1 INTRODUCTION TO VISAKHAPATNAM STEEL PLANT

1.1 Introduction: Steel comprises one of the most important inputs in all sectors of economy. The economy of the nation depends on the strong base of industries in core sector in that nation which includes Iron & Steel is the basic input for automobiles, construction,fabrication and machine building and transportation industries. The decision of the Government of India to set up an integrated steel plant at Visakhapatnam was announced in parliament by the then Prime Minister, Smt. Indira Gandhi on 17th April 1970. The site near Balacheruvu creak was chosen by the selection committee and the formal inauguration was done on 20th January 1971 by the Prime Minister. The consultant, M/s M.N. Dastur & Co (P) Ltd, submitted a techno economic feasibility report in February 1972, and detailed project report for the plant, with annual capacity of about 3 million tonnes of liquid steel, in October 1977. The Soviet examined the DPR and offered technical and economic co-operation for the same. The Government of India and USSR signed an agreement on June 12, 1979 for cooperation in setting up the 3.4 million tonnes integrated steel plant at Visakhapatnam. In terms of this agreement, the earlier DPR of Dastur & Co. was revised jointly by Soviet and Indian design organisation and comprehensive revised DPR (CRDPR) for VSP was submitted in November 1980. The project was estimated to cost Rs. 3897.28 crores, based on prices as in the 4lh quarter of 1981. But during the implementation of the project, it has been observed that the project cost has increased substantially over the sanctioned cost, mainly due to price. Escalations, under provision of DPR estimation, under the rationalized concept 3.0 million tones of liquid steel is to be produced in year & the project is estimated cost of Rs. 5822.17 crores based on fourth quarter of 1987 the plants.
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Estimation cost is around Rs.9000 crore, aspect of Quality, Environment, Occupational health & Safety and also ensure the same by contractor. Continually improve quality, encourage development and involvement of employees. Maintain high level of quality, environment, occupational health and safety consciousness amongst employees and contract workers by imparting education and training. 1.2 Introduction to vsp power generation & distribution: The average power demands at all units of VSP when operating the full capacity will be 221 MW is sufficient to meet all plant needs in normal operation time. In case of partial outage of captive generation capacity due to break down, shutdown or other reasons, the shortfall of power is availed from APSEB grid. The agreement with APSEB provides for exporting of surplus power to ASPEB. The captive generation capacity comprises of TPP- 247.5 MW (3x60 MW+ 1x6 7.5 MW) Backpressure Turbines (C&CCD)* -2x7.5 MW Gas Expansion Turbines (BF/ces) * - 2x12 MW 1.3 Activities in engg. shops & foundry: Engineering shops & foundry department's role is to meet the requirements of Visakhapatnam Steel Plant internal spares and also to repair several assemble various structural items etc. This dept is divided into Central machine shop (CMS), Steel structural shop (SSS), Forge shop (FS), Pattern making shop (WWS), Iron & Steel foundry (I&SF) and Utility equipment repair shop (UERS). All the six shops are coordinated by Central planning section (CPS), which acts as a interface between the customer depts. and the internal depts. of ESF, with total manpower around 650 employees. 1.3.1 Central Machine Shop (CMS): The major activity in these shops are machining, milling, boring, shaping, drilling, planning, pressing, balancing, heat-treatment, dismantling, assembling, repairing, fabricating, gas-cutting, heating, welding, new-product design, with many sophisticated machinery heavy duty, medium duty, light-duty lathes, Piano-millers, shapers, boring machines, drilling machines,
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heavy duty presses, balancing machines, furnaces. Gear- hobbing machines, gear-hardening machines, milling machines, surface grinders, precision lathes, vertical-turning, boring, column drillers. 1.3.2 Steel structural shops: Annual production of fabricated structures are about 4500t and the input consisting of sheets, plates, channels, angles, beams etc. Facilities for marking, cutting to size, forming & bending. Profile gas cutting CNC machine uses oxy-acetylene flame to cut the plates. Various types of jobs undertaken by SSS are production laminated hooks for steel ladle, pipes, tundish repair, ladel cover & various types of fabricated jobs. 1.3.3 Forge shop: The shop is designed for production of shafts, coupling flanges etc. and also forge shapes such as crusher hammer heads, special bolts, nuts etc..The annual production from the shop is about 2400t consisting of ingots, billets, blooms & flats of various sizes. 1.3.4 Foundry: Castings up to weight of 5t will be produced. Steel in gots up to 1.3t for forging also be produced here. The charge materials will consists of 5600t of steel scrap 4170t of foundry return scrap, 66t of ferro alloys& 660t of fluxes.

