INDSUTRIAL DRIVES &

APPLICATIONS

10EE74

VII SEMESTER-EEE

BALAJI RAMAKRISHNA S
ASSISTANT PROFESSOR
DEPARTMENT OF ELECTRICAL& ELECTRONICS ENGINEERING
DAYANANDA SAGAR COLLEGE OF ENGINEERING
 UNIT – 1

AN INTRODUCTION TO ELECTRICAL DRIVES & ITS DYNAMICS

Speed control of industrial machinery is one of the vital requirements in the industry and
there are various applications such as rolling mills, rock cutting, tool grinding, spinning mills,
lifts and hoists which need the controlling mechanism through drives.

A drive consists of prime movers such as petrol engine, diesel engine and a transmission
system. The transmission system may consist of shafts, pulleys, belts and gear boxes

ELECTRIC DRIVE

Electric drive is an electromechanical device for converting electrical energy to mechanical

energy and to control the various kinds of moments of machinery as per the application. The
electric drive adjusts the motor characteristics as per the variation in load under different
operating conditions

Fig 1 depicts the block diagram of an electric drive

Fig1-Electric Drive System [1]

SOURCE:

The source used is a single phase or three phases A.C voltage source, a rectified D.C source
is also used as per the requirement.

The power modulator will modulate the energy of the source to feed the motor; it consists of
a control circuit designed with power devices to control the motor for different operations
such as motoring, speed reversal and braking. Controlling can be done in local mode or
remote mode, basically the control unit will be a panel designed with electrical equipment
such as control push buttons, relays, contactors etc. A computerized data acquisition system
can also be integrated to control in it for efficient control.

Various Power modulators employed in an electric drive system

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 Fig-2 Power modulators [1]

MOTORS:

Electrical motors are used as prime movers for electric drives, using motor as a prime mover
will provide large life, lower noise and less maintenance work compared to that of diesel
engine or petrol engine on a prime mover. Also motor prime movers are adaptable to all
kinds of environments where loads are situated. They are pollution free and easily
transportable

LOADS

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Load is generally a mechanical load coupled to shaft with the help of bearings and other
coupling elements. Motor ratings are selected based on the loads being operated. The power
modulator will adjust the speed torque characteristics of the motor based on the variation in
load

SENSING UNIT

Sensing unit senses the parameters such motor speed, current and also temperature in certain
applications in a closed loop arrangement of a drive system giving the feedback to control
unit

ADVANTAGES & APPLICATIONS OF ELETRIC DRIVE [1]

1. Control characteristics of the motor can be efficiently altered based on the variation in
the load
2. Speed can be controlled in various ranges and better operation under transient
operations such as starting, braking and speed reversal
3. Microcontroller based control strategies can be employed in control unit
4. Multi quadrant operation can be carried out efficiently
5. Wide range of speed, torque and power can be controlled
6. Wide rag of motors can be selected based on the application
7. Easy for transportation and maintenance

APPLICATIONS

1. Driving fans, compressors and pumps

2. Lifts and hoists
3. Imparting motion to conveyors, rock cutting. Tool grinding and other industrial mills

CLASSIFICATION OF ELECTRIC DRIVE

1. Individual drive
2. Group drive
3. Multimotor drive

Individual Drive – Each individual load is driven by an individual motor, usually a

three phase squirrel cage motor drives the loads.
 Advantages: detection of fault is easy and reduces overall losses
 Disadvantages: Expensive compared to group drive

Group Drive: - A single motor is used as a prime mover which actuates several loads by
means of one of the line shafts supported on bearings

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  Advantages: A single large rating motor can be used instead of number of small rating
motors
 Cost effective performance
 Disadvantages: If any fault occurs on the driving motors, whole system will become
nonfunctioning causing production loss
 Level of noise produced is more

Multimotor Drive- multiple motors are used to drive a single load, this is mainly employed in
lifts and hoist and crane applications

 Advantages- faster completion of the task

 Disadvantages- expensive and proper maintenance is required

FACTORS INFLUENCING THE SELCTION OF ELECTRIC DRIVE SYSTEM [1]

