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Introduce Inverter or AC drive Drive is device that convert frequency and voltage
blowers, Flow rate and air flow quantityReplacing with motors of better efficiency
constant pumps Flow rate and quantity variable Speed variable Speed constant air flow
Collecting energy for excess facility capability (inverter application) Recovering throttling loss of valves or dampers (inverter application) Using an inverter drive makes an overall more efficient application (Eddy-current coupling drive Inverter drive) Replacing with motors of better efficiency Inverter power supply regenerative regenerative energy at lowering. function collects the
Extruders, conveyors
Re-use regenerative energy created by the unwinder. Stores up energy for starting torque
Fans: Energy Saving with Variable Speed Control Fan shaft power
Fan shaft power P is in proportional to the product of the air flow quantity q and pressure h.
Characteristics of Fan Air Flow Quantity and Pressure, and Principle of Energy Saving
H stands for the fan characteristic and R for air flow resistance at rated number of revolutions N. A, the intersection point of H and R, is the rated operation point of the fan. At point A, the air flow quantity and pressure is 1.0 of the rating. When the damper is throttled in order to reduce the air flow quantity to 50%, the curve of air flow resistance changes from R to R0.5. The power at that point is expressed with the area of HoQ0.5AdHd. Because controlling the speed reduces airflow by 50%, if we assume the change in speed from N to be N0.5, and the change in fan characteristics from H to be H0.5, then the amount of energy saved is found be calculating the area HoQ0.5AiHi .
P=
QH Qo Ho (kW) 60 f
Fan characteristic H is approximated at the following formula: = 1.03N2 + 0.56NQ - 0.59Q2, Air flow resistance R is approximated at the following formula: R = Q2 , Rated air volume Qo: 1000 m3/minutes, Rated pressure: 5kPa, Fan efficiency at rated air flow quantity: 0.7, Fan efficiency at 50% air flow quantity = 0.54 Inverter Energy-saving Effect When applied to a fan with air flow quantity 50% Power at damper control [Pd] H = 1.03N2 + 0.56NQ - 0.59Q2 Air flow pressure at air flow quantity 50% is: Hd = 1.03 x 1 + 0.56 x 1 x 0.5 0.59 x 0.52 = 1.16 Power: QH 0.5 1.16
PD =
m = 0.9: Motor efficiency Power at inverter control [Pi] R=Q2 Air flow pressure at air flow quantity 50% is: Hi=0.52=0.25 Q 0.5 0.25 Power:
60 fm
Q oHo =
60 0.54 0.9
1000 5 = 99.5kW
Pi =
60 fmi
Q oHo =
1000 5 = 17.4kW
Power saving amount [Ps] Ps = PD Pi = 99.5 - 17.4 = 82.1 k Assuming that power unit price is 15 yen/kWh and the fan runs continuously for one year (8,000 per year), then cost savings can be expressed as 82.1 kW x 15 yen x 8000 hrs = 9,852,000 yen per year! Characteristic of Power Consumption for Air Flow Quantity
When using an inverter, power consumption is either greater or equivalent to the inverter loss at 100% air flow quantity than when using damper control. However, as soon as the air flow quantity is reduced, the power consumption is rapidly reduced at inverter control.
In pump applications, the value for the actual pump head is normally provided. Actual pump head is the difference of height <ha> between the water level of the discharge tank and the suction tank as shown in Fig. (a). In fan applications, the air flow pressure is 0 when the air flow quantity is 0. However, in pump applications, the pressure that is always applied to the actual pump head is added to the pump even if the flow rate is 0. Since actual pump head becomes 0 for a circulation pump as shown in Fig. (b), a circulation pump can be regarded in the same way as a fan.