2 A.C MOTORS

2.1 Introduction to A.C motors: The a.c motors are classified into various types depending on various factors like; Synchronous speed Rotor construction A.C.MOTORS

Synchronous motors

Induction motors

Salient pole type motor

Cylindrical rotor type motor

Squirrel cage rotor type

Slip ring rotor type

Fig. 2.1 Classification of A.C. motors

2.2 Synchronous motor: The motors that rotate at synchronous speed are known as synchronous motor. They are generally classified into 2 types depending on their rotor construction they are 1) Salient pole type 2) Cylindrical rotor type 2.2.1 Salient pole type: It is used in low and medium speed alternators. It has a large no. of projecting having poles their cores bolted on to a heavy magnetic wheel of cast iron of good quality. Such generators are characterised by their large diameters and short axial lengths. The poles and poleshoes are laminated to minimise heating due to eddy currents. In large machines, field windings consist of rectangular copper strip wound on edge. 2.2.2 Cylindrical rotor type: It is used for steam turbine-driven alternators which run at very high speeds. The rotor consists of a smooth solid forged steel cylinder, having a no. of slots milled at intervals along the outer periphery for accommodating field coils. Such rotors are designed mostly for 2 or 4-pole turbo-generators running at 3600 rpm. The field coils are so arranged around these polar areas that flux density is maximum on the polar central line and gradually falls away on either side. The cylindrical construction of the rotor gives better balance and quieter- operation and also less windage losses. 2.3 Asynchronous motors (Induction motors): These motors rotate at the speed less than the synchronous speed hence these motors are known as asynchronous motors. Generally, all A.C. motors are classified into single phase and three phase induction motor and synchronous motors and some special types of motors .out of all these three

phase induction type motors are widely used for industrial purposes. The important advantages of three phase induction motor are 1) Self starting property 2) High power factor 3) Good speed regulation 4) Robust construction 2.3.1 Principle of operation: A 3-phase power supply provides a rotating magnetic field in an induction motor. The induction motor does not have any direct supply onto the rotor; instead, a secondary current is induced in the rotor. To achieve this, stator windings are arranged around the rotor so that when energized with poly phase supply they create a rotating magnetic field pattern which sweeps past the rotor. This changing magnetic field pattern induces current in the rotor conductors. These currents interact with the rotating magnetic field created by the stator, and in effect, cause a rotational motion on the rotor.

Fig. 2.2 Rotating magnetic field in an induction motor However, for these currents to be induced, the speed of the physical rotor must be less than the speed of the rotating magnetic field in the stator, or else the magnetic field will not be moving relative to the rotor conductors and no currents will be induced. If by some chance this happens, the rotor typically slows slightly until a current is re-induced and then the rotor continues as before. This difference between the speed of the rotor and speed of the rotating
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magnetic field in the stator is called slip. It is unit less and is the ratio between the relative speed of the magnetic field as seen by the rotor (the slip speed) to the speed of the rotating stator field. Due to this an induction motor is sometimes referred to as an asynchronous machine. When a three phase supply is given to the three phase stator winding a rotating magnetic field of constant amplitude (R.M.F) is produced. The speed of the rotating magnetic field is synchronous speed Ns. Ns=120f/P Where , f=supply frequency P=number of poles According to lenzs law the direction of induced current in the rotor is so as to oppose the cause producing it. The cause of rotor current in the induced e.m.f. which is induced due to relative motion between rotating magnetic field and rotor conductors, hence to oppose the relative motion the relative speed the rotor experiences a torque in the same direction as that of R.M.F and tries to catch up the speed as that of rotating magnetic field N=speed of the rotor i.e. motor in rpm. Thus, the motor always rotate in same direction of R.M.F. 2.3.2 Construction: Basically the induction motor consists of two main parts 1) Stator 2) Rotor .(2.1)

