Speed Control of DC Motor

Speed control means intentional change of the drive speed to a value required for performing the specific work process. Speed control is a different concept from speed regulation where there is natural change in speed due change in load on the shaft. Speed control is either done manually by the operator or by means of some automatic control device. One of the important features of dc motor is that its speed can be controlled with relative ease. We know that the expression of speed control dc motor is given as,

Therefore speed (N ) of 3 types of dc motor SERIES, SHUNT AND COMPOUND can be controlled by changing the quantities on RHS of the expression. So speed can be varied by changing (i) terminal voltage of the armature V , (ii) external resistance in armature circuit R and (iii) flux per pole . The first two cases involve change that affects armature circuit and the third one involves change in magnetic field. Therefore speed control of dc motor is classified as 1) armature control methods and 2) field control methods.

Speed Control of DC Series Motor

Speed control of dc series motor can be done either by armature control or by field control.

Armature Control of DC Series Motor

Speed adjustment of dc series motor by armature control may be done by any one of the methods that follow,

1. Armature resistance control method: This is the most common method employed. Here the controlling resistance is connected directly in series with the supply to the motor The power loss in the control resistance of dc series motor can be neglected because this control method is utilized for a large portion of time for reducing the speed under light load condition. This method of speed control is most economical for constant torque. This method of speed control is employed for dc series motor driving cranes, hoists, trains etc. 2. Shunted armature control: The combination of a rheostat shunting the armature and a rheostat in series with the armature is involved in this method of speed control. The voltage applied to the armature is varies by varying series rheostat R 1. The exciting current can be varied by varying the armature shunting resistance R2. This method of speed control is not economical due to considerable power losses in speed controlling resistances. Here speed control is obtained over wide range but below normal speed.

3. Armature terminal voltage control: The speed control of dc series motor can be accomplished by supplying the power to the motor from a separate variable voltage supply. This method involves high cost so it rarely used.

Field control of DC Series Motor

The speed of dc motor can be controlled by this method by any one of the following ways 1. Field diverter method: This method uses a diverter .Here the field flux can be reduced by shunting a portion of motor current around the series field. Lesser the diverter resistance less is the field current, less flux therefore more speed. This method gives speed above normal and the method is used in electric drives in which speed should rise sharply as soon as load is decreased. 2. Tapped Field control: This is another method of increasing the speed by reducing the flux and it is done by lowering number of turns of field winding through which current flows. In this method a number of tapings from field winding are brought outside . This method is employed in electric traction.

Speed Control of DC Shunt Motor

Speed of dc shunt motor is controlled by the factors stated below

Field control of DC Shunt Motor

By this method speed control is obtained by any one of the following means 1. Field rheostat control of DC Shunt Motor: In this method , speed variation is accomplished by means of a variable resistance inserted in series with the shunt field . An increase in controlling resistances reduces the field current with a reduction in flux and an increase in speed. This method of speed control is independent of load on the motor. Power wasted in controlling resistance is very less as field current is a small value. This method of speed control is also used in DC compound motor. Limitations of this method of speed control: A. Creeping speeds cannot be obtained. B. Top speeds only obtained at reduced torque C. The speed is maximum at minimum value of flux, which is governed by the demagnetizing effect of armature reaction on the field. 2. Field voltage control: This method requires a variable voltage supply for the field circuit which is separated from the main power supply to which the armature is connected. Such a variable supply can be obtained by an electronic rectifier. Armature control of DC Shunt Motor Speed control by this method involves two ways . These are : 1. Armature resistance control : In this method armature circuit is provided with a variable resistance. Field is directly connected across the supply so flux is not changed due to variation of series resistance. This is applied for dc shunt motor. This method is used in printing press, cranes, hoists where speeds lower than rated is used for a short period only. 2. Armature voltage control: This method of speed control needs a variable source of voltage separated from the source supplying the field current. This method avoids disadvantages of poor speed regulation and low efficiency of armature-resistance control methods. The basic adjustable armature voltage control method of speed d control is accomplished by means of an adjustable voltage generator is called Ward Leonard system.