1. Nature of power supply- A.C single phase or three phase or D.C is needed
2. Nature of Drive- It is important to figure out whether application demands individual
drive, group drive or multimotor drive
3. Nature of load- Issues related to load are very important to consider such as whether
load requires high starting torque or there is a requirements of any kind of starter,
starting time and stop time intervals and to know whether frequent start and stop has
to be imparted as a part of application
4. Capital and running cost
5. Maintenance requirements
6. Electrical characteristics needed
7. Environment and location

Motors used in electric drive system

For A.C Drives

Induction motors

1. Squirrel cage motors

2. Wound motors
3. Linear induction motors

Synchronous motors

Brushless D.c motors

Stepper motor

Switched reluctance motor

For D.C drives

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D.C motor

1. Shunt motor
2. Series motor
3. Compound motor

Status of A.C and D.C drives

In past induction motors were used as drives for only fixed speed applications, D.C drives
were employed for variable speed applications

Emergence of thyristor in 1957 led to variable speed A.C drives, the thyristor based control
provided smooth control of variable voltage to induction motor and matched the performance
as that of D.C drive

Because of advantages of squirrel cage induction motor over dc motor usage of variable
speed a.c drives increased, with advancements in digital and VLSI technology in designing
the control boards for A.c and Dc drives better performance and reliability has been achieved

Use of Power MOSFETS, IGBTs and microprocessor based control circuits reduced the
complexity of operation of drives and a also overall cost of the drives is reduced

Fundamental Torque Equation

The tendency of force to rotate an object about an axis is known as torque, In general the
magnitude of the torque depends on force applied, length of the axis of the body and angle
between force vector and lever arm

Moment of inertia is the measure of object’s resistance to change the state of rotation. It is the
inertia with respect to rotation

Newton’s law states that net force acting on the body of mass M equal to rate of change of its
mechanical momentum

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Multi Quadrant operation

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In multiqudrant operation of drive for hoist system, motor is operated in forward and reverse
direction with motoring and braking. The figure above represents the motor torque, load
torque and motion of the motor in 4 quadrants considering a cage with and without load

Quadrant1

The load torque acts in opposite direction of motor torque, the motor rotates in anticlockwise
(positive) direction to lift the loaded cage. So motor torque T and speed W m in same direction
as depicted. Power developed is also positive

Quadrant 2

In quadrant 2 empty cage is hoisted up, the cage may move up at dangerously high speed
because of counter weight having the gravitational pull.in order to avoid this the motor must
develop a torque T that acts in clockwise (Negative) direction known as braking torque.
Speed and power are negative in second quadrant

Quadrant 3

Empty cage is moved downwards. The motor ha stop produce a torque in same direction of
load torque so that the empty cage is protected from gravitational pull and also load torque is
counter balanced. The direction of motor is negative and power developed is positive

Quadrant 4

In this quadrant loaded cage is moved downwards, since weight of the cage is greater than the
counter weight the cage can come down at dangerously high speed and can hit the floor,
hence the motor has to provide a torque in opposite direction equal to that of load torque.
Speed and power developed are in negative direction

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Loads with rotational motion

Motor is driving two loads, one load L0 is directly coupled to shaft and other load L1 is
coupled to motor through a gear mechanism with gear ration n and n1.

J0 is the moment of inertia of load L0. Let Wm is the speed of motor and Tlo is torque produced

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Loads with translational motion

There are two loads connected to motor. Lo is load directly coupled to motor shaft. Mass M1
is also a load connected to motor through a transmission system which converts rotational
motion to linear motion

J0 is the moment of inertia of load coupled to shaft and T is the torque.

M1,V1, and F1 mass, velocity and force of the load having translational motion. If
transmission losses are neglected, kinetic energy due to equivalent inertia J must be same as
kinetic energy of various moving parts

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Components of Load Torque

Load torque can be divided into following components

Friction Torque- Present in motor shaft and various parts of the load

Friction torque is classified as

 Viscous friction which varies linearly with speed

 Coulomb friction is independent of speed
 Static friction is present in standstill, it occurs due to sticking nature of surface

Windage Torque-

 The torque is generated by wind opposing rotational motion of shaft

Torque required in doing useful mechanical work or Load Torque.