2.3.2.1 Stator: The stator has a laminated type of construction made up of stampings which are 0.4 to 0.5mm thick. The stampings are slotted on its periphery to carry the stator winding, the stampings are insulated from each other in order to minimize iron losses. The number of stampings are stamped together to build the stator core. The built up core is then fitted in a casted or fabricated steel frame. The choice of material for stampings is silicon steel which minimizes hysteresis losses. The slots on periphery of stator cores carries a 3 phase winding ,connected in either star or delta .this 3 phase winding is called stator winding it is wound for definite number of poles. This winding when excited by a three phase supply produces a rotating magnetic field, the choice of number of poles depends on the speed of the rotating magnetic field. 2.3.2.2 Rotor: Depending upon the construction Rotors are classified as follows Squirrel-cage rotor: The squirrel cage rotor is the rotating part used in the most common form of AC Induction motor. The change in magnetic field, a current is induced in the wire i.e., the relative motion between this field and the rotation of rotor induces electric current and conductive bars is called squirrel-cage induction motor (SCIM). It is made up of bars of either solid copper strips can be shorted or connected by a ring or sometimes not, i.e. the rotor can be closed or semi closed type. The rotor bars in squirrel-cage induction motors are not straight, but have some skew to reduce noise and harmonics the most commonly used material for copper or aluminium. Slip ring rotor: A slip ring rotor replaces the bars of the squirrel-cage rotor with windings that are connected to slip rings. When these slip rings are shorted, the rotor behaves similarly to a squirrel-cage rotor; they can also be connected to resistors to produce a high-resistance which can be beneficial in starting.

Solid core rotor: A rotor can be made from solid mild steel. The induced current causes the

rotation. 2.4 Wound rotor Induction Motors: A wound rotor induction motor has a rotor with windings brought out at the end of the rotor as insulated leads facilitated by slip rings and carbon brushes. It is also called as slip ring induction motor (SRIM). The slip rings are provided not to supply power but to facilitate the connection of end resistances, which are indispensable for the starting and speed control of the induction motor. In case of slip ring motors, the rotor resistance is increased by the addition of external resistance. This external resistance makes the rotor circuit current low and thus the stator current drawn is also low with a high starting torque. The point to be noted is the Slip necessary to generate maximum torque is directly proportional to the rotor resistance. So it is evident that the slip increases with increase in external resistance.

Fig.2.3 Wound rotor Induction Motor It has been observed that the squirrel cage induction motor draws a starting current of about 5 to 10 times the full load current. This poses a serious problem to motors of large rating. Placing a resistance in series with the rotor winding not only reduces the starting current, but also improves the starting torque. It can be observed from the graph below that with
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increase in the rotor resistance from R0 to R1 to R2, the breakdown torque peak is shifted left to lower and at last zero speed. Thus a high torque is produced during motor starting.

Fig. 2.4 Torque speed characteristics of an SRIM The resistance decreases the torque available at full running speed, but that resistance is cut out long before the rotor reaches its rated speed. The only disadvantage with SRIMs is that they require constant maintenance due to the use of slip rings and carbon brushes. 2.5 Advantages: Excellent starting torque for high inertia loads. Low starting current compared to SCIM. Speed through resistance is variable over 50% to 100% of full speed. Higher maintenance of brushes and slip ring compared to SCIM.

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3 SPEED CONTROL OF INDUCTION MOTORS

A three phase induction motor is practically a constant speed motor like D.C. shunt motor, but the speed of D.C. shunt motor can be varied smoothly just by using simple rheostats. But for induction motors we know that, N=Ns (1-S) (3.1)

From this expression it can be seen that the speed of the induction motor can be changed either by changing its synchronous speed Ns or changing the slip s. As the slip s depends on parameters like R and E the speed of the induction motor can be controlled by two methods: From rotor side From stator side From stator side it includes following methods: Supply frequency control to control Ns called v/f control Supply voltage control Controlling number of stator poles to control Ns Adding rheostats in stator circuits

3.1 Stator side: The induction motor fulfils admirably the requirements of a substantially constant speed drive. Many motor applications, however, require multiple speed or adjustable speed ranges. The present multiple speed or adjustable speed ranges.
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3.1.1 Supply frequency control or v/f control: The synchronous speed is given by Ns = 120f/p .. (3.2)

