoint using the speed controller so that the speed differentials
are kept as close to zero as possible.
The motor control creates the torque-creating iq and the magnetizing current id resulting from the output
value of the speed controller (torque). This is used as the calculation basis for the phase current
calculation. The field angle is calculated with the rotor position angle and the setpoint phase currents
are calculated from these values. These values are then formatted in each phase in a common voltage
vector using a current controller.
( see following description)
A three-phase voltage system is generated in the PWM modulator from the direct voltage vector of the phase
current calculation.

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Component description

ENCODER
M~ The actual speed has to be detected via an
encoder for the CFC control mode for motor and
speed control. This can either be an incremental
encoder (square-wave encoder signals) or a
sine encoder (sinusoidal encoder signals). An
incremental encoder provides a maximum
position resolution of 8192 steps (with 2048
graduations) per motor revolution. In this way,
the signals of a sine encoder can be evaluated
so that a position resolution of 262144 steps per
revolution. This means that the controller
Encoder evaluation properties of the speed controller can be
En- Rotor dimensioned more exactly when using an
Speed
coder pos ition incremental encoder.

Speed controller SPEED CONTROLLER


Input values of the speed controller build the
Controller required setpoint speed and the actual speed of
feed the motor, which is determined from the
forward encoder signal. The control differential is
created by subtracting the actual speed from
nset PI +
Current
lim itation the setpoint speed. This value is transmitted to
- Controller
Mse t a PI controller, which generates a setpoint
torque so that the speed differential is kept as
nact close to zero as possible. If the setpoint
changes are large, an acceleration feedforward
supports the PI controller.
The output value is not a slip speed as with
VFC, but the setpoint torque that is limited by
the current limit.

Motor control
MOTOR CONTROL
Ixset PI The motor control has the task of supplying the
- controller
Vx set setpoint torque as quickly as possible from the
Current controller
Ia ct speed controller to the motor shaft. The motor
Iu set Iv set Iwset control comprises the current setpoint
Current setpoint calculation calculation and the current controller. The
Motor
current setpoint calculation determines the
model required phase currents from the setpoint
Phas e
nact torque Msoll, actual speed nist and rotor position
Iu,v,w current id nact
angle . The current controller adapts the actual
set
calc ulation Flux
model Mse t
iq I M s et
currents of the rotor as accurately as possible to
M the required setpoint currents.

The new feature here is that when an


asynchronous motor is used, a connected, very
fast, digital current controller applies the phase
current and therefore the torque. In this way, the
smallest deviations in the rotor position
(detected from the rotor position angle) can be
corrected. Torque control is also possible now.

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Current setpoint calculation CURRENT SETPOINT CALCULATION


Motor

The motor control calculates the current
model required to create torque iq from the setpoint
Iu,v,w
Phase
current id nact torque of the speed controller. The current
set Flux nac t
calculation
model Mse t requires to create the magnetic field id is also
iq I M set
calculated. The actual speed of the motor is the
M basis for this calculation in the flux model. The
magnetic field is constant for speeds below the
base speed. Above this point, it is reduced due
to the limited output voltage of the inverter (field
weakening). In the motor model, the
corresponding slip frequency is calculated from
the currents iq, id and the motor data. This
frequency and the rotor position angle build
the field angle . This then determines the
frequency of the three-phase voltage system.
The phase current calculation generates the
setpoints of the three phase currents from the
model values iq, id and the field angle.

Motor control CURRENT CONTROLLER


Ixset PI
Input values of the current controller create the
- controller
Current controller Vx set required current and actual currents of the
I a ct motor phases. The current differential is
calculated by subtracting the actual currents
from the respective setpoint currents. These
values are transmitted to a PI controller, which
generates phase voltages so that the current
differential is kept as close to zero as possible.
The three phase voltages are grouped together
as a phase voltage vector.

THREE-PHASE VOLTAGE SYSTEM



The voltage vector U soll together with the
amount and angle position comprise the three
components for the three phase voltages. The
Three-phase system voltage vector is processed in a pulse width
Pulse- modulator. The modulator generates switching
width- PWM-MODULATOR signals for the power transistors from the three
modulation components of the voltage phasor according to
the principle of pulse width modulation.
Vxset

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5.10 CFC with Resolver for Synchronous Servomotors

Power supply

Current detection
BW

V mains~ M~ R

BRC

Unit


control
Iact
Resolver evaluation
Vz on En- Rotor Speed
of f Three-phase system
Coder pos ition
t Puls-
BRC Control PWM-MODULATOR
width-
modulation