 It depends on particular application, it may be constant or independent of speed

 It may be function of speed. It also depends on position of load or path followed by the
load.
 It depends on method of transmission mechanism.
 It can also be time variant or time invariant

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 UNIT-2

SELECTION OF MOTOR POWER RATING

CHOICE OF MOTOR

 The power rating of motor is chosen properly in accordance with mechanical work
required for the drive,
 when drive is loaded to do this work, its final steady state temperature rise must be
within permissible limits
 The motor selected should be capable of driving the load satisfactorily both under
steady state and transient conditions
 The motor chosen should be neither too small nor too big to drive particular load,
 If it is too small it draws more current to drive the load and there is increase in
temperature greater than expected limit.
 If the rating is too high motor will not be running in full load and hence operates in
less efficiency and causes power loss

POWER LOSSES

 An electric motor has power loss occurring in its various parts such as copper loss in
windings, core loss due to hysteresis and eddy currents in the magnetic core of the
machine and mechanical losses due to friction and Windage these power losses causes
localized heat and are responsible or temperature rise in motor
 As the motor temperature rises heat overflow increases and equilibrium will only set
if the heat generated becomes equal to heat dissipated into surrounding medium
 The steady state temperature depends on power loss of machine and in turn power
losses depends on the rating and loading on the machine

THERMAL MODEL OF MOTOR FOR HEATING AND COOLING

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CLASSES OF MOTOR DUTY

1. Continuous duty
2. Short time duty
3. Intermittent periodic duty
4. Intermittent periodic duty with starting
5. Intermittent periodic duty with braking
6. Continuous duty with Intermittent periodic duty with braking
7. Continuous duty with starting and braking
8. Continuous duty with periodic brake changes

Determination of motor power ratings

The maximum continuous demand of load is ascertained based on the types of loads

The duty cycles for selection of ratings are classified

1. Continuous duty load

Maximum continuous power demand of the load is ascertained, it is necessary to check

whether motor can fulfill starting torque requirements .It is necessary to check whether rotor
power can overcome normal disturbance in power supply system

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2. Fluctuating load

3.Short time and intermittent duty load

For 2 & 3 based on the approximation that actual variable motor current can be replaced by
an equivalent current which produces same losses as that of actual current

Motor power loss is P1= Pc+Iequ2 * R (constant loss + copper loss)

Short Time duty:

In this case time for motor operation is shorter than heating time constant. Motor is allowed
to cool down to ambient temperature before it is required to operate again.

If a motor with continuous duty power is subjected to a short time duty, then motor
temperature will be far below maximum permissible value and motor will be under utilized

θss/θp = α + k2 =
α+1/(1-e-tr/ ζ)

where k is overloading factor which can be calculated if copper losses and constant losses are
known.

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 UNIT 3 & 4

D.C MOTOR DRIVES

STARTING AND BRAKING

The most important process associated with control of electric motors are

1. Starting
2. braking
3. speed control
4. speed reversal

STARTING: During starting the motor draws more current from supply and if there is no
protection to armature the winding will damage. Hence starters are used in the starting
mechanism of d.c motors

In D.C drives controllers present in control unit will limit the armature current to safe value.
In manual methods a resistance is includes in armature circuit to limit the inrush current

BRAKING: During the application of brake to a running motor, a torque s developed which
opposes the motion. This makes the motor to work as a generator. Braking should be carried
out at appropriate time; a delay in braking may result in heavy damage to the equipment or
the manufactured products.

Electric Braking is necessary for following reasons

 In some applications such as traction, rapid emergency stops are required to prevent
accidents. Electric braking can achieve quick and smooth stops.
 In applications where frequent stops are required applying electric braking will allow
opposite torque to stop at right time without delay
 Electric braking is more important in applications where is position control is required
such as lifts, machine tools etc.

