INDUSTRIAL DRIVES

Prof. K. R. Rajagopal
Department Of Electrical Engineering
Electromechanical Converter System

Electromechanical Converter System (Cont.)

 Electrical energy input from the source = Mechanical Energy Output + Increased in stored energy in
coupling field + Energy losses

 % Overall Efficiency = ( Pmech / Pelect ) ? 100

 Losses
(a) Loss in the winding resistance of the energy converter
(b) Core loss
(c ) Friction and Windage loss

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  Block Diagram of Electric Drive

 AC-DC Converters or Rectifiers



AC-DC Converters or Rectifiers (Cont.)

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 AC Voltage
Controller

DC – DC Converter (Chopper)

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VSI Controlled Inverter for IM Drive

CSI Controlled Drives for IM

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LCI Controlled Drive for Synchronous Motor

Type of Loads

Load torque can be of two types

 Active load torque:- Active torques continues to act in the same direction irrespective of
the direction of the drive. e.g. gravitational force or deformation in elastic bodies.

 Passive load torque:- the sense of the load torque changes with the change in the
direction of motion of drive. e. g. torques due to friction, due to shear and deformation of
inelastic bodies

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Quadrant diagram of Speed-Torque Characteristics

 The speed is assumed to be positive if the direction of rotation is anticlockwise or in such

a way to cause an ‘upward’ or forward motion of the drive. For reversible drive positive
direction of the speed can be assumed arbitrarily either clockwise or anticlockwise.

 The motor torque is positive if it produces increase in speed in the positive sense. The
load torque is assigned the positive sign when it is directed against the motor torque.

 Plot of speed torque characteristics of the load/ motor for all four quadrant of operation is
known as quadrantal diagram.


 Four quadrant operation of the motor driving a hoist load

Four Quadrant Operation

 Motor is driving a hoist consisting of a cage with or without load, a rope wound on to a
drum to hoist the cage and a balance weight of magnitude greater than that of the empty
cage but less than that of the loaded cage.

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  The arrow in the figure indicates the actual directions of the motor torque, load torque
and motion in four quadrants.

 The load torque of the hoisting mechanism is of active type and assumed to be constant
due to negligible friction and windage for low speed hoist.

 Speed torque curve of the hoist is represented by vertical line passing through two
quadrants. Loaded hoist characteristics in first and fourth and unloaded in second and
third quadrants.

 In the first quadrant the load torque acts in the opposite direction to that of rotation.
Hence to drive the loaded hoist up, the motor developed torque must be in the direction
of the rotation or must be positive. The power will also be positive so, this quadrant is
known as ‘forward motoring quadrant’.

Four Quadrant Operation (Cont.)

 Speed torque curve of the hoist is represented by vertical line passing through two
quadrants. Loaded hoist characteristics in first and fourth and unloaded in second and
third quadrants.

 In the first quadrant the load torque acts in the opposite direction to that of rotation.
Hence to drive the loaded hoist up, the motor developed torque must be in the direction
of the rotation or must be positive. The power will also be positive so, this quadrant is
known as ‘forward motoring quadrant’.

 The hoisting up of the unloaded cage is represented in the second quadrant. As the
counterweight is heavier than the empty cage, the speed at which hoist moves upwards
may reach a very high value. To avoid this, the motor torque must act in the opposite
direction of rotation or motor torque must be negative. The power will be negative
though the speed is positive, so this quadrant is known as ‘forward braking quadrant’.

 The third quadrant represents the downward motion of the empty cage. Downward
journey will be opposed by torque due to counterweight and friction at the transmitting
parts, move cage downwards the motor torque should must be in the direction of the
rotation. Electric machine acts as a motor but in the reverse direction compared to first
quadrant. The torque is negative as speed is increased I the negative direction, but the
power is positive, this quadrant is known as ‘Reverse motoring quadrant’.

Four Quadrant Operation (Cont.)

 Fourth quadrant has the downward motion of the loaded cage. As loaded cage has more
weight than the balanced weight to limit the speed of the motion, motor torque must have
opposite polarity with respect to rotation and acts as a brake. The motor torque sign is
positive, but as speed has negative direction; the power will be negative, this quadrant is
designated as ‘Reverse braking quadrant’

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Type of Loads (Cont.)

 It is a passive load to the motor.

 Load torque is independent of the speed of the

motor.

 Characterized by the requirement of an extra torque

at very near zero speed.

 It is also known as break away torque or stiction.