This method involves using a motor generator (M-G) set. This method is best suited for steel rolling mills, paper machines, elevators, mine hoists, etc. Advantages of this method A. Very fine speed control over whole range in both directions B. Uniform acceleration is obtained C. Good speed regulation Disadvantages A. Costly arrangement is needed , floor space required is more B. Low efficiency at light loads

AC Motor Speed Control AC Induction Motor Speed Control

So what can we do to control the speed of an AC induction motor? Change the number of poles (in discrete increments - inefficient & rarely done) Change the frequency of the AC signal Change the slip Change AC Frequency Variable speed AC Motor adjustable speed drives are known as inverters, variable frequency drives (VFD) , or adjustable speed drives (ASD). Common ways to vary AC frequency: Six-step inverter Pulse-Width-Modulation Vector Flux

Six-step Inverter
AC rectified to DC, then switched to imitate a sine wavealso called a Variable Voltage Inverter or VVI

Pulse-Width-Modulation
DC voltage (rectified AC) rapidly switched to match "area under curve" also called Pulse-Density-Modulation

Changing Rotor Slip

Important to match the motor to the load ensure that a change in motor power gives a desired change in load speed Load should have a substantial inertial components inertial torque can "carry" the load through brief periods when motor torque cannot Best used with motors designed for high slip

Variable Series Resistance

Additional series resistance reduces voltage across main windings

Variable Voltage Transformer

More efficient than previous method, no power wasted in the series resistance

Tapped Winding
Commonly used with 3-speed fan motors (like the one in AC Motor Lab)

STARTER
Necessity of starter At starting ,the speed of motor is zero so that the back e.m.f. In the armature is zero. Armature resistance is so low, if it is connected to power supply directly ; huge current will pass thru armature. The huge current may damage the machine, major heat, very high speed in case of DC series motor. Ia = V/Ra
Function of starter Start and stop the motor. Limit inrush current where necessary. Permit automatic control when required Protect motor and other connected equipments from over voltage, no voltage, under voltage, single phasing etc. Motor Starter Features. Rated by current (amperes) or power (horsepower) Remote ON/OFF control Motor overload protection Starting and stopping (electrical life)

 Plugging and jogging (rapid making and breaking current) Type of starter For DC Motor Two point starter for DC series motor Three point starter for shunt motor Four point starter for compound motor For AC Motor DOL Starter Star-Delta Auto-transformer Variable Frequency drive Wiring Diagram of DOL Starte

r:

Motor Starting Characteristics on DOL Starter: Available starting current: Peak starting current: Peak starting torque: Advantages of DOL Starter: Most Economical and Cheapest Starter Simple to establish, operate and maintain Simple Control Circuitry Easy to understand and troubleshoot. It provides 100% torque at the time of starting. Only one set of cable is required from starter to motor. Motor is connected in delta at motor terminals. Disadvantages of DOL Starter: It does not reduce the starting current of the motor. High Starting Current: Very High Starting Current (Typically 6 to 8 times the FLC of the motor). Mechanically Harsh: Thermal Stress on the motor, thereby reducing its life. Voltage Dip: There is a big voltage dip in the electrical installation High starting Torque: Unnecessary high starting torque, even when not required by the load. 100%. 6 to 8 Full Load Current. 100%

Suitability DOL is Suitable for: Small water pumps, compressors, fans and conveyor belts. Motor rating up to 5.5KW DOL is not suitable for: The peak starting current would result in a serious voltage drop on the supply system Motor rating above 5.5KW Star delta starter Most induction motors are started directly on line, but when very large motors are started that way, they cause a disturbance of voltage on the supply lines due to large starting current surges. To limit the starting current surge, large induction motors are started at reduced voltage and then have full supply voltage reconnected when they run up to near rotated speed. Star-Delta Connection in transformer

Star-Delta Connection in motor

Star delta power circuit

Star delta control circuit

Motor Starting Characteristics of Star-Delta Starter: Available starting current: 33% Full Load Current. Peak starting current: 1.3 to 2.6 Full Load Current. Peak starting torque: 33% Full Load Torque. Advantages of Star-Delta starter: The operation of the star-delta method is simple and rugged It is relatively cheap compared to other reduced voltage methods. Good Torque/Current Performance.