There are three types of braking

 Regenerative braking
 Rheostatic braking
 Plugging

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REGEERATIVE BRAKING

In Regenerative braking the generated energy is supplied back to source. Mechanical energy
is converted to electrical eneegy.A part of electrical energy is returned to supply and rest is
lost as heat in windings of the machine

The shunt motor is run above rated speed and back emf Eb is made above supply emf, under
this condition the armature current will reverse imposing a torque opposite to direction of
rotation. The reverse torque will act a s break and feeds power back to supply.

RHEOSTATIC BRAKING

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Consider a motor operating on a d.c supply with switch S connected to position 1.Swith is
SPDT and when it is at position 1,motor runs at n rpm drawing armature current Ia and
develops a back emf Eb.

When switch is suddenly thrown to position 2, the armature gets disconnected from supply
and armature current will flow through Rb in reverse direction dissipating the energy through
it. The torque will act opposite to that of speed and speed decreases after an interval and
eventually the motor stops. This phenomenon is known as Rheostatic braking

PLUGGING

For usual motoring switch S is connected to position 1 and 1’.Across 2 and 2’ a series
combination of braking resistance Rb and a supply voltage with reverse polarity to that of 1
and 1’ is connected.

When motor is running at ‘n’ rpm the DPDT is thrown to 2 and 2’ and there by armature
supply is disconnected. By virtue of opposite polarity at 2 and 2’ current Ia changes its
direction producing torque opposite to that of speed and eventually the speed falls to zero
with in a time interval, once armature is connected to supply the current will not reverse its
direction after reaching zero speed. Hence once the motor speed reaches zero the DPDT from
2 and 2’ has to be disconnected.

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MULTI QUADRANT OPEARTION OF D.C SEPARATELY EXCITED MOTOR FED
FROM FULLY CONTROLLED RECTIFIER

The different schemes of multi quadrant operation are

1. Single fully controlled rectifier with reversing switch

2. Dual converter
3. Single fully controlled rectifier with field current reversal

All the above schemes can provide 4 quadrant operation.

1. Single fully controlled rectifier with reversing switch

A fully controlled rectifier feeds the motor through a reversing switches between a and b as
shown, which is used to reverse the armature connection w.r.t rectifier. It is capable of
providing operation in quadrant 1 and 4.the reversing of switch provides operation in
quadrant 3 and 2.

R- S is a relay operated contactor switch with two normally open NO and two normally
closed NC contacts. When maintenance of contactor becomes an issue, the contactor can be
replaced by four thyristor to obtain the same operation in a fully controlled way.

When thyristor pair TF on and TR off the 1 and 4 quadrant operation is achieved and with TR
on and TF off 3 and 2 quadrant operation is achieved. For speed reversal the firing angle is
maintained at high value such that armature current becomes zero, when zero current is
sensed firing pulses are stopped to already conducting thyristor with in a delay time of around
2 ms.

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Firing pulses are given to other two thyristors to reverse the direction and quadrant operation
is changed

DUAL COVERTER

 Rectifier A provides positive motor current and voltage in either direction for
quadrant 1 and 4
 Rectifier B is operated for quadrant 2 and 3

A dual converter consists of two fully controlled rectifiers A and B connected in parallel with
anti-polarity across armature as depicted in figure above

The converter can also be operated by operating both the rectifiers simultaneously such that
they provide same D.C voltage VA and VB

VA +VB =0

For three phase converter the voltage across the armature is given by

V= 3/π [Vm cosαA+ Vm cosαB]

αA+αB= 180 degrees

The inductors L1 and L2 are added to reduce a.c circulating currents and the values are chosen
such that maximum circulating current does not exceed 30 % of full load current.

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For speed reversal αA is increased and αB is decreased such that VA +VB =0

The dual control mechanism is also called circulating current control

FIELD CURRENT REMOVAL

The armature is fed from fully controlled rectifier and field is fed from a dual converter so
that field current can be reversed according to need. With field current on positive direction
the motor operates in 1 and 4 quadrants and with field current in negative direction the motor
operates in 2 and 3 rd. quadrants.