Dry Friction Load OR Coulomb Friction

Type of Loads (Cont.)

 Torque is directly proportional to the speed.

 Calendering machines, eddy current brakes and

separately excited dc generators feeding fixed
resistance loads have such characteristics.

Viscous Friction Load

Type of Loads (Cont.)

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Type of Loads (Cont.)

 Load torque magnitude is proportional to some

power of speed.

 Centrifugal pumps, propeller in ships or

aeroplanes, fan or blower type of load has such
characteristics.

 For fan,

Fan type Load

Types of Load (Cont.)

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  Hyperbolic speed-torque characteristics,
where load torque is inversely proportional
to speed or load power is constant.

 Certain type of lathes, boring machines,

milling machines, steel mill coilers etc are
having this type of load characteristics.

Constant Power Load

Types of Load (Cont.)

Load torques that dependent on the path or position taken by the load during motion

 Load torques in the hoisting mechanisms and transport systems are dependent not only on
the speed but also on the nature of the path traced out by the load during its motion.

 The resistance to the motion of a train traveling up- gradient or taking a turn depends on
the magnitude of the gradient or the radius of the curvature of the track respectively.

Types of Load (Cont.)

 Considering a very small a The force

resisting the motion of a train traveling
up-gradient is,

Types of Load (Cont.)

where, W = Dead weight of the train or any other transport system in kg,

G = Gradient expressed as a rise in meters in track distance of 1000 meters.

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  The tractive force required to overcome curve resistance is given by the empirical formula:

where, R = Radius of curvature in meters.

Types of Load (Cont.)

 In hoisting systems in which tail ropes or balancing

ropes are not used, the load torque is not only due to
the weight of the unloaded or the loaded cage but also
due to that of the lifting ropes or cables, which depends
on the position of the two cages.

 When cage 1 is at the bottom most position and is to be

lifted upwards, the entire weight of the rope is also to
be moved up.

 When both cages remains at the same height, the

weight of the rope to be lifted becomes zero, as the
weight of the ropes on both sides balances each other.

 When cage 1 is at higher position than cage 2, a portion

of the weight of the rope acts in such a way as to aid
the upward motion of the cage 1 and when cage 1
occupies the topmost position, the whole weight of the
rope aids in upward movement.

 
Types of Load (Cont.)

 The force that resists the upward motion of the load due to the varying weight of the rope
depending on the position of the load is,

where, Wr = Total weight of the rope (kg),

x = height of the cage at any arbitrary position from the bottom most position (m)

h = the desired maximum height to which the cage is to be moved upwards (m)

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Types of Load (Cont.)

Load torques that varies with angle of displacement of the shaft

 In machines having crank shafts such as reciprocating pumps and compressors, frame
saws, etc., the load torque is a function of the position of the crank, i.e. the angular
displacement of the shaft or rotor of the motor.

Types of Load (Cont.)

 Load torque
(TL) can be
resolved in to
two parts; a
constant torque
Tav and a
variable torque
TL’, which
changes
periodically in
magnitude
depending on
the angular
position of the
shaft.
Reciprocating Compressor Load

Types of Load (Cont.)

 Such load torque characteristics, for simplicity, can be Fourier series as a sum of
oscillations of fundamental and harmonic frequencies, as:

 is the angular speed of the shaft of the motor driving the compressor.

Types of Load (Cont.)

 During changes in the speed, since only small deviations from a fixed value of the
speed ?a occurs, the angular displacement can be represented by, ? = (?a + ??)t, then the
variable portion of the load torque will be:

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  The term is very small and can be neglected.

 Thus, restricting to small deviations in angle from the equilibrium position, a load torque
which varies with the angular displacement of the shaft can be transformed to one which
varies periodically with respect to time.

Types of Load (Cont.)

Load torques that vary with time

 Load variation with time can be periodic and repetitive in certain applications.

 One cycle of the load variation is called a duty cycle.

 The variation of load torque with time has a greater importance in the selection of a
suitable motor.

Classification of loads that vary with time:

(a) Continuous, constant loads: Centrifugal pumps or fans operating for a long time under
the same conditions, paper making machines etc.

(b) Continuous, variable loads: Metal cutting lathes, hoisting winches, conveyors etc.

Type of Loads (Cont.)

(c) Pulsating loads: Reciprocating pumps and compressors, frame saws, textile looms and
generally all machines having crank shaft.

(d) Impact loads: Apparent, regular and repetitive load peaks or pulses which occurs in
rolling mills, presses, shearing machines, forging hammers etc. Drives for such machines
will have heavy fly wheels.