Thus by controlling the supply frequency smoothly the synchronous speed can be controlled over a wide range But from the expression from the air V = 4:44N f . (3.3)

This is according to the E.M.F equation of a transformer where., = flux N = speed V= supply frequency f = supply frequency It can be seen from this expression that if the supply frequency f is changed the air gap flux is also changes. This may result into saturation of stator and rotor cores. Such a saturation leads to sharp decrease in the no load current of motor, hence it is necessary to maintain the air gap flux constant. To achieve this it can be seen from the above expression that along with f, v also must be changed so as to keep the v/f ratio constant this ensures constant air gap flux giving sped control without affecting the performance of the motor. Hence this method is called v/f control. 3.1.2 Supply voltage control: We know that T= (3.4)

Now E2 the rotor induced emf at stand still depends on the supply voltage V E2 is proportional to voltage

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Now if supply voltage is reduced below the rated value, torque also decreases. But to supply the same load it is necessary to develop the same torque, hence value of slip increases so, torque produced remains same. Slip increases means motor reacts by running at lower speed to decrease in supply voltage so motor produces the required load torque at a lower speed. But in this method due to reduction in voltage current drawn by the motor increases, large change in voltage for small change in speed is required is the biggest disadvantage. 3.1.3 Controlling number of poles: The method is called pole changing method of controlling the speed. In this method it is possible to have one, two or four speeds in steps by changing number of stator poles. A continuous smooth speed control is not possible by this method. The stator poles can be changed by following methods: 1. Consequent poles method 2. Multiple stator winding method 3. Pole amplitude modulation method 1. Consequent poles method: In this method, connections of the stator winding are changed with the help of simple switching. Due to this, the number of the stator poles get changed in the ratio 2:1, hence either of the two synchronous speeds can be selected. Thus series/parallel arrangements of the coil can be produced the pole sin the ratio 2:1, but the speed changes is in step and smooth speed control is not possible similarly the method can be used only for the squirrel cage type motors as squirrel type rotors adjust itself to same number of poles as stator which is not the case in slip ring induction motor.

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2. Multiple stators winding method: In this method instead of one winding, two separate stator windings are placed in the stator core. The windings are placed in the stator slots only but are electrically isolated from each other each winding is divided into coils to which pole changing with consequent poles facility is provided. Thus giving supply to one of the two windings and using switching arrangement two speeds can be achieved. Same is true for other stator windings. So in all four different speeds can be obtained. 3. Pole amplitude modulation method: The basic disadvantage of other methods which is non availability of smooth speed control is eliminated by this method. The ratios of two speeds need not to be 2:1 The basic principle of this method is the modulation of two sinusoidal varying m.m.f waves with different number of poles. This method is advantageous as it reduces the size to a great extent and hence cost of the machine. 3.1.4 Adding rheostats in stator circuit: We have seen that the reduced voltage can be applied to the stator by adding rheostats in the stator circuit. the part of the voltage get dropped across the resistances and reduced voltage gets applied across the stator. The reduction in stator voltage causes reduction in speed but the entire line current flows through the rheostats and hence there are large power losses. the method is not sufficient from speed control b point of view hence used as starter rather than as a speed control method.

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4 V/F DRIVE SPEED CONTROL METHODS

4.1 Introduction: Three-phase induction motors are more commonly employed in the variable speed drives. When 3-phase supply is connected to 3-phase stator winding, rotating magnetic field is produced. The speed of the rotating field is given by, Ns= 120f/p where, f=supply frequency in Hz p= number of stator poles. Rotor cannot attain synchronous speed. It must run at a speed Nr less than Ns, Nr= Ns (1-s) where, Nr =rotor speed in rpm s = slip= (Ns-Nr)/Ns 4.2 Speed control of 3-phase induction motors using drives: 3-phase induction motors are best suited to fulfil the demand of loads requiring constant speeds. The basic principle of speed control techniques employed to 3- induction motors through the use of drives. Speed control through semi conductor devices are as under: Stator voltage control Stator frequency control Stator voltage and frequency control . .. (4.3) . (4.2) (4.1)

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4.2.1 Stator voltage control: The motor torque is proportional to the square of the stator supply voltage. A reduction in the supply voltage will reduce the motor torque and therefore the speed. .. (4.5)

The motor torque is given.,

Fig.4.1 Stator Voltage Control

From the speed torque characteristics, for load torque TL, a is the operating point at rated voltage and OA is the motor speed. For reduced stator voltage, b is the operating point and OB is the reduced motor speed for load torque TL. This method is suitable for motors having large value of Sm.

