Frequency-controlled variable-speed

When the drive (motor and control) performance requirements are minimal, a standard industrial AC induction motor can often be successfiiUy applied to adjustable-frequency power, variable-speed applications. Indeed, some applications can be converted from constant speed to variable speed while utilizing an existing induction motor. However, when the performance level required is more demanding, a definite-purpose motor design is appropriate. This is usually the case when maximum process productivity is the goal. 

Variable Air Flow Fans. Variable air flow fans are needed ia the process iadustry for steam or vapor condensing or other temperature critical duties. These also produce significant power saviags. Variable air flow is accompHshed by (/) variable speed motors (most commonly variable frequency drives (VFDs) (2) variable pitch fan hubs (J) two-speed motors (4) selectively turning off fans ia multiple fan iastaHations or (5) variable exit louvers or dampers. Of these methods, VFDs and variable pitch fans are the most efficient. Variable louvers, which throttle the airflow, are the least efficient. The various means of controlling air flow are summarized ia Table 3. 

V ri ble Frecjuency Drives. An important energy by-product of soHd-state electronics is the relatively low cost variable speed drive. These electronic devices adjust the frequency of current to control motor speed such that a pump can be controlled direcdy to deUver the right flow without the need for a control valve and its inherent pressure drop. Eigure 11 shows that at rated load the variable speed drive uses only about 70% as much power as a standard throttle control valve system, and at half load, it uses only about 25% as much power. 

Inverters make it possible to control a variable-speed fan by changing the frequency modulation. Standard alternating-current fan motors may be speed-regulated between 0 and 60 Hz. In using inverters for this apphcation, it is important to avoid frequencies that would result in fan critical speeds. 

Process-flow control and buffer-gas control have been discussed under Variable Nozzles and Buffer-Gas System respectively. Speed is usually self-controlled by a matching speed-sensitive load such as a compressor or a pump. If the load is an induction or svn-chronous generator feeding into a stable ac system, the system frequency fixes the speed. Otherwise, the speed can be controlled by a conventional governor. 

Analysis type As discussed previously, data-collection analyzers incorporate analysis parameter sets that allow the user to control the data-gathering process. APSs provide the option of selecting either frequency analysis for fixed-speed machinery or orders analysis for variable-speed machinery. 

Feed tank and metering pump the flow rate through such a pump can be controlled by a stroke adjusting mechanism or a variable speed drive acting on the stoke frequency. Control can be achieved by a fixed adjustment or through a flow meter. 

Options for connecting the motor drive to the shaft depend on the shaft orientation. A vertical-shaft cantilever design would prefer a belt drive to reduce the cost of manufacture of the support structure and to facilitate maintenance. A horizontal shaft has the additional option of direct coupling. Variable speed can be accomplished through a gearbox or preferably through variable frequency control on the motor. In addition to the power requirements discussed previously, the startup power to overcome the torque of the rotor must be considered. This startup power is related to the time required to reach the desired rotor speed. 

For dual-head pumps with a special piston movement, the flow-rate is set by using an electronic device that controls the piston cycle frequency through a variable-speed motor (often a stepping motor), the distance travelled by the piston being constant. Hence the flow-rate can be ad.iusted over the range 1-100 or more... 

DC motor drives have always offered high torque at all speeds and exact control of motion speed. AC induction motors have reliably converted electricity into rotary power for many years, and recently adjustable-frequency controls add variable-speed capability. While AC motors were originally relegated to relatively simple tasks, such as varying the flow rates of fans or pumps, advances in both motor and control technologies have allowed their use in higher performance operations. They are reliable sources of fixed-speed and variable-speed rotating power. Electric drives with appropriate closed-loop control operate only when required. However, to avoid unsuccessful apphca-tions, it is important to properly match the load, motor, and controller. 

Occasionally d.c. motors were used in the 1980s in order to provide an infinitely-variable control of the auger shaft speeds, but since then frequency-controlled squirrel-cage motors have become the standard. 

During the 1980 s attention turned to AC machines technology with both synchronous and induction being successfully applied. Variable speed and torque control was made possible by variable rotor resistance in the form of Wound Rotor Induction Motors and then the Cyclo Convertor which applied thyristor technology to produce low frequency ac output suitable for the driving large AC machines. 

A variable speed operation is required to control the "hot-cold interface in the lower density lock. The variable frequency electric supply is provided by two generators driven by a common variable-speed turbo coupling wth a flywheel of high mechanical inertia (about 5000 Kg m ). 

Internal circular grinding machines are usually equipped with high frequency grinding spindles (three-phase asynchronous motors) and frequency converters for continuously variable speed control. As a measure of the mechanical power emitted by the grinding spindle, one can use the electrical output power delivered by the converter, which can easily be acquired by conventional measurement techniques. The required control variable - one speaks in this case of constant-power grinding - is therefore almost free of charge. 

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