(e) Short time intermittent loads: Almost all forms of cranes and hoisting mechanisms,
excavators, roll trains etc.

(f) Short time loads: Motor generator sets for charging batteries, servo motors used for
remote control of clamping rods of drilling machines.

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  Loads of the machines like stone crushers and ball mills are characterized by frequent
impact of small peaks so they are classified as continuous variable loads rather than the
impact loads

Types of Load (Cont.)

 One and the same machine can be represented by a load torque which either varies with
the speed or with the time.

 For example, a fan load whose load torque is proportional to the square of the speed, is
also a continuous, constant load.

 Load torque of a crane is independent of the speed and also short time intermittent nature.

 Rocking pumps for petroleum have a load which vary with angular position of the shaft,
but also be classified as a pulsating load.
 Type of Load (Cont.)

High speed Hoist Traction Load

Power requirement for different Loads

Polishing Machine
Mine Hoist

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Power requirement for different Loads (Cont.)

Sheering machine for cutting Textile loom

Power requirement for different Loads (Cont.)

Planing Machine

Power requirement for different Loads (Cont.)

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 Drilling Machine Grinding Machine

Dynamics of Motor-Load Combination

 The motor and the load that it drives are represented by the rotational system.

 The basic equation of the motor-load system is,

Dynamics of Motor-Load Combination

 where is motor and load torque respectively in Nm, J is the moment of

inertia and is the angular velocity in rad/sec.

 Motor torque is the applied torque and load torque is the resisting torque.

 Different states at which an electric drive causing rotational motion are

(i) :- The drive will be accelerating, in particular, picking up speed to

reach rated speed.

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 (ii) :- The drive will be decelerating and particularly, coming to
rest.

(iii) :- The motor will continue to run at the same speed, if it were
running or continue to be at rest, if it were running.

Dynamics of Motor-Load Combination

 the drive accelerates and when the drive decelerates is true only for
the passive load. The reverse may be true for active load.

 The term represents the inertia or the dynamic torque, which is available
during transient conditions.

 During acceleration the dynamic torque is directed against the motion and during the
braking it will help motion of the drive.

Dynamics of Motor-Load Combination (Cont.)

 The different loads connected to the motor will have different speed, to select the motor it
is desirable to refer all mechanical quantities like load torque, inertia etc at one single
axis, mostly the output shaft of the motor.

 Principle of energy conservation is used.

 Let ?M and ?L be the motor and load speeds respectively,

 Equating power,

Dynamics of Motor-Load Combination (Cont.)

where, = Load torque,

= Load torque referred to the motor shaft,

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 = Speed transmission ratio (gear ratio),

= Efficiency of transmission.

Motor Load System with Gears

Dynamics of Motor-Load Combination (Cont.)

 For the gear ratios of in and the respective efficiencies of

the load torque referred to the motor shaft is,

 Moments of inertia are referred to a given shaft on the basis that the total amount of
kinetic energy stored in the moving parts and referred to the given shaft remains
unchanged.

Dynamics of Motor-Load Combination (Cont.)

 Rotating parts having moment of inertia and angular speeds

the equivalent moment of inertia referred to the motor shaft J’ is,

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Dynamics of Motor-Load Combination (Cont.)

How to refer the forces and masses having translation motion to a rotating shaft?

 In applications like hoists, cranes and shaping machines will have some of the moving parts rotate while
others go through a translational motion.

 If the moving mass has a velocity of v m/sec, motor shaft has an angular velocity is
the resistive force developed by the load due to gravitational pull of the moving weight the
efficiency of transmission.

 Dynamics of Motor-Load Combination (Cont.)

 Motor Hoist Load System

Dynamics of Motor-Load Combination (Cont.)

 Referred load torque,

 A mass having translational motion is referred to a rotating one on the basis of constant
kinetic energy,

 The moment of inertia referred to the motor shaft,

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Dynamics of Motor-Load Combination (Cont.)

Drive System

 Inertia torque: Based on the kinetic energy,

Dynamics of Motor-Load Combination (Cont.)

 Hoist Load: A constant load torque and the inertia referred to the motor shaft
based on equating power and kinetic energy stored by weight respectively,

Dynamics of Motor-Load Combination (Cont.)

 Dry Friction: It is constant load torque,

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  Viscous friction: This load torque is proportional to the speed

Dynamics of Motor-Load Combination (Cont.)