 It draws 2 times starting current of the full load ampere of the motor connected Disadvantages of Star-Delta starter: Low Starting Torque, only 33% starting torque Break In Supply Possible Transients Six Terminal Motor Required (Delta Connected). It requires 2 set of cables from starter to motor. The delta of motor is formed in starter and not on motor terminals. Applications with a load torque higher than 50 % of the motor rated torque will not be able to start using the startdelta starter. Low Starting Torque: reduction of the line voltage by a factor of 1/3 (57.7%) to the motor and the current is reduced to 1/3 of the current at full voltage, but the starting torque is also reduced 1/3 to 1/5 of the DOL starting torque . Reversing of Direction

Variable frequency drive (VFD) A variable-frequency drive (VFD), also termed adjustablefrequency drive, variable speed drive, AC drive, micro drive or inverter drive is a type of adjustable-speed drive used in electro-mechanical drive systems. It controls AC motor speed and torque by varying motor input frequency and voltage. Principle of VFD Variable frequency Drive, principle of the same is by regulating the frequency, we can regulate the speed of drive Example - n=120f/p Where, n - speed f - frequency p nos. of poles VFD flow diagram

VFD 3-phase power conversion

Application Application Cane Carrier Drive, Feeder Table Drive, Milling Plant Drive, Raw juice Pumps, Sulphited Juice Pumps, Molasses Pumps, Injection Pumps, Cooling Tower Pumps and Centrifugals for a Sugar Curing and Chemical Dosing pump.

Auto transformer

Circuit and function An auto-transformer starter makes it possible to start squirrel-cage induction motors with reduced starting current, as the voltage across the motor is reduced during starting. In contrast to the star-delta connection, only three motor leads and terminals are required. On starting, the motor is connected to the tappings of the auto-transformer. Starting Characteristics Motor terminal voltage less than line voltage (by transformer ratio). Motor current exceeds line current (by inverse of transformer ratio). Starting torque is reduced by the square of the terminal voltage.

Applications: Where complete acceleration at reduced amperes is needed. Where line ampere reduction requirements are severe, and load torque is not minimal. Difference between DOL/Star delta /Autotransformer

Sr. DOL Starter 1 2 Used up to 5 HP Does not decrease the starting current 3

Star delta starter Used 5 HP to 20HP Decreases the by 1/3 times

Auto transformer starter Used above 20 HP Decreases current as required It is more costly

starting current the starting

It is cheap It is costly

It connects directly with starting as well as for running

It connects the motor first in star at the time delta for

It connects the motor according to the taping taken out from the auto transformer

the motor of starting in supply for running

KV

Series Super-small Programmable Logic Controllers

General Specifications
Model Programming language Number of instructions Execution time (basic I/O instructions) Avg. number of steps Input (Maximum extendable number of inputs) Output (Maximum
KV-10RW KV-10T2W

(R and T in model names indicate relay output and transistor output)

KV-16RW KV-16T2W KV-24RW KV-40RW KV-24T2W KV-40T2W KV-80RW KV-80TW

Ladder diagram and expanded ladder diagram Basic: 16, application: 34, arithmetic:26, interrupt: 4 1.0 s min., 1.92 s average 500 steps/program 6 inputs (70 max.) 4 outputs 10 inputs (74 max.) 6 outpus 1.4 s min., 3.12 s average 3000 steps/program 16 inputs (80 max.) 8 outputs 24 inputs (72 max.) 16 outputs 48 inputs (80 max.) 32 outputs

extendable number of inputs) Maximum extendable number of I/Os Internal utility relays (with latching function) Special utility relays Data memory (16 bits) Temporary memory (16 bits)