U xso l l
Current controller

Ixset PI-Controller Vxset


-
Ia ct
I uset Ivset Iwset
Iext. Current setpoint calculation
Iint.
P h a se id = 0
Iu,v,w set cu rre n t
Ms et
iq
Imax ca l cu l a ti o n I
M
Isetl Imax ?
Motor control
Speed controller

+10V nset nset Controller


nmax feed
nsetm ax nsetmax forward

nset nset PI controller + I Current


lim itation
- Ms et
ns et/U Ramp generator t nact
-10V

The setpoint speed resulting from the analog speed setpoint value is limited or controlled via a ramp
generator.
The actual speed is adjusted to the setpoint using the speed controller so that the speed differentials
are kept as close to zero as possible.
The motor control generates the current required for the torque from the output values of the speed
controller. The phase currents are calculated with the rotor position angle. These values are then
formatted in each phase in a voltage vector via a current controller. In this way, the currents required to
create torque can be adjusted in the motor.
The servo system has always been a field-oriented system.
A three-phase voltage system is created in the PWM modulator from the voltage vector. The output
stage is controlled with the PWM pulses that are generated.

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Component description

RESOLVER
M~ R The resolver is the integrated encoder system
of a synchronous motor or a servo system. The
absolute position of the rotor (rotor position
angle ) is detected using a resolver. It creates
two sinusoidal voltages offset in phase by 90.
The period of this AC voltage corresponds to
one motor revolution. In this way, the resolver
evaluation can determine the position of the
rotor. The resolution of this position is
dependent on the maximum speed required.
Up to a maximum speed of 300 rpm, a
Resolver evaluation resolution of 16384 steps is possible. 4096
En- Rotor Speed steps are possible with higher maximum
Code r pos ition speeds.

CURRENT LIMITATION
Iext.
Iint. The actual current (Iist) is measured in the motor
phases and compared with the current limitation
Imax. If the apparent current is higher than the
Imax current limit, the output of the speed controller is
influenced by restricting the setpoint torque.
Iset Imax ?
Lowering or restricting the setpoint torque
ensures stable motor operation.

MOTOR CONTROL
The motor control has the task of supplying the
setpoint torque as quickly as possible from the
speed controller to the motor shaft. The motor
control comprises the current setpoint
calculation and the current controller. The
current setpoint calculation determines the
required phase currents from the setpoint
torque Msoll and the rotor position . The current
controller adapts the actual currents of the
motor as accurately as possible to the specified
setpoint currents.
The user does not have to make sure that the
rotor is provided with constant magnetization.
The rotor of the synchronous servomotor is
magnetized permanently by magnets.

CURRENT SETPOINT CALCULATION


The motor control calculates the current required
to create torque iq from the setpoint torque Msoll of
the speed controller. The current required to
generate the magnetic field is given to zero
because a constant magnetic field is created by
the permanent magnets on the rotor. The phase
current calculation generates the setpoints of the
three phase currents from the model value iq and
the rotor position angle. Current controller and
PWM unit are identical to the CFC for
asynchronous motors.

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5.11 Differences Between Voltage/Frequency and Field-Oriented Systems

5.11.1 Voltage/Frequency-Controlled, Field-Oriented Systems

Principle system response to a step change in load

Torque

Step change in load

Response

After a sudden change in the load torque, the required, constant shaft torque is set at the shaft with
minimum vibrations after a short torque rise time.

Voltage/frequency-controlled field oriented systems are designed for stationary continuous power. The
advantage compared with V/f systems is the continuing calculation of the motor model. Whether with or
without speed feedback, the motor voltage and slip (slip compensation) are calculated precisely and
adapted to the load state. This is the reason for the improved features of the VFC mode compared with
the V/f mode.

Advantages of the VOLTAGE FLUX CONTROL mode

Static speed accuracy is a tenth of the slip or less than 1 % or the rated speed.
At least 150 % torque up to 0.5 Hz.
Less power consumption in part-load operation due to optimum, adapted magnetization of the
motor. This factor also ensures lower thermal load.
High tightening torque independent of the motor temperature because the stator resistance is
measured.
Highest dynamic properties due to torque rise times of around 5 10 ms.
Smooth speed curve thanks to dynamic effective vibration damping; particularly in larger motors.
Very stable output frequency for high speed rigidity and synchronized operation.
Unlimited operation at standstill due to reliable speed feedback.
Operation with sine output filters and operation of group drives possible.

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5.11.2 Voltage/Frequency-Controlled Systems

Principle system response to a step change in load

Torque

Step change in load

Response

Zeit

After a sudden change in the load torque, the required, constant shaft torque is set after a delay and
transient process at the shaft.