Characteristics of Pump Flow Rate and Pump Head Calculating Inverter Energy-saving When applied to pump at flow rate 50% Power at valve control [P B ] H=1.25N 2 0.25Q 2 Pump head at flow rate 50%: HB = 1.25 x 12 - 0.25 x 0.52 = 1.188 QH 0.5 1.188 Power: P = Q H = 24 25 = 115.5kW
B
6.12 pm
Pump head at flow rate 50%: = 0.7 + 0.1 x 0.52 = 0.725 QH 0.5 0.725 Power:
Pi =
6.12pmi
Q oHo =
24 25 = 54.7kW
= 0.95: Inverter efficiency Saved power [P s ] Ps = PB Pi = 115.5 54.7 = 60.8 kW Assuming that power unit price is 15 yen/kWh and the pump runs continuously for one year (8,000 per year), then cost savings can be expressed as 60.8 kW x 15 yen x 8000 hrs = 7,296,000 yen can be saved. Characteristics of Flow Rate and Efficiency The following shows the characteristics of the pump efficiency for the flow rate. The 100% speed characteristics show the efficiency characteristics when using valve control. It can be seen that the efficiency decreases due to reduction of the flow rate. Efficiency decrease when the flow rate is reduced by rotational speed control at the peak point of the pump efficiency characteristics at each speed. We can see that there is no efficiency reduction up to 50% speed. Although the efficiency is reduced to 0.88 at 20% speed, the reduction is very slight compared to the efficiency reduction 0.35 in case of valve control. The relation between the fan air quantity and efficiency is almost the same what we see for pumps. Relation between Flow Rate and Rotational Speed Pump characteristic H and piping resistance R0 are calculated as follows in the example shown on the previous page: H = 1.25N2 - 0.25Q2 , R = 0.7 + 0.1Q2 By replacing 1.25 with a , 0.25 with b , 0.7 with ha and 0.1 with c , the above formula can be expressed as follows: H = a N2 - b Q2, R0 = ha + c Q2 Since the pump operating point is where H and R0 intersect, H equals R0. In other words, a N2-b Q2=ha+c Q2 Therefore, rotational speed N is: ha + (b + c)Q 2 N= Accordingly, the flow rate is not proportion to the rotational speed.
N=
b+c Q a
Only when the actual pump head is 0, the rotational speed is in proportion to the flow rate. Since there is no actual pump head in case of fans, it is always in proportion to the flow rate. Energy Saving by Replacing Variable Speed Drive System Other AC variable systems other than inverter drive include VS motors (motor with eddy-current coupling) as well as the winding motor secondary resistance control method. The figure below shows the configuration of a VS motor. The motor to be driven is always turning at a constant speed. Eddy-current coupling is composed of the drum connected directly to the motor and the magnetic coil connected directly to the load side. By applying the DC current to the magnetic coil, eddy current is generated in the drum. Torque is generated by this eddy current and by the excited current flowing in the coil. Load shaft connected directly to the coil rotates at the slip almost in proportion to the torque. Since the slip can be adjusted by controlling the current flowing in the coil, the load shaft speed can be adjusted, too. Principle of Speed Control The following graph shows the characteristics of rotational speed and torque of an eddy-current coupling. In the graph below, a is the torque characteristics when excitation current is large. The operating point is the point of intersection Pa with load torque T . Thus the rotational speed is Na. When the excited current is reduced and the torque characteristic becomes b, the point of intersection with T is Pb, and the rotational speed is reduced to Nb. In this way, adjusting excitation current can control the speed of the load shaft.
TL =
Motor rated speed 1750min-1 VS motor output shaft rated speed 1500min-1 Motor input power at 1750min-1 37kW Motor efficiency 91% Load torque TL at 37kW input and 1750min-1 is calculated based on the above specifications:
1000 = 183.5 Nm Constant Torque Load TL = 2 1750 To calculate power P relative to torque T L and number of revolutions N, P=
-3 2TL N 10 (kW) 60
60 0.91 37
(1) Calculating energy saving when operating with constant torque With a VS motor or secondary resistance control, reducing the speed reduces the motor shaft output in proportion to the speed. However, because this reduction in output is essentially a loss, the motor input power is almost the same. Using an inverter to adjust the speed can eliminate this loss. Output power when using a VS motor 37 kW. This is because the motor input power does not change even if the speed is reduced. Output power when using an inverter drive Assuming that the motor efficiency is 87% and inverter efficiency is 95% at 750min-1, inverter input power will be:
Amount of energy saving 37 kW17.4 kW 19.6 kW If the pump operates for 6000 hours a year with power unit price 15 yen/kWh, then: 19.6 kW 15 yen 6000 hrs 1,764,000 yen saved! (2) Calculating energy saving at square reduction torque load Torque is reduced in proportion to the square of the speed. Power when VS motor used 183.5 0.25 = 45.9 Nm since torque becomes 25% of that at rated speed. Calculate the motor input as follows. Assume that the motor efficiency is 83% at 1750min-1 with a load ratio of 25%. Power when inverter used Inverter input power is calculated as follows assuming that the motor efficiency is 82% and the inverter efficiency is 95% at 750min-1 and load ratio 25%.
