Welcome to the future of drives

G N V SUBBA RAO BUSINESS MANAGER - AC DRIVES.

Welcome to the future of drives

Basic Motor Principle

Control Variables

Torque Speed Position

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DC Drive
DC Drive
Speed Control Torque Control = DC

Features:
Torque control is direct

Controlling variables:
Armature current Field current

Field orientation via

Mechanical commutator

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DC Drive
DC Drive
Speed Control Torque Control = DC

Advantages:
Accurate and fast torque control High dynamic response Simple to control

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DC Drive
DC Drive
Speed Control Torque Control = DC

Drawbacks:
Reduced reliability of motor Regular maintenance Motor costly to purchase Needs encoder for feedback

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AC Drive - Frequency Control

The AC Motor is:
Frequency control

Small - kW for kW

V
Freq. ref. V/F ratio Moduf lator AC

Very Robust
Simple in design Light and Compact Requires minimal maintenance Low Cost

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AC Drive - Frequency Control

Features:
Frequency control

Controlling variable voltage and frequency Flux provided with constant V/F ratio Load dictates the torque level Simulation of variable AC sine wave using modulator (PWM) Open-loop drive

V
Freq. ref. V/F ratio Moduf lator AC

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AC Drive - Frequency Control

Advantages:
Frequency control

Low cost
Freq. ref.

V
V/F ratio Moduf lator AC

No feedback device required - Simple Controls robust AC motor

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AC Drive - Frequency Control

Drawbacks:
Frequency control

Ignores the motor status

Freq. ref.

V
V/F ratio Moduf lator AC

Not torque controlling Field orientation not used A delaying modulator used

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AC Drive - Flux Vector Control

Features:
Field oriented control simulates DC drive

Motor electrical characteristics are simulated - Motor Model

Flux vector control
V
Speed control Torque control Moduf lator AC

Torque controlled indirectly Closed-loop drive Modulator needed

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AC Drive - Flux Vector Control

Advantages:
Good torque response Accurate speed control
Flux vector control
V
Speed control Torque control Moduf lator AC

Can provide full torque at zero speed Performance approaching DC drive

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AC Drive - Flux Vector Control

Drawbacks:
Feedback is needed
Cost Reliability
Flux vector control
V
Speed control Torque control Moduf lator AC

Modulator provides delay to performance

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Direct Torque Control

Direct Torque Control DTC

Speed Control Torque Control

AC

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Evolution of drives to - DTC

DC Drive
Speed Control Torque Control = DC

Frequency control
V
Freq. ref. V/F ratio Moduf lator AC

Flux vector control

V
Speed control Torque control Moduf lator AC

Direct Torque Control DTC

Speed Control Torque Control

AC

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Why Direct Torque Control - DTC ?

Better product quality
Better Speed Accuracy Better Torque Control

Less down time

Tripless Drives Less Harmonics

Fewer products to support

Universal Drive

Comfortable working environment

Less noise

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DTC Operating Principle

How does DTC work?
Direct Torque Control DTC

Speed Control

Torque Control

AC

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DTC Torque Control

FIRST EVER TORQUECONTROLLED OPEN-LOOP AC DRIVE

1
3~

Torque control
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DTC Motor Model

Fastest ever developed
Calculations 40 000 times each second

Most advanced mathematics

Exact calculation of flux even at zero speed

NO TACHO FEEDBACK NEEDED

Motor Model
3~

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Torque Comparator
Compares calculated and reference values 40 000 times each second
REF

Comparator
ACT

Motor Model
3~

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Optimal Switching Logic

Input from Comparator, when switching is needed
Just-in-time switching

Comparator

Determines the optimal switch combination Motor state known at all times -> Instead of fuzzy logic CRYSTAL CLEAR LOGIC Motor Model

Optimal switching Logic

3~

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Integrated Drive & Motor Control

No separate modulator needed
Direct control of main motor parameters

Comparator

Optimal switching Logic

Every single voltage pulse (switching) controlled separately

No wasted switchings Atom level in AC drive control

Motor Model
3~

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Optimal Torque Response

Typical torque step response times:
DTC
PWM

1...2 ms

Flux vector 10...20 ms over 150 ms

Torque: DTC

MOTOR IS THE LIMITING COMPONENT, NOT THE INVERTER

PWM

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DTC Performance
Slow reversing: Rapid acceleration: Load impulse: full torque over zero speed starting torque dynamic speed accuracy

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DTC - Direct Torque Control

The ULTIMATE step in motor controlling

Outperforms all AC and DC drives Torque response 10 times faster than any openloop drive Dynamic speed accuracy 8 times than any open-loop drive