The armature rectifier firing angle is set to highest value to force the armature current to zero
while changing quadrants and then firing pulses are withdrawn. Next the rectifier of the field
is operated to which the firing angle is set to highest value to make field current zero to
achieve inverter operation. Also with desired firing angles through the armature rectifier the
speed control can be carried out

CHOPPER CONTROL OF SEPARATELY EXCITED MOTOR

In chopper control method the transistor Tr is operated periodically with period T. The
transistor Tr is operated for a period ton.

During 0<= t<= ton, the motor terminal voltage is V and the armature current rises from ia1 to
ia2 as depicted in figure below. The period 0 to t is called duty interval

At t=ton the transistor is turned off and motor current freewheels through the diode DF.

For ton <=t <=T motor current reduces from ia2 to ia1

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THREE PHASE HALF CONTROLLED RECTIFIER CONTROL OF SEPARATELY
EXCITED D.C MOTOR

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THREE PHASE FULL CONTROLLED RECTIFIER CONTROL OF SEPARATELY
EXCITED D.C MOTOR

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In the above arrangement of three phase full controlled rectifier at any given interval of time
on of the thyristor from top group T1,T3,T5 whose anode voltage is maximum positive will
conduct and simultaneously one thyristor from bottom group T2,T4,T6 whose cathode
voltage is maximum negative will also conduct.

The thyristors are triggered at 60 degree intervals. There are 6 output pulses each of 60
degree duration. The circuit is also called six pulse converters

RECTIFIER CONTROL OF D.C SERIES MOTOR

During positive half cycle T1 is triggered at wt=α and starts conducting, value of α should be
such that Vm sinα is greater than the motor emf E

The current flows through T1 and D2 from wt=α to wt=π. At wt=π, D1 I forward biased and
current flows through D1 and D2 till wt=π+α

At wt= π+α, T2 gets triggered and current flows through T2 and D1 till wt=2π.

At wt=2π D2 gets forward biased and current flows through D1 and D2 till wt=2π+αand
same procedure repeats

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CHOPPPER CONTROL OF SERIES MOTOR

A chopper controlled D.C series motor is shown. When the chopper is ON for a duration t on
motor terminals will be connected to supply.

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CHOPPPER CONTROL OF SERIES MOTOR FOR REGENERATIVE BRAKING

The circuit functions as self-excited series generator. Field current must be reversed with
respect to armature current when the circuit operation has to be changed from motoring to
braking.

Waveform of Va and ia and the nature of speed torque characteristics are depicted above

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 UNIT 5 &6

INDUCTION MOTOR DRIVES

OPERATION OF INDUCTION MOTOR WITH UNBALANCED VOLTAGE

SOURCES

The performance of induction motor under unbalanced supply volatges is very important for
analysis.
A three phase unbalanced voltage Va, Vb and Vc can be resolved into three phase balanced
positive sequence, negative sequence and zero sequence voltages using their symmetrical
component relations

Positive sequence voltages have same phase sequence as original system and negative
sequence voltages have opposite phase sequence.it will be assumed that machine does not
have neutral connection. In the absence of neutral connection the zero sequence line voltages
become zero.

Motor performance can be calculated for positive and negative sequence voltages separately.
Resultant performance is obtained by principle of superposition by assuming motor to be a
linear system.

Positive sequence voltages

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Negative sequence voltages produce an air gap flux wave which rotates at synchronous speed
in the reverse direction and the slip is

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Maximum Torque equation of induction motor is given by

Slip at maximum toque and the characteristics

The nature of speed torque and rotor current characteristics is shown.

Both rotor current and torque are zero at synchronous speed. With decrease in speed both will
increase, torque reduces after reaching break down value an rotor current continue to increase
reaching maximum value at zero speed. Drop in speed from no load to full load depends on
rotor resistance, when rotor resistance is low drop is small and motor operates in constant
speed

STARTING

Starting arrangement is chosen based on load requirements and nature of supply. It is

required to have the following features

 Motor should develop enough starting torque to overcome friction, load torque and
inertia of motor to load system and thus complete the process within prescribed time
limit.
 Starting current magnitude should be such that it does not cause the overheating of the
machine and does not cause dip in source voltage beyond permissible value
 During starting of the machine, it draws more current with in short interval, the
temperature rise of the machine in the interval should be in permissible limits.

