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The Control Techniques Drives and Controls Handbook
2nd Edition Bill Drury Digital Instant Download
Author(s): Bill Drury
ISBN(s): 9781849190138, 1849190135
Edition: 2
File Details: PDF, 9.90 MB
Year: 2009
Language: english
IET POWER AND ENERGY SERIES 57
Bill Drury
This publication is copyright under the Berne Convention and the Universal Copyright
Convention. All rights reserved. Apart from any fair dealing for the purposes of research or private
study, or criticism or review, as permitted under the Copyright, Designs and Patents Act 1988, this
publication may be reproduced, stored or transmitted, in any form or by any means, only with
the prior permission in writing of the publishers, or in the case of reprographic reproduction in
accordance with the terms of licences issued by the Copyright Licensing Agency. Enquiries
concerning reproduction outside those terms should be sent to the publishers at the
undermentioned address:
The Institution of Engineering and Technology
Michael Faraday House
Six Hills Way, Stevenage
Herts SG1 2AY, United Kingdom
www.theiet.org
While the author and publisher believe that the information and guidance given in this work
are correct, all parties must rely upon their own skill and judgement when making use of
them. Neither the author nor publisher assumes any liability to anyone for any loss or damage
caused by any error or omission in the work, whether such an error or omission is the result
of negligence or any other cause. Any and all such liability is disclaimed.
The moral rights of the author to be identified as author of this work have been asserted by him in
accordance with the Copyright, Designs and Patents Act 1988.
Preface xxv
Acknowledgements xxxix
A1 Industrial motors 11
A1.1 Introduction and basic electromagnetic principles 11
A1.1.1 Magnetic circuits 11
A1.1.2 Electromechanical energy conversion 16
A1.1.2.1 The alignment of magnetic force/flux lines 16
A1.1.2.2 The interaction between a magnetic field
and a current-carrying conductor 18
A1.2 D.C. motors 20
A1.2.1 General 20
A1.2.2 Operating principles 21
A1.2.3 Fundamental equations of steady-state performance 25
A1.2.3.1 The separately excited d.c. motor 25
A1.2.3.2 The series d.c. motor 29
A1.2.3.3 The shunt d.c. motor 30
A1.2.3.4 The compound d.c. motor 30
A1.2.4 Permanent magnet d.c. motor 31
A1.2.5 Construction of the d.c. motor 32
A1.2.5.1 D.C. motor frame 32
A1.2.5.2 D.C. motor armature 33
A1.2.5.3 Brush gear 34
A1.2.5.4 Degree of protection and mounting 34
A1.2.5.5 DCPM design 35
A1.3 A.C. induction motors 36
A1.3.1 General 36
A1.3.2 Operating principles 36
A1.3.2.1 Rotating magnetic field 37
A1.3.2.2 Torque production 38
vi Contents
B7 Protection 433
B7.1 Protection of the drive system and power supply infrastructure 433
B7.1.1 General 433
B7.1.2 Fuse types 433
B7.1.3 Application of fuses to drive systems 434
B7.1.4 Earth faults 435
B7.1.5 IT supplies 435
B7.1.6 Voltage transients 436
B7.2 Motor thermal protection 438
B7.2.1 General 438
B7.2.2 Protection of line-connected motor 438
B7.2.3 Protection of inverter-driven motor 439
B7.2.4 Multiple motors 440
B7.2.5 Servo motors 440
Bibliography 715
Index 717
Preface
With the rapid developments in the last 20 years in the area of industrial automation,
it can be argued that the variable-speed drive has changed beyond all recognition.
The functionality of a modern drive is now so diverse that its ability to rotate a
motor is sometimes forgotten. Indeed, some customers buy drives not to control a
motor but to utilise the powerfull auxiliary functionality that is built in. This is,
however, unusual, and the drive remains a key component of the boom in all
aspects of automation. Drives are also critical components in relation to energy
saving. For over 30 years the case for energy saving through the use of variable-speed
drives has been made by drive companies, and at last it seems that industry is
moving quickly to adopting the technology. Consider the facts: 55– 65 per cent of
all electrical energy is used by electric motors. On average, fitting a variable-speed
drive will save 30 per cent of the energy used by a fixed-speed motor, but today
only 5 per cent of those motors are controlled by variable-speed drives. The opportu-
nity is therefore enormous. Drives could save the world, or make a significant
contribution to the cause. Before taking a brief look into the future it is helpful to
look back at the relatively short history of drives and see how far and how quickly
the technology has come.
1820 Oersted was the first to note that a compass needle is deflected when an electric
current is applied to a wire close to the compass; this is the fundamental prin-
ciple behind an electric motor.
