Electricity: motive power systems – Induction motor systems – Primary circuit control
Reexamination Certificate
2002-09-30
2004-07-27
Patel, Rajnikant B (Department: 2838)
Electricity: motive power systems
Induction motor systems
Primary circuit control
C318S808000
Reexamination Certificate
active
06768284
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to adjustable frequency drive (AFD) systems and, in particular, to such AFD systems, which control the speed, torque, horsepower and/or direction of an induction machine, such as an AC motor.
2. Background Information
An Adjustable Frequency Drive (AFD) system may be employed in a wide range of commercial applications, such as, for example, HVAC, fans, pumps, conveyors, material handling and processing equipment, and other general industries, such as, for example, forest products, mining, metals and printing.
If the stator terminals of an induction machine are connected to a three-phase AFD system, then the rotor will rotate in the direction of the stator rotating magnetic field. This is the induction machine motoring mode of operation. When load torque is applied to the motor shaft, the steady state speed is less than the synchronous speed.
When the induction machine speed is higher than the synchronous speed, and the induction machine rotates in the same direction as the stator rotating field, then the induction machine is in the generating mode of operation. A generating torque acting opposite to the stator rotating magnetic field is produced. For example, to stop an AFD system, the power supply frequency is gradually reduced. In the deceleration process, the instantaneous speed of the AFD system is higher than the instantaneous synchronous speed because of the system inertia. As a result, the generating action of the induction machine will cause the power flow to reverse and the kinetic energy of the AFD system is fed back to the power supply source.
For AFD systems, the braking or regenerative energy of the system flows, for example, from the motor, through diodes in the inverter section of the drive, and into DC bus capacitors. Typically, the input diodes of the upstream converter do not provide a path for this energy to be returned to the AC power line. Hence, the regenerative current flows into the DC bus capacitance and, thus, the DC bus voltage increases.
There are four common methods to deal with the high DC bus voltage due to the regenerating condition. The first method employs silicon controlled rectifiers (SCRs), insulated gate bipolar transistors (IGBTs) or gate controlled thyristors (GCTs or GTOs), as converters in order to both provide power to the DC bus when motoring and to regenerate from the DC bus back to the AC line when braking. This method has the disadvantage of relatively higher cost since the converter section is similar to or the same as the inverter section.
The second method simply initiates a drive fault and trip when the DC bus voltage becomes too high. The disadvantage of this solution is the disruption of the process because of a resulting shut down or nuisance trip.
The third method handles the regenerating energy without tripping by employing a braking resistor, which provides a path to dissipate the regenerative energy. A braking resistor control circuit senses the high voltage condition and, then, electrically connects the braking resistors across the DC bus. The braking resistors (e.g., bus clamps; snubbers; voltage limiters) dissipate the excess energy. For example, for 230 VAC drives, the DC bus is approximately 310 VDC, and for 460 VAC drives, the DC bus is approximately 620 VDC. The actual DC bus voltage is about 1.35 times the RMS AC line voltage. The current through the braking resistor is proportional to the DC bus voltage divided by its resistance. For example, a 20 &OHgr; resistor module connected across a 460 VAC line dissipates about 10 kW, while the same resistor dissipates about 20 kW when electrically connected to a DC bus, which is produced by rectifying a 3-phase AC line for a 460 VAC drive. The costs of the braking resistor can be significant, while the physical size of the resulting drive assembly increases. Both of these are normally undesirable results.
The fourth method actively limits the DC bus voltage at a safe threshold by applying proper control algorithms in response to regenerating conditions. However, when the induction machine operates in its normal motoring mode, the high input (utility) AC line voltages can push the DC bus voltage to reach the regenerating voltage threshold. In order to prevent the control algorithms from limiting the DC bus voltage in this scenario, it is known to employ input AC potential transformers or other voltage amplifier apparatus to measure the AC line input voltages. This approach similarly has the disadvantages of relatively higher cost and relatively larger physical dimensions.
The known solutions to handle AFD regenerating conditions have the disadvantages of shutting down industrial processes, relatively higher equipment costs and/or relatively larger physical sizes.
The generating mode of an AFD system causes the DC bus voltage to rise. The AC line input voltages to the system can be higher than the rated value in steady state. Also, momentary surges can occur in such voltages of any electrical distribution system, thereby causing a relatively higher DC bus voltage to be present in these cases. Therefore, it is difficult to determine which source is creating the energy that results in an over-voltage condition on the DC bus.
There is room for improvement in AFD systems and methods and apparatus for controlling the same.
SUMMARY OF THE INVENTION
These needs and others are met by the present invention, which identifies and controls regenerating energy flow for Adjustable Frequency Drives (AFDs). This regenerating energy flow is developed in both steady state and dynamic operating conditions of a three-phase induction machine, which is controlled by the AFD. The method and apparatus distinguish the energy source both in steady state and in dynamic transient conditions.
The three-phase currents of the AFD are converted into a stationary vector of current. The three-phase AC currents are measured by employing suitable current sensors (e.g., Hall effect) and are transformed into two-phase AC currents through the Clarke Transformation in the stationary reference frame. A space vector technique is employed to develop an angle. The Park Transformation employs the two-phase AC currents and the angle to produce two-phase DC current vectors in the rotating reference frame. These DC current vectors include the induction machine torque and flux producing components.
If the torque producing current vector reverses its polarity (e.g., direction; sign) when the commanded speed is less than the actual rotor speed, then the regenerating condition is confirmed.
If the regenerating condition is true, then a control algorithm turns on to limit the rising DC bus voltage at its predetermined threshold. When the induction machine is in the regenerating mode, the DC bus voltage is clamped at the predetermined threshold without tripping. The DC bus voltage is regulated dynamically by a compensation module, in order to stay at the predetermined threshold, thereby controlling the regenerating energy flow without necessarily tripping the AFD or adding costs and sizes to the overall electrical system. After the regenerating energy is dissipated and the induction machine is no longer in the generating mode, the DC bus voltage is automatically reset to the normal level in the motoring mode.
If the regenerating condition is not true, then the predetermined threshold adjusts itself based on the DC bus voltage level as determined by the AC line inputs.
The present invention provides a stable operating system and eliminates the disadvantages of the known prior art. In addition, the torque and flux producing current vectors in the rotating reference frame may be employed to conveniently calculate the induction machine power factor.
As one aspect of the invention, a method for dynamically controlling induction machine regenerating energy flow and direct current bus voltage for an adjustable frequency drive system comprises: sensing a direct current voltage of a direct current bus; sensing a plurality of alternating currents at alternati
Becker Scott K.
Lee Kevin
Schmidt Kevin J.
Eaton Corporation
Kastelic John A.
Patel Rajnikant B
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