Energy saving amount 10.1 kW4.73 kW 5.37 kW If the pump operates for 6000 hours a year with power unit price of 15 yen/kWh, then: 5.37 kW 15 yen 6000 hrs = 483,300 yen saved! Energy Saving by Power Regeneration of Mechanical Energy How a load creates regeneration When a crane is lowering a load or when winder is unwinding a load, the motor acts like a generator, creating energy as the load pulls against the rotation of the motor. This is considered the regenerative status.
Regenerative Energy Processing by Braking Resistor Regenerative energy flows into the inverter from the motor when the motor enters into regenerative status. This regenerative energy increases the voltage in the DC bus, and can trigger the overvoltage protection function (thus causing the drive to stop). In order to prevent this, a braking unit and a braking resistor are added in a generalpurpose inverter drives to absorb regenerative energy and dissipate it as heat. Using Regenerative Energy in an Inverter Drive Typical Calculation for Energy Saving The following example shows an inverter with a regenerative function used to operate a crane application. Crane specifications Rated load :10t Rated hoisting speed :22 m/min Applicable motor capacity :45 kW Motor speed :1150 min-1 Machine efficiency:87% Using the specifications listed above, rated motor torque T is calculated as follows:
T=
60 45 = 374 Nm 2 1150
Operation Pattern
PL =
Load torque:
TL =
Load inertia:
Assuming that the motor inertia is 0.49 kg m and machine inertia is 0.75 kg m, the total inertia is: 0.49 + 0.75 + 2J N 2 1.333 1150 0.0927 = 1.333 kgm T = = = 107.0 Nm(28.7%) Acceleration torque: 60t 60 1.5 Acceleration torque when lowering :91.70.87228.740.7 Constant speed torque when lowering :91.70.87269.4 Deceleration torque when lowering :69.428.798.1 Regenerative power is calculated as follows when the motor efficiency is 90% and inverter efficiency is 95%: P = 450.407/21.5 + 0.69415 + 0.981/21.5)/760.950.9 = 5.8 kW If the crane operates for 3600 hours with power unit price of 15 yen/kWh, then cost savings becomes: 5.8 kW 15 yen 3600 hrs = 313,200 yen saved!
W V 2 10 10 3 22 = JL = = 0.0927kgm 4 N 4 1150
Energy Saving by Motor Operation with High Efficiency Inverter drives control frequency and voltage. This explains how inverter drives are used to achieve higher efficiency from the motor. The graph below shows the motor slip-torque and efficiency characteristics. Imagine a case where the load of the machine is being driven at rated load T L1 is reduced to TL2. When the load is TL1, the motor is running at slip S1 determined by P1 (the intersection of motor torque characteristics TM1 and load torque TL1). The efficiency at that point is 90%. When the load is reduced to TL2, slip S2 is determined by point P2 (the intersection of TM1 and TL2). The efficiency is reduced to 72%, lower than the efficiency at rated load. However, the efficiency becomes 90% since the slip is changed again from S2 to S1 when voltage is reduced so that the torque characteristics will be TM2. In this way, by controlling the voltage according to the load, the motor can always be driven with greater efficiency. Yaskawa calls this the Energy Saving Control function. We offer this function in most of our drives. Energy Saving Control Block Diagram A block diagram illustrating Energy Saving control appears below. During acceleration, switch SW closes on side 1 to output voltage as determined by the standard V/f pattern. Once acceleration is complete, SW then switches over to side 2, and outputs voltage at the maximum efficiency as calculated by the load conditions and the frequency at that point. Typical Calculation of Energy Saving Energy Saving in centrifugal separator Although a great deal of power is required to accelerate the load in a centrifugal separator due to the large inertia, it becomes relatively light when operating at a constant speed. The figure on the left shows the operation cycle. Even if the Energy Saving control is available, it is not active during acceleration (i.e., the power required to use
Energy Saving is equal to that when Energy Saving control is disabled). We should therefore compare the power required with a light load after acceleration. Specifications of centrifugal separator Applicable motor : 400 V 75 kW 4PYearly operation time: 8000 hours Inverter efficiency : 95%Power unit price: 15 yen/kWh Calculating Energy Saving Inverter operation without energy-saving control 2 40 1790 Motor output power at constant speed: P10 = 10 3 Inverter input power: 60
= 7.5kW
P1i =
Average power in one cycle: 1 = 10.41800/2340 = 8.00 kW Energy-saving control inverter operation Motor output power at constant speed: 2 40 1790
P20 =
P2i =
Average power in one cycle: 2 = 9.181800/2340 = 7.06 According to the above calculations: Electrical charge of 8.00 - 7.06800015 = 112,800 yen can be saved. New Motor and Inverter Technologies New motor technology Motor loss must be reduced in order to improve the motor efficiency. There are 4 types of motor loss: stator copper loss, rotor copper loss, iron loss, and mechanical loss. Reducing these four types of loss improves motor efficiency.
