Electric Drives 1

ELECTRIC DRIVES
Ion Boldea S.A.Nasar


2005
Electric Drives 2
1. ENERGY CONVERSION IN ELECTRIC
DRIVES
1.1. ELECTRIC DRIVES - A DEFINITION
Figure 1.1. Constant speed
electric drive
About 50% of electrical energy produced is used in electric drives today.
Electric drives may run at constant speed (figure 1.1) or at variable speed
(figure 1.2).
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Figure 1.2. Variable speed
electric drive
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1.2. APPLICATION RANGE OF ELECTRIC
DRIVES

A summary of main industrial applications and power range of electric drives is
shown on figure 1.3.
Figure 1.3. Electric drives - variable speed applications
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Figure 1.4. A.C. versus D.C. electric
drives markets dynamics
Traditionally for variable speed d.c. brush motors have been used for decades
[1] but a.c. motors [2,3] are catching up lately (since 1990) as shown on figure
1.4. This radical shift is mainly due to the rapid progress in power electronic
converters for a.c. motors [4].
Singular applications such as pumped - storage hydroelectric plants are now
built for unit powers of 100MW or more.
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1.3. ENERGY SAVINGS PAYS OFF RAPIDLY
Consider a real case when a motor pump system of 15kW works 300 days a year,
24 hours a day and pumps 1200m
3
of water per day. By on/off and throttling
control, only, the system uses 0.36kWh/m
3
of pumped water to keep the pressure
rather constant for variable flow rate.
Adding a P.E.C., in the same conditions, the energy consumption is 0.28kWh/m
3

of pumped water, with a refined pressure control.
Let us consider that the cost of electrical energy is 8cents/kWh.
The energy savings per year S is:
( ) year / $ 2304 year / $ 08 . 0 28 . 0 36 . 0 300 1200 S = = (1.2)
Now the costs of a 15kW PWM - P.E.C. for an induction motor is less than
$8000. Thus, to a first approximation, the loss savings only pay off the extra
investment in less than 4 years.
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Example 1.1. The revenue time.
Let us still consider that S dollars (1.2) have been saved in first year on energy
losses through the introduction of an P.E.C. system, and denote by i the interest
rate and by i
p
the power cost yearly increase.
Thus the effective interest rate per year i
E
is:
1
i 1
i 1
i
p
E

+
+
=
(1.3)
The net present value (NPV) of losses for an n year period is:
( )
( )
E E
n
E
i 1 i
1 i 1
S NPV
+
+
=
(1.4)
We may now consider the influence of taxes and inflation on these savings:
d e
E
NPV NPV NPV + =
(1.5)
where NPV
e
is the net present value of energy savings and NPV
d
is the net
present value of depreciation on premium investment (straight line
depreciation is assumed).
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With T the tax range:
( ) T 1 NPV NPV
e
= (1.6)
( ) | |
( )
T
i 1 i
1 i 1
n
NPV
NPV
n
n
e
d

+
+
=
(1.7)
With S = $2304 as the first year savings, for a period of n = 5 years, with i =
10%, i
p
= 5% and T = 40% we obtain gradually:
from (1.3):
0476 . 0 1
05 . 0 1
1 . 0 1
i
E
=
+
+
=
from (1.4):
7 . 10047 $
0476 . 1 0476 . 0
1 0476 . 1
2304 NPV
5
5
=

=
from (1.6): ( ) 6 . 6028 $ 4 . 0 1 7 . 10047 NPV
e
= =
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Finally the premium investment that can be expanded to achieve $2034
energy savings in the first year for a period of 5 years is, from (1.5),
7857 $ 8 . 1828 6 . 6028 NPV
E
~ + =
This is roughly $8000 (the costs of the P.E.C.), so more exact
calculations have led to an increase of the revenue duration from 4 to 5 years.
Considering that life time of P.E.C. drives is more than (10 - 15) years,
the investment pays off well.
from (1.4):
( )
( )
8 . 1828 $ 4 . 0
1 . 0 1 1 . 0
1 1 . 0 1
6 . 6028 NPV
5
5
d
=
+
+
=
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1.4. GLOBAL ENERGY SAVINGS THROUGH
P.E.C. DRIVES
So far the energy savings produced by the P.E.C. in variable speed drives
have been calculated for the drive only - P.E.C. and motor.
Figure 1.5. Primary energy consumption for throttle / motor / pump system
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Figure 1.6. Primary energy consumption for P.E.C. / motor / pump systems
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1.5.1. Typical load torque / speed
curves

Typical load torque / speed curves are
shown on figure 1.7. They give a
strong indication of the variety of
torque / speed characteristics. Along
such curves the mechanical power
required from the motor varies with
speed.
Figure 1.7. Typical load speed /
torque, speed / power curves
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1.6. MOTION / TIME PROFILE MATCH
Figure 1.8. Motion / time profile
a.) speed b.) position c.) required load torque

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Figure 1.9. Required speed / time profile
( ) ( ) ( )
T t J t T t
e
r
L
= +
-
O
Example 1.2. The direct drive torque / time curve
A direct drive has to provide a speed / time curve such as in figure 1.9. against a
constant load torque of T
L
= 10Nm, for a motor load inertia J = 0.02 kgm
2
.
Neglecting the mechanical losses let us calculate the motor torque (T
e
) / time
requirements.
The motion equation for a direct drive is:
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O
O
-
= = =
r
r
a
t
rad s
max
.
.
/
376 8
0 2
1884
2
T
Nm
Nm
Nm
e
=
+ = + = s s
+ = s s
+ = + = s s