1821 Faraday (Figure P.1), built two devices to produce what he called electromag-
netic rotation: that is, a continuous circular motion from the circular magnetic
force around a wire. This was the initial stage of his pioneering work.
1824 Arago discovered that if a copper disc is rotated rapidly beneath a suspended
magnet, the magnet also rotates in the same direction as the disc.
1825 Babbage and Herschel demonstrated the inversion of Arago’s experiment by
rotating a magnet beneath a pivoted disc causing the disc to rotate. This was
truly induced rotation and just a simple step away from the first induction
motor, a step that was not then taken for half a century.
1831 Using an ‘induction ring’, Faraday made one of his greatest discoveries –
electromagnetic induction. This was the induction of electricity in a wire by
means of the electromagnetic effect of a current in another wire. The induction
ring was the first electric transformer. In a second series of experiments in the
xxvi Preface
as a motor. This simple experiment did a great deal to establish the credibility
of the d.c. motor.
1879 Bailey developed a motor in which he replaced the rotating magnet of
Babbage and Herschel by a rotating magnetic field, produced by switching
of direct current at appropriately staggered intervals to four pole pieces.
With its rotation induced by a rotating magnetic field it was thus the first
commutatorless induction motor.
1885 Ferraris produced a motor in which a rotating magnetic field was established
by passing single-phase alternating current through windings in space quad-
rature. This was the first alternating current commutatorless induction
motor, a single-phase machine that Dobrowolsky later acknowledged as the
inspiration for his polyphase machine.
1886 Tesla developed the first polyphase induction motor. He deliberately generated
four-phase polyphase currents and supplied them to a machine with a four-
phase stator. He used several types of rotor, including one with a soft-iron
salient-pole construction (a reluctance motor) and one with two short-circuited
windings in space quadrature (the polyphase induction motor).
1889 Dobrowlsky, working independently from Tesla, introduced the three-phase
squirrel-cage induction motor.
1890 Dobrowlsky introduced a three-phase induction motor with a polyphase
slip-ring rotor into which resistors could be connected for starting and
control. The speed of these motors depends fundamentally upon its pole
number and supply frequency. Rotor resistance control for the slip-ring
motor was introduced immediately, but this is equivalent to armature resist-
ance control of a d.c. machine and is inherently inefficient.
By 1890 there was a well established d.c.. motor, d.c. central generating
stations, three-phase a.c. generation and a simple three-phase motor with
enormous potential but which was inherently a single-speed machine. There
was as yet no way of efficiently controlling the speed of a motor over the
full range from zero to full speed.
1896 The words of Harry Ward Leonard first uttered on 18 November 1896 in his
paper entitled ‘Volts vs. ohms – speed regulation of electric motors’
marked the birth of the efficient, wide-range, electrical variable-speed drive:
The system he proposed was of course based upon the inherently variable-
speed d.c. machine (which had hitherto been controlled by variable armature
resistors). His work was not universally accepted at the time and attracted
much criticism, understandably, as it required three machines of similar
rating to do the job of one. Today, however, all d.c. drives are based upon
xxviii Preface
The faster switching performance of the new silicon, however, opened many
new doors, notably in the field of forced commutation. The way was clear for
commercial variable-frequency drives (VFDs).
1957 The ‘back to back’ reversing d.c. drive introduced.
1960s Power semiconductor voltage and current ratings grow and performance
characteristics improve. Inverters became commercially viable, notably in
industries such as textiles where a single (bulk) inverter was used to feed
large numbers of induction motors (or reluctance motors, despite their low
power factor, where synchronisation was required).
1963 Gain –bandwidth relationships of power converters were investigated.
1970 The 1970s saw a new and very significant revolution hit the variable-speed
drives market – packaging. Up until this time the static variable-speed drive
design process had essentially concentrated on performance/functionality.
Both a.c. and d.c. drives of even low rating were broadly speaking custom
built or hand crafted. This approach resulted in bulky, high-cost drives, the
very uniqueness of which often compromised reliability and meant service
support was difficult. The drives industry was not fulfilling its potential.