STARTERS

We have three types of starters majorly used in starting of induction motors

 Star delta starter

 Auto transformer starter
 Part-winding starter

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 STAR DELTA STARTER

The induction motor is made to operate in delta connection is connected in star winding, this
allows reduction in stator voltage and current by 1/(3)1/2 .since motor torque is proportional to
square of terminal voltage ,starting torque is reduced by one third.

Circuit breakers CBm and CBs are closed to start the machine with star connection. When
steady state speed is reached CBs is opened and CBr is closed to connect the machine in delta.

AUTO TRANSFORMER STARTER

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Reduced voltage at starting can be obtained using auto transformer starter. For a secondary –
primary turns ration of X, motor terminal voltage and stator current also reduced by this
reduces the current drawn from the supply by X2, since torque is proportional to square of
motor terminal voltage it will also be reduced by X2

First CBs1 is closed and then CBs2, when motor gets accelerated to full speed CBs2 is opened
and CBm is closed. Now CBs1 is opened to disconnect the auto transformer from the supply.

PART WINDING STARTER

Some squirrel cage motors have two or more windings which are connected in parallel during
normal operation. During starting operation only one winding is connected. This increase
stator impedance and reduces starting current, such a starting scheme is called part winding
starting. Its implementation with two star windings is shown. Machine starts with winding 1
when CBm is closed, after full seed is reached CBs is connected to winding 2.

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VARIABLE FREQUENCY CONTROL FROM VOLTAGE SOURCES

The motor speed can be controlled by varying voltage or frequency. Voltage induced in
stator is proportional to product of supply frequency and air gap flux. If stator drop is
neglected terminal voltage can be considered as product of supply frequency ad flux.

If we reduce the frequency keeping the terminal voltage constant there will be an increase in
air gap flux, Induction motors are designed to operate at knee point of magnetization
characteristics. Therefore the increase in flux will saturate the motor, which further increases
current and distort the line current and voltage and in turn increase the losses.

Hence V/f ratio is maintained constant at rated value

K is a constant, Ls and Lr is stator and rotor resistances, positive sign for motoring operation
and negative sign for braking operation. Tmax equation suggests that with constant V/f ratio
motor develops maximum torque, except at low speeds,

The variable frequency control provides good running and transient performance because of
following reasons.

 Speed control and braking are available from zero speed to above base speed
 Above base speed V is kept constant and below base speed V/f ratio is maintained
constant

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  Transient operations can be carried out at maximum torque with reduced current
giving good dynamic response
 Copper losses are low and efficiency and power factor are high.
 Drop in speed from no load to full load is small

CYCLOCONVERTER CONTROL

Fig below shows the cycloconverter control

Cycloconverter allows variable frequency and variable supply to be obtained from a fixed a.c
supply. A half wave converter is shown below along with its nature of output voltage.
Because of the low harmonic content when operating at low frequencies, smooth motion is
obtained at low speeds, harmonic content increases with frequency making it necessary to
limit maximum output frequency 40% of the source frequency.

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The maximum speed is restricted to 40% of the synchronous speed at the mains frequency. A
motor with large leakage inductance is used to minimize deration and torque pulsations due
to harmonics in motor current. The drive has regenerative braking capability and also full
four quadrant operation can also be obtained

CURRENT SOURCE INVERTER CONTROL

A thyristor current control is shown in figure below

Diodes D1 and D6 and capacitors C1 and C6 provides commutation for thyristors T1 and T6
which are fired with a phase difference of 60 degrees in sequence of their numbers.

It also shows the nature of output current waveforms. Inverter behaves as current source due
to presence of large inductance Ld in d.c link.

The fundamental component of motor phase current is shown

For a given speed, the torque is controlled by varying D.C link current Id, by changing the
value of Vd. Therefore when supply is AC a controlled rectifier is connected between supply
and inverter and when supply is DC chopper is connected between supply and inverter.