 Fan: Load torque of the fan is proportional to square of speed

 Fan: Load torque of the fan is proportional to square of speed

Dynamics of Motor-Load Combination (Cont.)

How to referred torques and masses which undergoes translational motion at variable speeds?

 The machines which converts the rotational motion into a translational one using the
crankshaft, the speed and the moving masses vary both in magnitude and sign during
each revolution of the crankshaft. The kinetic energy stored I the masses will go to zero
to a maximum. The moment of inertia referred to a crankshaft is , where m
is the mass of the body undergoes translation motion with a velocity of v and is the
angular velocity of the shaft.

Dynamics of Motor-Load Combination (Cont.)

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Forces in a crankshaft Mechanism

Dynamics of Motor-Load Combination (Cont.)

 The relationship between the linear velocity of the piston v and the angular speed of the
crankshaft is,

 The moment of inertia refereed to crankshaft,

Dynamics of Motor-Load Combination (Cont.)

 The load torque referred to the motor shaft is,

where, F is the resisting force applied by the part which undergoes translational motion, i
is the gear ratio and is the efficiency of transmission.

 For the mechanism having crankshaft, the equation of motion will be,

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  Kinetic energy stored in the crankshaft

Dynamics of Motor-Load Combination (Cont.)

 The dynamic power and the inertia torque is

Determination of Moment of Inertia (Cont.)

 Initial kinetic energy stored in the system will be used to supply the rotational losses and
gradually speed reduces to zero.

 The power consumed in overcoming the rotation losses is given by:

P = Rate of change of kinetic energy

 dN/dt at the normal speed N can be found out graphically using the oscillogram of speed
vs. time.

Determination of Moment of Inertia (Cont.)

By Graphical Method:-

 In this method, apart from the speed vs. time curve, power (i.e., the rotational losses) vs.
speed (from which the power vs. time curve can be plotted), are obtained and plotted to
the same time axis.

 The area under the power vs. time is the kinetic energy used by the rotating masses
during retardation.

 Moment of inertia can be worked out from the fact that:

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 Area under the Power vs. time curve

Where N is the normal rated speed.

Determination of Moment of Inertia

Graphical method for the determination of J

Steady State Stability of an Electric Drive

 The drive is said to be in equilibrium if the torque developed by the motor is exactly
equal to the load torque.

 If the drive comes out of the state of equilibrium due to some disturbance, it comes back
to steady state for stable equilibrium but for unstable equilibrium the speed of the drive
increases uncontrollably or decreases to zero. When the drive coming out of the state of
equilibrium preserves it steady state at different speed (lying in small range), it is said to
be in neutral range.

 The stability of the motor load combination is defined as the capacity of the system
which enables it to develop forces of such a nature as to restore equilibrium after any
small departure therefore.

 Equilibrium state of the drive mainly disturbs because of the following two types of
disturbances,

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 1.Changes from the state of equilibrium takes place slowly and the effect of either the
inertia or the inductance is insignificant – Steady state stability.
2.Sudden and fast changes from the equilibrium state so effect of both inertia and
inductance can not be neglected- Dynamic or transient stability

Steady State Stability of an Electric Drive (Cont.)

Criteria for steady state stability:-

 Let the equilibrium of the torques and speed is and the small deviations are
After the displacement from the equilibrium state the torque equation becomes,

Steady State Stability of an Electric Drive (Cont.)

 Considering the small deviation, changes can be expressed as a linear function of change
in speed,

 From the torque equation, where all quantities are expressed in terms of their deviations
from the equilibrium,

Steady State Stability of an Electric Drive (Cont.)

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  Solution is,

 Where, is the initial value of the deviation in speed. For the stable system the
exponent must be negative, so speed increment will disappear with time. The exponent
will always be negative if,

Steady State Stability of an Electric Drive (Cont.)

 Criteria for the steady state stability is for a decrease in the speed the motor torque must
exceeds the load torque and for increase in speed the motor torque must be less than the
load torque.

 Load torque results in a stable

equilibrium point, and the load
torque results in an unstable

Steady State Stability of an Electric Drive (Cont.)

To check the stability at an operating point of the motor, if an increase in speed brings greater increase in load
torque than the motor torque, the speed will tend to decrease and return to its original value, so operating point will
be a stable point else operating point will be an unstable point.

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  Cases (a), (b) and (c) represents stable
operation of drive.

 Cases (d), (e) and (f) represents unstable

operation of drive.

 Case (g) represents indeterminate

condition.

Various Speed and Torque Curves of Motor and Load

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