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4.2.2 Stator frequency control: By changing the supply frequency, motor synchronous speed can be altered and thus torque and the speed of 3- induction motor can be controlled. Supply voltage., V= fn KV (4.6)

This expression shows that under rated voltage and frequency operation, flux will be rated. In case supply frequency is reduced with constant V. In case the supply frequency is reduced with constant voltage the flux increases and the motor magnetic circuit is gets saturated. This leads to inaccurate speed torque characteristics. At low frequencies the motor efficiency is reduced, so reduced frequencies are rarely used. With constant voltage, if the supply frequency is increased, the synchronous speed and therefore the motor speed also rises. The flux and the torque get reduced. 4.2.3 Stator voltage and frequency control: For 3- induction motor, stator voltage per phase is given by Supply voltage., V= fn KV (4.7)

It is seen from the equation that as the ratio of voltage and frequency is kept constant, the air gap flux also remains constant. Starting torque is given by.,

ST

... (4.8)

Maximum torque is given by Tm = .. (4.9)

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The above equation indicates that the starting torque is inversely proportional to supply frequency, even if flux is constant .At low frequencies, the supply voltage is increased to maintain the level of maximum torque. This method of speed control is also called as volts/hertz control.

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5 SYSTEM BEFORE MODIFICATION

The existing system table is driven by squirrel cage induction motor. As the speed of induction motor is almost constant the speed of the table drive is controlled by gears and zero limit switch. The working principle and technical description of the existing system is as described: 5.1 Working Principle of Machine and Technical Description: The Table type Horizontal Boring and Milling Machine has a wide range of machining possibilities. If the special equipment is used the versatility of the machine is still enhanced. The machine consists of the following main assembly groups: A. Gear Box B. Bed

C. Slide and Table D. Back Rest (Stay) E. Electrical Equipment

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Fig. 5.1 Block diagram of BH 100 horizontal boring machine

Fig.5.2 Control panel

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5.2 Machine particulars: Name of Machine: Table type Horizontal Boring & Milling Machine Type: BH100 Manufacture: Heavy Engineering Corporation Ltd Heavy Machine Tools Plant Version of Machine: Standard/Special Overall Length: 6000mm Overall Width: 2650mm Overall Height: 3050mm Total Net Weight: 13550Kg

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5.2.1 Parameters: Features Supply Voltage Standard 3, 415 6% 50Hz 3% 3Wire System Spindle Drive 7.5KW 1500RPM Back Rest Drive 0.55KW 1500RPM Coolant Pump 0.18KW (Approx) 1/220Is 2161 Maximum demand in KW Rating of fuse wire 9kw 50amp (HRC) Maximum torque on spindle at speed limits Low(5.6/7.1)rpm High(900/1120)rpm 110kg/m 5kg/m 11KW 1500RPM 0.55KW 2800RPM 0.18KW (Approx) 1/220IS 2161 12.5kw 50amp (HRC) Special

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5.3

Modes of operation:

5.3.1 Inching of main motor : Inching of main motor 1m1 is effected by push button 1b4, located on the pendant. So long as this push button is pressed, the motor operates. As soon as the same is released, electrical breaking of the motor takes place by means of the plugging switch 1b6 and auxiliary relay combination, and the motor stops. 5.3.2 Continuous run of main motor : . Continuous run of the main motor is effected by push button 1b2 and 1b1 located on the pendant panel. For starting the motor, press the push button 1b2.For stopping the motor, press push button 1b1. In case the stopping of the motor is unsatisfactory(too slow or too fast) the setting screws on ZPS(1b6) can be adjusted for either direction independently satisfactory braking.