1970s A.C. motor drives had made great advances in terms of performance but still
lacked the dynamic performance to really challenge the d.c. drive in demand-
ing process applications. Since the early 1970s considerable interest was being
generated in field oriented control of a.c. machines. This technique, pioneered
by Blaschke and further developed by Leonhard, opened up the opportunity
for a.c. drives not only to match the performance of a d.c. drive but to
improve upon it. The processing requirements were such that in its early
days commercial exploitation was restricted to large drives such as mill
motor drives and boiler feed pump drives. Siemens were very much in the
forefront of commercialising field orientation. Siemens were also rationalising
the numerous alternative drive topologies that had proliferated and, while
stimulating to the academic, were confusing to drive users:
1. D.C. drives
a. Single converter
b. Double converter
i. Circulating current free
ii. Circulating current
2. A.C. drives
a. Voltage (phase) control
b. Voltage source inverters
i. Quasi-square V/f
ii. Quasi-square V/f with d.c. link chopper
iii. Pulse width modulated (PWM)
c. Current source inverters
i. Induction motor
ii. Synchronous machine
d. Static Kramer drive
e. Cycloconverter
Preface xxxi
1972 Siemens launched the SIMOPAC integrated motor with ratings up to 70 kW.
This was a d.c. motor with integrated converter including line reactors!
1973 A new approach to drives in terms of packaging. Utilising 19-in rack
principles, a cubicle-mounting standard well used in the process industry,
compact, high-specification ranges of d.c. drives in modular form (Figure
P.4) became available off the shelf. Companies such as AEG, Thorn
Automation, Mawdsley’s and Control Techniques pioneered this work. A
new era of drive design had started.
1979 Further advances in packaging design were made possible by the introduction
of isolated thyristor packages.
1983 In 1983 plastic mouldings (Figure P.5), made their first significant impact in
drives. Bipolar transistor technology also arrived, which eliminated bulky
auxiliary commutation circuits.
1985 Takahashi and Noguchi published a paper on direct torque control (DTC) in
the IEEE. This date is included not because of its technical significance but
rather as a point of interest as DTC has received much commercial attention.
1986 Great advances were being made at this time in the field of microprocessors
making possible cost-effective digital drives at low powers. Further drives
were introduced containing application-specific integrated circuits (ASIC),
which to that time had only been used in exceptionally large-volume/
domestic applications. Further, new plastic materials were introduced that gave
structural strength, weight, size, assembly and cost advantage (Figure P.6).
1988 IGBT technology was introduced to the drives market. IGBTs heralded the era
of relatively quiet variable-speed drives (and introduced a few problems, some
of which have led to substantial academic activity, and only a very few of
which have required more pragmatic treatment).
Figure P.6 Digital d.c. drive with microprocessor and ASIC [photograph courtesy
of Control Techniques]
Preface xxxiii
1989 The first implementation of the field orientation or flux vector drive was intro-
duced to the high-volume, lower-power market (Figure P.7). It found immedi-
ate application in machine tool spindle drives and has grown rapidly in
application (and rating) since. It should be said that the name vector has
been prostituted by some in the drives industry with ‘voltage vector’ and
other such names/techniques, causing confusion and frustration to customers.
1990 The trend to smaller drive products, which were also simpler to design, was
given a significant boost by Mitsubishi, who introduced intelligent power
modules that integrated into the semiconductor package the necessary gate
drive and protection functions.
1992 A new packaging trend emerged – the bookform shape (Figure P.8); this had
previously been applied to servo drives and was now being applied to the
broader industrial a.c. drives market. The trend continues today but there is
not a consensus that this is the most suitable shape for all market segments.
1993 Another innovation in packaging arrived – at the low-power end of the spec-
trum when a DIN rail mounting 0.4kW inverter package (Figure P.9), similar
to that used widely in equipment such as contactors and control relays, was
xxxiv Preface
Figure P.9 DIN rail mounting drive with built in EMC filter [photograph courtesy of
Control Techniques]
Preface xxxv
launched. The first drive with a built-in supply-side filter fully compliant with
the then impending EU regulations on conducted EMC was introduced.
1996 The first truly universal drive (Figure P.10) was launched that met the diverse
requirements of a general-purpose open-loop vector drive, a closed-loop flux
vector drive, a servodrive, and a sinusoidal supply converter with the selection
purely by parameter selection. This was also the birth of what has become
known as the intelligent drive with user-programmable functionality as well
as a broad range of Fieldbus connectivity.
1998 The integrated d.c. motor launched in 1972 was not a great commercial
success – much has been learnt since those days. In 1998 integrated a.c.
motor drives were introduced onto the market (Figure P.11). These products
are, for the most part, open-loop inverter-driven induction motors and were
initially targeted on replacing mechanical variable-speed drives. Integrated
servo motors followed.
1999 A radical servo drive was introduced with the position and speed loop
embedded in the encoder housing on the motor itself (Figure P.12). This
brought with it the advantage of processing the position information close
to the source, thereby avoiding problems of noise etc, and allowed dramatic
xxxvi Preface
A book of this type relies upon the contribution and help of a great number of people.