1884 0 02 10 37 68 10 47 68
0 10 10
1884 0 02 10 37 68 10 27 68
. . . ;
;
. . . ;
for 0 t 0.2s
for 0.2 t 0.8s
for 0.8 t 1s
O
-
=
r
0 0 .
For the linear speed / time (acceleration - deceleration) zones the speed
derivative is:
For the constant speed (cruising) zone .
Consequently the torque requirements from the motor for the three zones are:
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Figure 1.10. Motor torque / time requirements
The motor torque / time requirements are shown on figure 1.10.
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Example 1.3. gear - box drive torque / time curve
Let us consider an electric drive for an elevator with the data shown in
figure 1.11.
Figure 1.11. Elevator electric drive with multiple mechanical transmissions and
counterweight
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The motor rated speed n
n
= 1550rpm. The efficiency of gearing system is q =
0.8.
Let us calculate the total inertia (reduced to motor shaft), torque and power
without and with counterweight.
First the motor angular speed e
m
is:
rad/s 22 . 162
60
1550
2 n 2
n m
= t = t = e
(1.12)
The gear ratios may be defined as speed ratios - O
t
/e
m
for J
4
+J
5
and O
d
/e
m
for
J
6
(figure 1.11).
Consequently the inertia of all rotating parts J
r
, reduced to the motor shaft,
(figure 1.11), is:
( ) =
e
O
+
e
O
+ + + + =
2
m
2
d
6
2
m
2
t
5 4 3 2 1 r
J J J J J J J
( )
2
2 2
kgm 062 . 25
22 . 162
5 . 7
8
22 . 162
5 . 2
200 5 . 0 2 8 15 =
|
.
|

\
|
+
|
.
|

\
|
+ + + + =
(1.13)
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For the cabin and the counterweight, the inertia, reduced to motor shaft (J
e
) is:
( ) ( )
2
2
2
2
m
2
cw c e
kgm 07238 . 0
22 . 166
1
800 1200
u
m m J = + =
e
+ =
(1.14)
Thus the total inertia J
t
is:
2
e r t
kgm 135 . 25 07238 . 0 062 . 25 J J J = + = + =
(1.15)
In absence of counterweight the la of energy conservation leads to:
u g m T
c m em
= q e (1.16)
Consequently the motor torque, T
em
, yields:
Nm 71 . 90
8 . 0 22 . 162
1 81 . 9 1200
T
em
=

= (1.17)
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The motor electromagnetic power P
em
is:
W 14715 22 . 162 71 . 90 T P
m em em
= = e = (1.18)
On the other hand in presence of counterweight (1.16) becomes:
( ) u g m m ' T
cw c m em
= q e (1.19)
( )
Nm 71 . 30
8 . 0 22 . 162
1 81 . 9 800 1200
' T
em
=

=
(1.20)
So the motor electromagnetic P
em
is:
W 4905 22 . 162 71 . 30 ' T ' P
m em em
= = e = (1.21)
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1.7. LOAD DYNAMICS AND STABILITY
load friction e
r
t
T T T
dt
d
J =
O

(1.22)
W V C S friction
T T T T T + + + =
(1.23)
where T
S
is the static friction torque (at zero speed); T
C
is Coulomb friction
torque (constant with speed); T
V
is viscous friction torque (proportional to
speed) and T
W
is windage friction (including the ventilator braking torque,
proportional to speed squared):
r V
' B T O =
2
r W
C T O =
(1.24)
(1.25)
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Figure 1.13. Mechanical characteristics:
a.) d.c. brush motor with separate excitation b.) induction motor
c.) synchronous motor
Figure 1.12. Components of friction torque, Tfriction
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Example 1.4. D.C. brush motor drive stability.
A permanent magnet d.c. brush motor with the torque speed curve: drives a
d.c. generator which supplies a resistive load such that the generator torque /
speed equation is O
r
= 2T
L
. We calculate the speed and torque for the steady
state point and find out if that point is stable.
Solution:
Let us first draw the motor and load (generator) torque speed curves on
figure 1.14.
Figure 1.14. D.C. brush motor load match
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The steady state point, A, corresponds to constant speed and B = 0
in (1.27). Simply the motor torque counteracts the generator braking
torque:
e L
T T = (1.37)
Using the two torque speed curves we find:
2
1 . 0 200
rA
rA
O
= O (1.38)
and thus:
rad/s 476 . 190
2 / 1 . 0 1
200
rA
=
+
= O
(1.39)
and
Nm 238 . 95
2
476 . 190
2
T T
rA
LA eA
= =
O
= = (1.40)
The static stability is met if:
A
r
L
A
r
e
T T
|
|
.
|

\
|
O c
c
<
|
|
.
|

\
|
O c
c
(1.41)
In our case from the two torque / speed curves:
2
1
10 <
(1.42)
and thus, as expected, point A represents a situation of static equilibrium.
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1.8. MULTIQUADRANT OPERATION
These possibilities are summarised in Table 1.1 and in figure 1.16.

Table 1.1.
Mode of
operation
Forward
motoring
Forward
regenerati
ve braking
Reverse
motoring
Reverse
regenerati
ve braking
Speed, e
r
+ + - -
Torque, T
e
+ - - +
Electric
power flow
+ - + -
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Figure 1.16. Electric drives with four quadrant operation