This type of frequency inverter system or control mode is sufficient for the majority of applications in the
field of automation engineering with regard to dynamics, torque rise times, speed accuracy or response
times.
Constant, permanent behavior is often demanded in the stationary operating range. Good overload
capacity is also often required of the frequency inverters.
This means that this type of voltage-controlled inverter is not designed particularly for the highest
possible dynamic properties and very fast torque rise times.
Nevertheless, you should not underestimate the dynamic properties or positioning accuracy of a speed-
controlled V/f system.
Very good results can be achieved within specific limits.
The variety and range of applications for inverter systems has arisen due to the wide variety of tasks in
the area of drive engineering.
Each system has a particular area of application in which it can be used.
This means that project planning for one V/f system cannot simply be copied to achieve the same result
with a field-oriented system for asynchronous motors.
Different project planning guidelines would have to be taken into account in this case.

Advantages At least 150 % torque up to a setting range of 1:20 (with speed feedback 1:200 is possible)
Motors can be operated above their rated speeds.
Constant magnetization of the motor for variable speeds
Smaller motors can be used to a certain extent when operated with inverters
Careful treatment of mechanical components through controlled acceleration and braking
Increase in starting frequency
Load removed from supply system
Increase in brake service life

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5.11.3 Field-Oriented Drive Systems

The most important factor for field-oriented control is the magnetic rotor flux. This flux is known in
synchronous servo systems because the rotor has a constant, permanent magnetization. However, the
flux has to be determined for asynchronous servomotors. To do so, a sensor system must be installed
in the motor windings to ensure exact measurements, which means that standard asynchronous motors
cannot be used. At the same time, the rotor flux has to be simulated using a model simulation.

Systems from SEW-EURODRIVE are divided into voltage/frequency-controlled field oriented (VFC) and
current-controlled field oriented (CFC) systems. The conditions named above for realizing field
orientation apply to both systems.

One striking difference between the two systems is the subordinate current controller, which is only
implemented in the current-controlled systems. It is this feature that gives the CFC mode its decisive
advantages in the area of dynamics.

5.11.4 Current-Controlled, Field-Oriented Systems

Principle system response to a step change in load

Torque

Step change in load

Step response

time

After a sudden change in the load torque, the required, constant shaft torque is set at the shaft with
virtually no vibrations after a short torque rise time.

The CFC mode makes it possible to run the asynchronous motor with virtually all the characteristics of a
servo system. The subordinate current controller with a cycle time of 125 s (1 ms for VFC with speed
control) produces the drives dynamic properties calculated by the motor control. In this case, the motor
model must be adapted exactly to the individual motors in order to achieve the precise results. This
system also requires speed feedback and relative information on the rotor position to be able to
calculate the required slip.
Limitations of this drive type compared with the VFC mode are, for example: a reduction in the
stationary continuous power as the corresponding energy reserves must be available for acceleration or
braking processes. Group drives cannot be implemented because in this case, the current injection
cannot be performed precisely.

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Advantages of the CURRENT FLUX CONTROL mode

Decoupled torque and flux control


Static speed accuracy of less than or equal to 0.1 % of the rated speed
At least 160 % torque to standstill when operating the system with a motor that has been adapted to
the power.
Unlimited operation to zero speed due to standard speed feedback.
Real servo drive characteristics

5.11.5 Torque Rise Times

The following diagram illustrates the dynamic between the CFC mode and the VFC mode over the torque rise time.
Available Torque /

Time /

The rise time is based on a change in load for CFC of 0 % to 160 % rated torque and for VFC, from 0 %
to 150 % rated torque.
In the CFC mode, rise times of between 1 ms and 2 ms were achieved. The VFC mode reached torque
rise times of between 7 and 10 ms.

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6. Notice

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Indexverzeichnis

4 M
4 Q operation 17 Magnetic 7
motor 7
MOTOR CONTROL 40, 43
5
50 Hz characteristic curve 24
P
Power recovery 20
7
70 Hz characteristic curve 24
R
RESOLVER 43
A rotor 6
Air gap 7 Rotor 5, 10

B S
Brake chopper 20 Slip 10
braking resistor 20 SPEED CONTROLLER 40
speed/torque characteristic curves 3
Star connection 27
C stator 6
CFC 32 Stator 4, 10
CURRENT CONTROLLER 41
CURRENT LIMITATION 43 T
CURRENT SETPOINT CALCULATION 41, 43
THREE-PHASE VOLTAGE SYSTEM 41

D
V
Delta connection 27
delta operation 26 V/f 22
Design 4 V/f mode 21, 31
VFC 32
Voltage 10
E
ENCODER 40 W
Winding 4

20.04.2012
10588019/ 0207

Version 4.0 T_EN_I_002

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