The maximum value of D.C output voltage of fully controlled rectifier and chopper are
chosen such that motor terminal voltage saturates at rated value
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Advantages

 Reliability
 Suitable time for commutation
 Protective control of devices

CLOSED LOOP CONTROL

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In closed loop control actual speed Wm is compared with reference speed Wm*. The speed
error is processed through PI slip regulator. The slip regulator sets up slip speed command
Ws1*.The synchronous speed obtained by ( Wm Ws1*) determines the inverter frequency. The
flux control block provides reference current Id*, which through a closed loop current control
adjusts the dc link current Id to maintain a constant flux. Any correction in speed error is
carried at maximum permissible inverter current and maximum available torque.

VOLTAGE SOURCE INVERTER CONTROL

The voltage source inverters are used to obtain variable frequency and variable voltage to
control induction motor loads efficiently

The D.C supply is inverted to variable A.C supply by using power semiconductor devices

In transistor fed drives, the speed of induction motor is controlled by H bridges of transistors.

The stator voltage to induction motor is a stepped waveform produced using PWM method.

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The transistors are switched in the sequence of numbers with a time difference of T/6 and
each transistor is kept on for a period T/2 where T is the period of one cycle.

Frequency of the induction motor is varied for controlling the speed. By varying the dc
voltage Vd the output voltage of the drive or line voltage can be varied. If the input is a fixed
DC, variable D.C is obtained by including a chopper at input side. When source is AC
controlled rectifies with capacitive filters are employed at source side to get variable DC

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 STATIC SCHIERBUS DRIVE

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CLOSED LOOP CONTROL

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STATIC KRAMERS DRIVE

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 UNIT-7

SYNCHRONOUS MOTOR DRIVES

COMMONLY USED SYNCHRONOUS MOTORS ARE

 Wound field motors

 Permanent magnet motors
 Synchronous reluctance motors
 Hysteresis motors

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Balaji Ramakrishna S
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Balaji Ramakrishna S
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Balaji Ramakrishna S
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Balaji Ramakrishna S
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Balaji Ramakrishna S
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Balaji Ramakrishna S
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Balaji Ramakrishna S
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Balaji Ramakrishna S
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VARIABLE FREQUENCY CONTROL OF MULTIPLE SYNCHRONOUS MOTORS

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Balaji Ramakrishna S
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Balaji Ramakrishna S
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 UNIT-8

INDUSTRIAL MILLS
 ROLLING MILLS
 CEMENT MILLS
 PAPER MILLS
 TEXTILE MILLS

ROLLING MILLS

In rolling mills the process of rolling of steel is taken place in which the cross section of the
metal gets reduced, while increases its length proportionately.

Bloom slabs, rails, rods, sheets, beams and bars are the product of rolling mill. Any length of
rolled metal having square cross section is known as a bloom, blooms of reduced cross
section are known as billets, a billet can be further rolled into a bar, squares, angles and rods.
A bloom of rectangular cross section is known as slab. The mill that produces above shapes
of steel is known as merchant mills. The slabs are further reduced into Plates whose thickness
is small compared to width. This is done in plate rolling mill; further plates are changed into a
strip in strip mill and again to thin sheets in a sheet mill

All the above variants and shapes are manufactured by changing the number of passes or by
stand mills having an appropriate pattern

Rolling mills are classified into

 Continuous cold rolling mills

 Continuous hot rolling mills
 Reversing hot rolling mills
 Reversing cold rolling mills

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REVERSING HOT ROLLING MILLS

Reverse rolling mills roll out blooms or slabs from hot steel ingots which come directly either
from steel making shops or from heating chambers called soaking pits. Red hot ingots are
taken one by one by special crane and placed on a car known as ingot buggy.Theingot buggy
travels a short distance on rails along the same line as mill bed and takes ingot to the front
end of the mill bed.

The mill bed consists of large number of rolls. The ingots are tilted and placed on the
receiving table such that they lie with the longitudinal axis horizontally on the bed, they move
over the weighing table where it is possible to weigh the passing ingot. The travel of ingots
over roll table is facilitated by rotation of rolls on which they are laid.