60 = 9.18kW
10
= 7.5kW
P motors are designed to 10 = 7.5kW and minimize loss types Motors called high-efficiency motors or power-saving 20 = 60 . To reduce stator copper loss (), increase the size of copper wire used in the motor windings. For , iron core material is upgraded to minimize the loss. Unlike induction motors, synchronous motors use permanent magnets for 7.5 P2i = the rotors, and consequently have hardly any rotor copper = 9.18kW loss. This makes synchronous motors capable of even 0.86 0.95 greater efficiency.
Cross Section of a Motor For greater efficiency Yaskawa has designed synchronous motors using permanent magnets with the product name Super Energy Saving Motor, and super econo motor. The figures below illustrate how each motor is built. Fig. (a) is an induction motor where the magnetic flux is generated in the stator winding. Fig. (b) is a Super Energy Saving Motor where the magnetic flux is generated by permanent magnet implanted in the rotor. Fig. (c) is a super econo motor which has a permanent magnet implanted in the rotor of an induction motor. This motor can be driven by standard line power while the Super Energy Saving Motor cannot be driven by line power. At start, it generates torque as an induction motor using current flowing in the rotor conductor, then operates as a synchronous motor when the speed is close to the synchronous speed.
2 40 1790
New Inverter Technology The diagram below illustrates five steps that can be taken to improve motor control and inverter drive performance: Reducing the loss generated in the inverter unit; and concern circuitry and the control method used for high-efficiency performance; covers improvements to drives power supply side; involves a new approach to power conversion.
Reducing Inverter Component Loss One way to improve inverter efficiency is to reduce loss from various components. The circle graphs below show the amount of loss generated from each component in the drive. About 10 years ago, the loss generated from IGBT (Insulated Gate Bipolar Transistor) switching in the main circuit exceeded 60% of all loss. Recent improvements in switching technology have now minimized loss from IGBTs down to 40%. Improving the switching characteristics of the IGBT device has reduced the power loss to the half of what it was 10 years ago. In addition to reducing power consumption for the control power supply and control circuit, inverter efficiency is 9o% better than in the past. Improvements with PWM Control The high carrier frequency used in PWM (pulse width modulation) increases the amount of IGBT switching loss. Yaskawa has created a 2-phase modulation method to minimize this switching loss. As shown below, the 2-phase modulation method stops switching when current is large. This way, one of the 3 phases is always in the stopped status. Using this 2-phase PWM control method can reduce the switching loss by approx. 30%. Employing 2-phase modulation can reduce IBGT switching loss by approximately 30%. Improving the Output Voltage Waveform Although high carrier PWM control makes the output current waveform very close to sinusoidal, the actual voltage waveform created is still a group of square waves. The surge voltage generated at rising and falling edges of this square waves causes trouble. A surge suppression filter is normally attached between the inverter and the motor in order to prevent the motor insulation from being damaged by surge voltage. This filter is called RLC filter, and is is composed of a resistor, reactor, and a capacitor. A large filter is not needed if the inverter and motor are close together. If they are far apart, however, a large capacity filter is needed. For example, with the motor capacity of 75 kW, the filter consumed power is 0.3 kW, 1.4 kW and 12.6 kW when the wiring length is 30 m, 100 m and 300 m, respectively. As the distance gets longer, the required capacity is sharply increased. Additionally, the size of the filter also becomes larger, it will be necessary to examine where to install. To omit this filter, 3-level control inverters have been devised. Using these inverters can solve the problem of . Furthermore, this control method can reduce the remaining 3 failures (, and ) at the same time. Common Problems Motor insulation damaged by surge voltage Peripheral devices malfunctioning due to noise generated by the inverter Earth leakage breaker malfunctioning due to leakage current Motor bearings corroded by shaft current What Is 3-Level Control? Principle of 3-Level Control Method In conventional 2-level control, 2 transistors are used for each phase, making a total of 6 transistors for 3 phases to switch DC bus bar voltage VPN. Phase voltage turns ON and OFF depending on the size of VPN, and changes according to it. In the 3-level control, 4 transistors are used per phase, for a total of 12 transistors for 3 phases. The illustrations below shows how transistors switching works during one phase. In this figure, voltage P appears in phase U when transistors A and B turn ON. Then O appears in phase U through diodes E and F when transistors B and C turn ON. N appears when transistors C and D turn ON. It means that phase U can take three states: P, N, and O. This is how 3-level control was named.