This edition of The Control Techniques Drives and Controls Handbook has been
created with contributions from engineers both within Control Techniques itself
as well as sister companies within the family that is Emerson. Accordingly, the con-
tributions of all the following are acknowledged with great thanks.
Introduction
A1 Industrial motors
A2 Drive converter circuit topologies
A3 Power semiconductor devices
A4 Torque, speed and position control
A5 Position and speed feedback
A6 Motion control
A7 Voltage source inverter: four-quadrant operation
A8 Switched reluctance and stepper motor drives
Introduction
The selection of a drive is determined by a great many factors. Section A of this book
describes the core technology and performance of the different elements of a drive
system. To put this into context, the main types of industrial drives are tabulated
below with a brief summary of their features. Reference is made to areas of the
book for further more detailed descriptions.
The number of topologies is so broad so for convenience the table has been split
into the following:
† D.C. drives
† A.C. inverter drives
† Slip energy recovery and direct converter drives
† Soft starter, switched reluctance and stepper motor drives
4
Drive type Single quadrant drive Single quadrantA Four quadrant drive Four quadrant drive D.C. chopper
with single half drive with single fully with single converter with significant period
controlled converter controlled converter and armature or field without torque
reversal
Motor type D.C. Separately Excited Motor (A1.2.3.1) or d.c. Permanent Magnet Motor (A1.2.4)
Converter type Single/three phase Single/three phase Single/three phase Dual single/three Four quadrant d.c.
half controlled fully controlled fully controlled phase fully chopper (A2.3.2.3)
thyristor bridge. thyristor bridge. thyristor bridge. controlled thyristor usually fed from
(A2.2.4/A2.2.2.2/ (A2.2.4/A2.2.2.2/ (A2.2.4/A2.2.2.2/ bridge. (A2.2.4/ uncontrolled converter
Part A Drive types and core technology
St. Patrick himself, in the very old hymn attributed to him, prays to
be protected
And again—
We thus see that the paganism which characterised the Irish tribes
and the nation of the northern Picts exhibits precisely the same
features; and all the really ancient notices we possess of it are in
entire harmony with each other in describing it as a sort of fetichism,
which peopled all the objects of nature with malignant beings to
whose agency its phenomena were attributed, while a class of
persons termed Magi and Druadh exercised great influence among
the people from a belief that they were able through their aid to
practise a species of magic or witchcraft, which might either be used
to benefit those who sought their assistance, or to injure those to
whom they were opposed. How unlike this is in every respect to the
popular conception of what is called the Druidical religion will be at
once apparent. The process by which this monstrous system has
been evoked was simply to invest these same Druadh with all the
attributes which Cæsar and the classical writers give to the Druids of
Gaul, and to transfer to those northern regions all that they tell of
Druidism in Gaul; to connect that with the stone monuments—those
silent records of a remote age, and possibly of a different race,
which have outlived all record of their time; and to assume that the
stone circles and cromlechs, which are undoubtedly sepulchral
monuments,[238] represent temples and altars. Add to this some false
etymologies of terms which are supposed to contain the name of Bel
or Baal,[239] and we have at once the popular conception of the
Druidical religion, with its hierarchy of Archdruids, Druids, Vates, and
Eubates, and all its paraphernalia of temples, altars, human
sacrifices and the worship of Baal.[240]
Proceedings of Adamnan, unfortunately, gives us no details of
St. Columba in the conversion of the nation of the northern Picts
converting the from the pagan system which prevailed among
northern Picts.
them; but so powerful a monarch as their king,
Brude mac Maelchon, having been won over to the Christian faith,
the task of spreading the knowledge of the true religion among the
nation at large would be greatly facilitated, and less reluctance
would be shown to follow his example. Columba, no doubt,
proceeded in the usual way by establishing monasteries, or small
Christian colonies, among the Pictish tribes. Adamnan records but
two instances of conversion beyond the districts which more
immediately surrounded Iona; but as we find, in the former,
Columba in friendly intercourse with the families of peasants whom
he had won over to the Christian faith, so, in the latter, the
conversions are of those in the rank of chiefs. In the one case he
was travelling near Loch Ness, and hearing that an old man, who
was a heathen, but ‘who had preserved his natural goodness
through all his life even to extreme old age,’ was at the point of
death, he hurried on to the district of Airchartan, or Glen Urquhard,
on the north side of the lake, where he found ‘an aged man called
Emchat, who, on hearing the Word of God preached by the saint,
believed and was baptized, and immediately after, full of joy and
safe from evil and accompanied by the angels who came to meet
him, passed to the Lord. His son Virolec also believed and was
baptized with all his house.’[241] In the other instance he was staying
for some days in the Island of Skye, when ‘a boat came into the
harbour, on the prow of which sat an aged man, the chief of the
Geona cohort. Two young men took him out of the boat and laid him
at the feet of the saint. After being instructed in the Word of God,
through an interpreter, the old man believed and was at once
baptized by him; and when the baptism was duly administered, he
instantly died on the same spot, and was buried there by his
companions, who raised a heap of stones over his grave.’[242] In both
cases these old men, who were obviously of the Flaith, or chieftain
class, seem to have been prepared to accept the true religion, and
probably partially instructed in its truth, and hastened to be received
into the church before death carried them off.