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6 MODIFIED V/F DRIVE

6.1 Working of modified control circuit of BH 100(7E): When single phase ac supply of 220v is applied under normal condition the E.STOP and STOP.PB acts as short circuit. When the inching button is pressed, the inching command will be executed internally. Until the button is held pressed the relay RL5 will be activated since the RL6 switch is in NC State. When the continuous button is pressed, the relay RL6 will be activated & the RL5 switch is in NC State. Since a bi path is provided the supply will be continuous in this path hence it is not necessary to hold the button pressed. Using the forward and reverse switch we can select the direction of rotation of job as per the requirement. Based on the selection of the directions the relays RL7 & RL8 will be activated making the job to rotate in forward & reverse directions respectively. CASE 1: Inching mode and forward direction When the system is in inching mode the push button will be closed & RL6 will be in NC State. Until the button is held pressed the relay RL5 will be activated and the RL5 switch (11-14) will be closed. Since the forward direction is required button is rotated accordingly then the relay RL7 will be activated and RL8 will be in NO State. CASE 2: Continuous mode and forward direction When the system is in continuous mode the push button will be closed & RL5 will be in NC State. The relay RL6 will be activated and the RL6 switch (11-14) will be closed. Since
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the forward direction is required button is rotated accordingly then the relay RL7 will be activated and RL8 will be in NO State. CASE 3: Continuous mode and reverse direction When the system is in continuous mode the push button will be closed & RL5 will be in NC State. The relay RL6 will be activated and the RL6 switch (11-14) will be closed. Since the forward direction is required button is rotated accordingly then the relay RL8 will be activated and RL7 will be in NC State.

Fig. 6.1 Modified Control Circuit of BH 100 (7E) of A.C. Drive

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7 ELECTRICAL DRIVE
7.1 Definition: A set of devices to convert electric energy into mechanical energy and to regulate the converted energy flux according to a specific law. An electric motor together with its control equipment and energy-transmitting device forms an electric drive. An electric drive together with its working machine constitutes an electric-drive system.

Main power source

Power controller

Motor

Working machine

Fig. 7.1 An electric-drive system 7.2 AC drive controller: AC drives and AC control circuits are considered to be part of the high tech electrical market. Even the more straight forward AC controllers involving controllers involving contactors, starters, timers, metering and relay logic can become quite technical. Knowing, what is going on with the demands on your electrical machinery through first hand knowledge and visual inspections can save you a lot of headaches and downtime. Therefore, the importance of using solid state monitoring devices that send valuable information to your electrical maintenance office or provide you with visual information on the door of the cabinet cannot be underestimated in keeping your equipment up and running & making money.

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Fig., 7.2 AC drive controller 7.3 AC Drives - principles of operation Adjustable frequency AC motor drive controllers frequently termed inverters are typically more complex than DC controllers since they must perform two power section functions, that of conversion of the AC line power source to DC and finally an inverter change from the DC to a coordinated adjustable frequency and voltage output to the AC motor. The appeal of the adjustable frequency drive is based upon the simplicity and reliability of the AC drive which has no brushes, commutator or other parts that require routine maintenance, which more than compensates for the complexity of the AC controller. The robust construction, and low cost of the AC motor makes it very desirable for a wide range of uses. Also, the ability to make an existing standard constant speed AC motor an adjustable speed device simply by the addition of an adjustable frequency controller creates a very strong incentive for this type of drive. 7.4 Induction motor drive: Three-Phase induction motors are more commonly employed in adjustable-speed drives than three-phase synchronous motors. Three-phase induction motors are of two types, squirrel-cage induction motors (SCIMs) and slip-ring (or wound-rotor) induction motors
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(SRIMs). Stator windings of both types carry three-phase windings. Rotor of SCIM is made of copper or aluminium bars short-circuited by two end rings. Rotor of SRIM carries three-phase winding connected to three slips rings on the rotor shaft. 7.5 Torque-Speed characteristics Constant v/f operation (Drives): When the voltage at each frequency is adjusted so that the ratio V/f is kept constant up to base speed, and full voltage is applied thereafter, a family of torque-speed curves as shown in Figure 8.3 is obtained. These curves are typical for a standard induction motor of several kW output. As expected, the no-load speeds are directly proportional to the frequency, and if the frequency is held constant, e.g. at 25 Hz in Figure 7.5, the speed drops only modestly from noload (point a) to full-load (point b). These are therefore good open-loop characteristics, because the speed is held fairly well from no-load to full-load. If the application calls for the speed to be held precisely, this can clearly be achieved (with the aid of closed-loop speed control) by raising the frequency so that the full-load operating point moves to point (C).We also note that the pullout torque and the torque stiffness (i.e. the slope of the torque-speed curve in the normal operating region) is more or less the same at all points below base speed, except at low frequencies where the effect of stator resistance in reducing the flux becomes very pronounced.

