Bina eel ence) PU eas(o yy SUPPORTING NOTES 5 MOTOR METHODS OF BRAKING Objectives To be able to explain why some loads are difficult to stop To be able to describe the operation of an electromechanical brake To be able to describe the operation of a plug braking system To be able to describe the operation of a DC injection braking system To be able to describe the operation of a speed ramping system using an inverter To be able to describe the operation of a dynamic braking system using an inverter To be able to describe the operation of a regenerative braking system using an inverter Nogaeene 1. The need for a brake There are many types of mechanical load that can be connected to a motor such as fans, pumps and fri brakes. The latter could be used for measuring the loading on the motor and from this data the torque speed curves can be drawn. We would have no problem stopping the motor when coupled to these types of toad. The instant that the three-phase supply is disconnected, the motor will stop due to the braking effect of the load. However, if we had a load such as a grinding wheel which has a large amount of kinetic energy at speed, when the motor is switched off, the load will naturally continue to rotate at high speed for a long time especially where there is very little friction present in the system. This is commonly called coasting or free-wheeling. If you've ever ridden a bicycle, you'll be able to identify with this scenario, although you’ve stopped peddating, it takes a long while to come to a halt even on the flat. Induction motor G® Coupling t Grinding wheel None of the types of motor starter covered so far on this course incorporate a method of stopping such a load as this. There are several ways of doing it including electromechanical, plugging, DC injection, speed ramping, dynamic and regenerative braking. The last two require complex power electronics to achieve. Coe NGfL CYMRU GCaDBina eel ence) PU eas(o yy SUPPORTING NOTES 5 MOTOR METHODS OF BRAKING 2. Electromechanical Braking This type of brake is similar to that used on the wheels of a car. However, instead of using hydraulics to apply a force to press the brake shoes against the drum, a large spring is used. This means that the brake is normally on. A powerful solenoid coil is used to release the shoes off the drum (against the force of the spring). This allows the motor to turn. The coil must be interlocked with the control circuit so that it energises with the main contactor. This is a fail safe system and can be used in dangerous situations such as ona lift or a crane. power off power on > + -_ > {OY solenoid overcomes spring to release brakes spring holds the brakes on 3. Plug Braking This method of braking is very crude, However it is the fastest way to stop an induction motor. It involves putting the motor into reverse while still moving forward. Before attempting this, you must make sure that the contactors used are capable of handling the very large currents produced. Care must be taken not to plug brake too often as it causes 4 times the kinetic energy of the load to be dissipated in the stator windings. This will overheat the motor and trip out the overload. The power circuit is identical to a reversing DOL starter while the control circuit has some differences. Remember, all you have to do to reverse an induction motor is to swap two of the phases. A timer could be used to control the plug braking contactor but the delay must be set to prevent the motor from reversing. It would be better to employ a speed sensing relay to detect that the motor has actually stopped before switching off the braking contactor. 4, DC Injection Braking This type of braking involves disconnecting the stator from the supply and then injecting a DC current into two of the phases. It can be explained by the fact that the torque produced in the rotor proportional to slip. When DC is injected into stator coils, it makes the stator field stationary. The rotor is then turning faster than the stator field so that stip is negative. A negative slip produces a negative torque which of course is a braking torque i.e. the torque fs in the opposite direction to the motion of the rotor. Once the rotor comes to a stop, there is no more braking torque because the stip is zero. Care must be taken not to put too much DC into the stator as this will burn out its windings. A timer or speed sensing relay can be used to set the time for which DC is applied. This feature is often found in an inverter since it already has a source of DC inside. DC injection braking can also be incorporated into a DOL starter by adding a transformer, a rectifier and a