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Optimal torque response

Integrated torque controller and modulator Torque control in every 25 s - 10 times faster than the best AC drives, over 100 times more often than in DC drives Motor is the limiting factor - not the inverter
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I:

DTC T: PWM

Starting properties
DC magnetizing
Automatic With given time

Automatic start
Very quick starting Automatic determination of starting condition

No restart delay

High starting torque (in normal control mode)

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Flux braking & optimization

Flux braking:
Like in DC injection, mechanical energy is fed into the motor

Unlike in DC injection, we can instantly continue operation

Flux Optimization
The magnitude of flux can be reduced at low load
E.g. HVAC

Energy saving & less noise

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Other features of DTC

No limits with maximum decelerating and accelerating Ripple (and motor losses) vs. switching frequency optimum No fixed carrier frequency => acoustic noise reasonable

On line modulation gives possibilities to realize new kind of inverter functions

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High performance of DTC

Torque control without tacho
Repeatibility: +/- 1% of nominal value Static accuracy: +/- 10% of nominal value in all speeds (including zero )
Superior to scalar control

Torque step response

< 1 ms when f < 35HZ

< 2 ms when f < 40HZ

< 7 ms when f < FWP < 10 ms when f > FWP

FWP: field weakening point

ACV 700: about 10 ms

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Speed control performance

Without tacho
Static accuracy 10 % of nominal slip
Temperature dependency taken into account

Very fast step response

Integrated speeed drop 0,4 %s with nominal load torque step Good enough for most applications

With tacho
Static accuracy 0,01 % Dynamic accuracy 0,2 %s Better operation at low frequency Enables position control
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Direct Torque Control

Fast Torque Step Rise Time High Dynamic Speed Accuracy

Torque Torque Open Loop DTC Closed Loop Flux vector Speed

Speed error

Open loop DTC <5 msec Open loop flux vector > 100 msec Closed loop flux vector 10 to 20 msec

Open loop DTC 0.4 %sec Open loop flux vector 3.0 %sec Closed loop flux vector 0.4 %sec

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Direct Torque Control

Torque Control
Resolution Non-linearity Repeatability Torque step rise time 1:10000 1 %* 0.7 %* 1 to 5 ms 1:10000 4 %* 1.0 %* 1 to 5 ms

With a pulse encoder

Without a pulse encoder

Speed Control

Resolution Speed range Static accuracy Dynamic accuracy

1:20000 1:6000 0.01 % 0.2 %s

1:20000 1:3000 0.10 %** 0.4 %s

* Nominal torque ** 10 % of the motor slip

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No loss of accuracy by heavy speed impacts Fast torque control allows high gain in speed control ==> good speed accuracy
Improved dynamic and static accuracy

Reacting to special situations

power losses over and under voltages

rapid load changes

mechanical resonances

New features
flux braking, automatic start, regenerative braking etc

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DTC is based on ultrafast calculation and control of torque

Flux vector control can calculate torque control only at 1-3 ms intervals. A modulator is needed to calculate switching times Control response is around 10 ms DTC can calculate torque control at 0.025 ms intervals Each switching is directly activated by torque control Control response is around 1 ms

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Less stress to mechanics

Backlash appears in gearboxes and couplings. In backlash range motor may accelerate leading to backlash impact. Fast DTC control limits impact. Mechanical resonances often appear due to elasticy of shafts or web and inertias of motor, gearbox and driven machine. Fast DTC attenuates the resonances.

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DTC Customer Benefits - Web Handling

One of worlds largest web machine manufacturers Web winder in film finishing
exact torque control needed

With DTC, previous solutions can be replaced with tachless drive Benefit to the customer
considerable cost saving (assembly & wiring of each tacho equals the cost of a 30 kW motor) Rewind station construction simpler and easier

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DTC Customer Benefits - Textile Industry

One of the worlds largest textile machine manufacturers Power-loss control of a ring spinningmachine With DTC, drive reacts in 25 s to the power loss
Changes immediately from motoring to generating

Benefit to the customer

Controlled stop in 20...30 sec No extra capacitors needed in the dc link

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DTC Customer Benefits - Lifts

One of worlds largest lift manufacturers With DTC, extremely rapid torque control
allows high gains in speed control

Excellent drive comfort for high performance lift

jerkfree at start & stop

Also, regenerative bridge integrated in the drive resulting in compact design

Energy savings, high power factor, and low harmonics to the line

Manufacturer refers to the drive as servo

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