Fig. 7.3 Torque-Speed Characteristics-Constant V/F Operation

the starting torque at the minimum frequency is much less than the pull-out torque at higher frequencies, and this could be a problem for loads which require a high starting torque. The low-frequency performance can be improved by increasing the V/f ratio at low frequencies
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in order to restore full flux, a technique which is referred to as low-speed voltage boosting. Most drives incorporate provision for some form of voltage boost, either by way of a single adjustment to allow the user to set the desired starting torque, or by means of more complex provision for varying the V/f ratio over a range of frequencies. A typical set of torque-speed curves for a drive with the improved low-speed torque characteristics obtained with voltage boost is shown in figure 7.3., The curves in figure 7.3 have an obvious appeal because they indicate that the motor is capable of producing practically the same maximum torque at all speeds from zero up to the base (50 Hz or 60 Hz) speed. This region of the characteristics is known as the constant torque region, which means that for frequencies up to base speed, the maximum possible torque which the motor can deliver is independent of the set speed. Continuous operation at peak torque will not be allowable because the motor will overheat, so an upper limit will be imposed by the controller, as discussed shortly. With this imposed limit, operation below base speed corresponds to the armature-voltage control region of a DC. drive. means that not only can the inverter-fed motor provide rated torque at low speeds, but perhaps more importantly it does so without drawing any more current from the mains than under full-load conditions, which means that we can safely operate from a weak supply without causing excessive voltage dips. For some essentially fixed-speed applications, the superior starting ability of the inverter-fed system alone may justify its cost. Beyond the base frequency, the V/f ratio reduces because V remains constant. The amplitude of the flux wave therefore reduces inversely with the frequency. Now we saw in topic 5 that the pull-out torque always occurs at the same absolute value of slip speed, and that the peak torque is proportional to the square of the flux density. Hence in the constant voltage region the peak torque reduces inversely with the square of the frequency.

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8 CONCLUSION
In this project an attempt has been made to study the conversion of speed &torque control for table drive mechanism of horizontal boring and milling machine with squirrel cage induction motor speed control to variable voltage, variable frequency AC drive. The modified system comprising of thyristorised digital control system to which the parameter of the drive motor are fed through console & all other control parameters are also inputted during commission. The new system is of simple architecture comprising of V/F control along with few external hard ware .unlike existing system of hard ware components such as dc machines .large ac machine. Transistorized wise electronic cards with are failing frequently rendering frequent brake down. Loss of speed control and damage to job under progress. Graphical representation of speed-torque is done and the results are comparable to that of the characteristic curve of the motor using V/F drive as per the manufacturer. The speed & torque control are smooth & satisfactory for the performance of the table drive of horizontal boring and milling machine. In addition to the above the following advantages are also obtained by this modification. It easy to maintain this V/F controller for which ready spares are available. The change saved huge cost of the three motor and generator. Cost of contactors/relays is avoided by simplifying the relay logic in the new electrical system. The movement can have the continuous speed control with this new V/F control from 0 rpm to 1500 rpm. The speed can be monitored through a pendent mounted RPM gauge meter .through which the speed can be adjusted conveniently, which was originally measured every time which a tachometer and the proportionate movement was calculated, The features in the new pendent are convenient to operate where all operations can be done through this pendent mainly all the big size 3panels was replaced with a small electrical panel thus clearing the machine area for properly loading the jobs.
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REFERENCES

1. 2. 3. 4.

P.S Bimbra, Electrical Machinery, 6th Edition B.L. Thereja, AC & DC Machines, Vol 2 Multi color Illustrative Edition Gopal k. Dubey , Fundamentals of electrical drives,2nd Edition MD Singh, Power electronics, 2nd Edition

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