pair of interlocked contactors to prevent the DC mixing with the AC. The power schematic and control Circuit are shown on the next pages. Coe NGfL CYMRU GCaDBina eel ence) PU eas(o yy SUPPORTING NOTES 5 MOTOR METHODS OF BRAKING Power Schematic for DOL starter with DC injection brake. u 2 B 4 E Fuses [l isolator ‘Transformer Fuses Transformer Bridge Rectifier Run Brake contactor contactor cz 3 DC current travels down from rectifier, through one phase (W1) and back up through another phase (ut), NGfL CYMRU GCaDBina eel ence) PU eas(o yy SUPPORTING NOTES 5 MOTOR METHODS OF BRAKING The control circuit for DC injection braking is shown below. DC must not be injected for longer than necessary as this will damage the stator coils. 24VAC () 2avac st oO a wy) “4 on oF % at x START PUSHBUTTON STOP OVERLOAD Tun PUSHBUTTON UNIT CONTACTOR col. RETAINING CONTACT n STOP LJ PUSHBUTTON START TIMER ‘BRAKE PUSHBUTTON CONTACT CONTACTOR COIL cR RETAINING ~ ~ CONTACT LI TIMER coll Circuit Operation (a) Starting & Running - Pressing the start button S2 will energise coil C2 provided the stop button 51 is not pressed and the overload OL2 has not tripped. The retaining contact of C2 will keep the contactor energised when the start button $2 is released. The motor then runs up to speed. (b) Stopping & Braking - Pressing the stop button S1 will de-energise contactor C2 and energise contactor C3 provided the start button S2 is not pressed. The retaining contact of C3 will keep the contactor energised when the stop button S1 is released. This causes the motor to stop due to the injection of DC. C3 will remain energised until the timer CR finishes timing. Then its normally closed contact will open de-energising C3 and removing DC from the stator. This in turn de-energises the timer coil. The motor will experience a braking torque while C3 is energised and will therefore stop rapidly. The stopping time depends on the DC voltage injected into the two phases of the stator. If the time delay is too short, the motor will coast after the DC is removed from the stator. It is normal to fine tune the delay time by trial and error. This circuit can also be used for plug braking with care, since if the time is set too short, the motor will reverse. Coe NGfL CYMRU GCaDBina eel ence) PU eas(o yy SUPPORTING NOTES 5 MOTOR METHODS OF BRAKING 5. Speed Ramp Braking This type of braking involves ramping down the frequency of the supply with an inverter drive. When the stator field frequency is reduced, synchronous speed falls causing the rotor to run faster than the stator temporarily. The effect is that the relative motion between stator and rotor reverses causing the induced currents to reverse. This reverses the direction of the torque created in the rotor thus a braking torque is produced. Therefore, as the frequency of the supply is ramped down to zero, the rotor follows it until the speed also reaches zero, frequency of supply The ramp down time tx can be adjusted in the inverter drive to suit the system. ° time te Frequency decreasing IA LN S SoH2 402 30H 20H oH 6. Dynar Braking In this method, the kinetic energy of the load is used to assist the stopping process by converting it into electrical energy which is then dissipated in a resistor. This method turns the motor into an induction generator. From the previous lesson, you will remember the basic structure of the variable frequency inverter. A resistor RDB has been added across the DC link. The size of the resistor must be calculated to obtain the correct stopping performance. Complex power electronics are needed to perform this energy conversion. This means that although block 1 in the diagram below can be a simple rectifier, block 2 must be able to invert DC into AC when motoring and convert AC back into DC when braking. Inverter Energy “1 recovered Energy wasted |} om Roe $=) i Block t ~ Block2 +o T2 |—i—o1 | from motor 5 terminals Ut, enw Coe NGfL CYMRU GCaDBina eel ence) PU eas(o yy SUPPORTING NOTES 5 MOTOR METHODS OF BRAKING 7. Regenerative Braking This method also converts the kinetic energy of the load back into electrical energy using the generator principle. However, instead of wasting it in a resistor, it is pumped back into the three-phase mains supply. This calls for even more complex power electronics making this type of inverter more expensive. Block 1 in the diagram below must therefore be able to convert AC into DC when motoring and invert DC it back into AC when braking. Block 2 must have the same capabilities as with the previous method. Energy Inverter Energy recovered recovered Energy recovered from motor terminals U1, vi, Wt mains input @ 50Hz NGfL CYMRU GCaD