The position which Columba appears now to have held at the
court of King Brude, and the disappearance of the ‘Magi,’ or Druadh,
from the struggle, show the extent to which the Christian Church
had been adopted in the land; for we find him staying among the
Picts, and addressing King Brude in the following terms, in the
presence of the ruler of the Orkneys:—‘Some of our brethren have
lately set sail, and are anxious to discover a desert in the pathless
sea. Should they happen, after many wanderings, to come to the
Orcadian islands, do thou carefully instruct this chief, whose
hostages are in thy hand, that no evil befall them within his
dominions. The saint took care to give this direction because he
knew that, after a few months, Cormac would arrive at the
Orkneys.’[243] This is the language of one in a position of influence
and authority. It is unfortunate that Adamnan should tell us so little
of St. Columba’s real history and work among the heathen Picts, and
so much of his miracles, prophetic utterances, and the
manifestations of angels towards him; but his work is rather a
panegyric than a biography, and his object is more to throw light
upon his character, and to demonstrate his superior holiness, than to
contribute a detail of historical events. The early period at which he
wrote makes every hint, however slight, of great value; and we must
be thankful for what we have got.
Columba seems to have been mainly engaged in the work of
spreading the truth among the Pictish tribes for nine years after the
conversion of King Brude, when he appears to have at length also
attained the political object of his mission. In the year 574 died
Conall, son of Comgall, king of Dalriada, in the thirteenth year of his
reign.[244] The territories over which he ruled were, as we have seen,
greatly restricted in extent, as compared with those of the previous
rulers, who were termed kings of Alban; and Saint Berchan says of
him—
170. Adam. B. i. c. 7.
174. Dr. Reeves has conclusively shown that the name of Iona has
arisen from a misprint of the word Ioua, the adjective form used by
Adamnan—the root of which was Iou.—See Reeves’s Adamnan, p.
cxxvii. The oldest forms of the name are Hii, Ia, and I. But we shall,
for greater convenience, retain the conventional name of Iona. The
usual etymologies of I thona, the island of waves, or I shona, the
sacred isle, are of course untenable.
175. Bass Conaill mic Comgaill Ri Dalriada xiii anno regni sui qui
oferavit insolam Ia Colaimcille.—Chron. Picts and Scots, p. 67.
183. The original of this interesting poem is in one of the Irish MSS.
in the Burgundian Library at Brussels. It was transcribed and
translated for the late Dr. Todd by the late Professor O’Curry, and
was kindly given to the author by Dr. Reeves, Bishop of Down and
Connor, then Dean of Armagh, in 1866.
184. Bede, H. E., B. iii. c. 4.
187. Pennant, who visited the island in 1772, after describing the
existing ruins and the small rising ground on the west of them called
the Abbot’s Mount, says, ‘Beyond the mount are the ruins of a kiln
and a granary, and near it was the mill. The lake or pool that served
it lay behind.’
195. See Reeves’s Adamnan, Ed. 1874, App. i. p. 318, for a fuller
account of these remains.
197. Reeves’s Adamnan, p. 33. The site of this cell must have
been close to where the present house called Clachanach stands,
and the remains of the cross which stood here were found behind
the barn.
198. Adamnan, Vit. S. Col., B. i. c. 24.
200. Lib. Hymn., part ii. p. 220. Mr. Hennessy suggests that the
syllable Blath here stands for Blad, a portion, fragment, partition,
division, which is also written Blod, Blag, Blog, and by O’Clery in his
glossary Bladh, who explains it by rann no cuid do ni, a portion, or
share, of a thing. That Moel, or Mael, when applied to a stone
means a flat-surfaced stone, which exactly answers the description
of the boulder. He thinks Moelblath may be fairly rendered ‘the flat
stone of division.’