DC Motor Drive System

Some early DC extruder drives used fixed-speed AC motors to drive DC generators that produced the variable voltage for the DC motor. Nowadays, the DC motor drives usually operate from a solid-state power supply, since this power supply is generally more cost-effective than the motor generator set. The DC motor drive can be simpler and cheaper than the variable frequency drive, even when the higher cost of the DC motor is included. The smaller number of solid-state devices tends to give the DC drive a better reliability than the variable frequency drive. Brushes and commutator maintenance is the principal drawback to the use of DC motors. If the drive has to be expiosion-proof, the additional expense associated with this option may be quite iarge for a DC drive, more so than with a variable frequency AC drive or a hydraulic drive. A schematic of the DC drive is shown in Fig. 3.4. 

This circuit uses only three thyristors and four diodes. The drawback of this rectifier circuit is its high ripple current the typical form factor is 1.05, with the ripple current frequency 180 Hz. 

Another popular rectifier circuit is the full-controlled three-phase full wave rectifier. This circuit is more expensive because six thyristors are used. However, the form factor is much better, about 1.01, and the ripple current is 360 Hz. The higher frequency makes it easier to filter the ripple current. The half-controlled three-phase bridge rectifier circuit may require armature current smoothing reactors to reduce the ripple current. Another problem associated with the non-uniform DC input to the motor is the commutation. The motor must commutate under a relatively high degree of leakage reactance. 

A potential safety hazard is the fact that with armature current feedback, the armature current is connected to the operator control and potentiometers maybe operated at high potentials (500 V). This problem can be eliminated using isolation transformers or DC to DC chopper circuits. 

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