While voltage fluctuates between P and N in 2-level control, it fluctuates between P & O, and between O & N in 3-level control. Therefore, phase voltage turns ON and OFF depending on the size of VPN/2, which is half of VPN during 2-level control. This creates an output waveform very close to a perfect sine wave. Surge voltage is cut in half when voltage fluctuation becomes half, which means that noise and leakage current is also cut in half, resulting in reduction of shaft current.
Comparison of Surge Voltage Waveform in 3-level Control Method The following figures show the output voltage waveforms of 400 V class inverter 2-level control and 3-level control, respectively. In the 2-level control method, the peak value of the waveform is almost 1200 V, while it is limited to 770 V in the 3-level control method. Since this value is lower than the insulation voltage of the 400 V class motor, the existing motors can be driven by an inverter without using surge suppression filters.
Comparison of Radiation Noise in 3-level Control Method These graphs show noise levels. In the frequency bandwidth between 30 MHz and 300 MHz, the noise level is limited to 20 dB at the maximum. This reduces the effects on surrounding peripheral devices caused by noise. Comparison of Leakage Current in 3-level Control Method The graphs below compare leakage current in 2-level and 3-level control. Leakage current in the 3-level control method is almost the half of that in the 2-level control method. Less leakage current means fewer faults with the leakage breaker.
No Surge Suppression Filter Needed Because of Surge Reduction 3-level control contributes to energy saving because there is no need for a surge suppression filter that would otherwise consume power. Consumed power WR of the resistor is calculated as follows: WR = CfE2fi2 Cf: Capacitor size is determined by cable type or wiring length E: DC bus bar voltage (600 V at 440 Vac input) fi: Inverter carrier frequency2: Multiplied by 2 for charging and discharging of capacitor Power Consumption of Surge Suppression Filter Energy saved because no filter is used
Improvement of Inverter Input Power Factor Power factor is approx. 0.65 when the inverter is connected directly to the power supply. However, it can be increased to approx. 0.9 by connecting a DC reactor, and to up to approx. 0.95 with a 12-pulse rectifier. Since improving the power factor decreases the input current needed, this in turn reduces the wiring loss, therefore saving more energy for the entire system. New Power Conversion Unit (Matrix Converter) Just to review, an inverter drive is used to convert line power to supply to some desired frequency and voltage. It changes AC into DC in the rectifier circuit, then adjusts the voltage and frequency to the desired level. Because a voltage ripple is created when converting AC into DC, a smoothing capacitor is needed between the inverter and the power supply to even out this ripple. These capacitors take up space, making it difficult to design compact
inverter drives and also limiting the lifespan of the unit. A new design called the matrix converter offers a new environmentally friendly approach to power conversion.
Features of eco-friendly matrix converters No capacitors in the main circuit: Smaller size, longer life Free from power supply harmonics: Input current a near-perfect sine wave (distortion ratio: 5%) Power supply regenerative function: No braking resistor is needed, which contributes to space and energy saving. High conversion efficiency: Greater energy saving.
Matrix Converter and Inverter Main Circuit Configuration The diagrams below compare the designs of a matrix converter main circuit and the inverter main circuit. The matrix converter has a simple configuration. It is composed of 9 bi-directional switching elements, and does not have the converter and DC bus sections which are needed for inverters. However, the controlling procedure is complicated and needs high-speed calculation and two-directional switching elements. Since the two-directional element is composed of 2 transistors in the reverse parallel, the actual number of transistors is 18.
Comparison of I/O Waveform I/O waveforms for an inverter drive and the matrix converter appear below. There is a fair amount of distortion generated in the input current for an inverter drive, while matrix converter has a near-perfect sine wave. Since the distortion ratio for the matrix is 5% or less, there is no need take extra steps to prevent harmonic distortion (otherwise necessary in an inverter drive).
Power Supply Regeneration: Matrix Converters vs. Inverter Drives Matrix converters dont need capacitors in the main circuit, so they can be built much smaller Space saving Simple main circuit configuration without excessive loss High efficiency Total 6 cables of main circuit wiring (3 at power supply side and 3 for motor side) Reduction of wiring and labor Type Matrix converter Power supply regenerative PWM converter + inverter Inverter with regenerative function
Similar to sinusoidal wave Not needed (therefore longer lifespan) Possible 0.201
Distorted wave
Smoothing capacitor 100% load continuous operation at low speed Mounting direction (m2)
Necessary
Necessary
930 6 45
2200 20 118
1400 6 59