(68 max.) 74

(70 max.) 80

(72 max.) 88

(80 max.) 88 800 160 2,000 words 32 words

(80 max.) 128

160 160 1,000 words 32 words

Timer/counter

A total of 64 timers, up, and up-down counters are provided: A total of 120 timers, up, and up0.1-s timer (0 to 6553.5 down counters are provided: s) 0.1-s timer (0 to 6553.5 s) 0.01-s timer (0 to 655.35 0.01-s timer (0 to 655.35 s) s) 1-ms timer (0 to 65.535 s) 1-ms timer (0 to 65.535 2 analog timers (two of 0 to 24.9 s, 0 s) to 2.49 s, or 0 to 0.249 s) 1 analog timer (0 to 24.9 s, 0 to 2.49 s, or 0 to 0.249 s) 2 auto-reset up-counters (max. input response frequency: 10 kHz) 4 4

High-speed counter High-speed counter comparator

Direct clock pulse

2 channels, 20 kHz max. 2 channels, 2 kHz max. 2 channels, 2 kHz max. (output from (output from 0500), 1.5 (output from 0500), 1.5 0500), kHz max. (output from kHz max. (output from 1.5 kHz 0501) 0501) max. (output from 0501) Program memory: EEPROM, programs retained for 10 years min., rewritable 50,000 times min. Data memory: data retained for 2 months min. by capacitors (at 25C) 24 VDC +10% to -20% KV-10RW: KV-16RW: KV-24RW: KV-40RW: 75 mA 105 mA 130 mA 220 mA KV-10T2W: KV-16T2W: KV-24T2W: KV-40T2W: 65 mA 70 mA 75 mA 115 mA 0 to 50C 1500 VAC applied between power terminal and I/O terminal, and between terminals and housing (1 min.) KV-80RW: 400 mA KV-80TW: 300 mA

Memory backup Supply voltage Maximum current consumption Ambient temperature Withstand voltage

Weight

KV-10RW: KV-16RW: KV-24RW: KV-40RW: KV-80RW: approx. 130 approx. 200 approx. approx. approx. 600 g g 250 g 340 g g KV-10T2W: KV-16T2W: KV-24T2W: KV-40T2W: KV-80TW: approx. 120 approx. 180 approx. approx. approx. 500 g g 220 g 270 g g

input/Output Specifications
Type Model No. of inputs No. of outputs Type of output Type Model No. of inputs No. of outputs
Basic unit KVKVKVKVKVKVKVKVKVKV10RW 16RW 24RW 40RW 80RW 10T2W 16T2W 24T2W 40T2W 80T2W

6 4

10 6

16 8

24 16

48 32

6 4 BJT

10 6 MOSFET

16 8 MOSFET

24 16 MOSFET

48 32 BJT

Relay Relay Relay Relay Relay

Expansion unit KVKVKVKVKVKVKVKV8ERW 8ET2W 8EXW 8EYRW 8EYT2W 16EXW 16EYRW 16EYTW

4 4

4 4 BJT

8 -

8 Relay

8 BJT

16 -

16 Relay

16 BJT

Type of output Relay

Power Supply Unit Specifications

Model Operation system Power supply voltage Output voltage Output current Weight (brackets not included)
KV-U6W

Switching type 100 to 240 VAC (50/60 Hz) 10% 24 VDC 10% (Ripple: 240 m Vp-p max.) 0.8 A Approx. 210 g

Analog I/O Specifications (Input: KV-AD4, Output: KV-DA4)

Type Analog I/O range Input impedance Output impedance Number of I/O Resolution
Voltage Current

-10 to +10 V 1 M ohm 0.5 ohm min. 5 mV (1/4000)

4 to 20 mA 300 ohm 4 A (1/4000)

4 channels of inputs or outputs 4 channels of inputs or outputs