Before reaching mill stand the ingots move over approach table and several other
intermediate tables and front work table. On the other side of the mill stand there are several
other back work tables, several intermediate tables, run out table in succession with shear
table where rolled metal is cut into standard lengths

The ingots are rolled by the working rolls into blooms as they pass through mill stand several
times in forward and reverse direction

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The main requirements of the drive are

 Double armature motor for larger drives

 Wide range of speed variation ability of the motor and its control equipment to permit
frequent starts and reversals
 Reverse of direction of motor without causing serious disturbances in power handing
circuit
 Automatic control of operation
 High reliability and accuracy

CONTINUOUS HOT ROLLING MILLS

In this mill billets and strips are produced. They consist of Group stand, Roughing stand
finishing stand. Each stand may consist of two or four rolls depending on depending on
which the stands are called two high or four high.

In a four high stand the inner rolls of smaller diameter are working rolls and outer rolls are
used to vary and maintain the gap between the working rolls. The metal passes through the
stands only in one direction and gets rolled in finishing stand.

Requirements:

 The speed of the motor must be capable of variation over a range 1.5 – 2.In order to
avoid sag of the metal between the stands,
 The speed of stand motors should be controlled to a high degree of accuracy.
 The motor control must be automatic and the speed of the motor must be restored to
its set value as quickly as possible

REVERSE COLD ROLLING MILLS

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The steel strip to be rolled is received in form of a reel, wound on a mandrel, mounted on one
reel stand as shown above, another stand carries empty mandrel, the end of the strip is
threaded manually through stand rolls and round the empty mandrel

The mill is then run with a slow speed and then strip is wound on the rolling drum for few
turns with low tension and roll pressure, the speed is then increased with uniform acceleration
and metal is rolled with required pressure and tension. During this one reel gets coiled and
another gets uncoiled, when only few turns are let out to be rolled ,the speed is reduced and
direction is reversed, thus ensuring that strip does not come out of the uncoiling reel. The
same procedure is repeated while rolling in the opposite direction

Requirements

 Mill stand requires four quadrant drive at required speeds

 Control system should have both armature voltage control and field weakening
 Field is kept at its rated value until the maximum back emf is reached and
subsequently reduced depending on the speed requirement.
 In order to maintain constant tension of the strip, the armature current of the motor
and ratio of flux to effective diameter of the reel of the coil must be kept constant

CONTINUOUS COLD ROLLING MILLS

Metals in the mill pass in only one direction in four high stands.

It consists of coiler and uncoiler reel. The strips are subjected to large inter stand tension
which is kept at constant value depending on the desired thickness of the sheet to be produced
the threading of the metal through the stand is done at low speed, as soon as the threading is
done the speed of the mill is raised to working value. Again it is brought to low value before
the strip leaves the first stand. Depending on the product to be obtained, variation in speed of
mill drive is adjusted.

PAPER MILL

Pulp making and paper making are two important process that takes place in paper mill and
drives required are quite different from each other.

Pulp is made of two ways

 Purely by mechanical means

 By means of both mechanical and chemical process

In mechanical method grinding of logs of wood of about 1m length on large grind stones,
Grinders operate at almost constant speed and can be started under light load conditions.

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Hence synchronous motors are considered as they are most suitable for grinder drives as they
work at 200 to 300 rpm.Geared drives are used especially when motors are installed in a
separate room for protection from humid atmosphere.

The grinders are driven by motor rating of 3000 to 4000 Kw.Pulp can also be made by cutting
logs of wood into chips of several cm length and treating them with alkalis along with other
raw material like grass, rags etc. During this chemical treatment the material is continuously
beaten.

Wood choppers have random load characteristics and has high inertia, depending on the size
of the disc on which knives are mounted, large wood is transported. The end product of the
grinders and beaters are refined and stored in large tanks as pulp for making paper

PAPER MAKING

The machine that makes paper in a paper mill has to perform the job of forming sheets,
removing water from sheets, drying of sheets, pressing of sheets and reeling of sheets. There
are five sections of paper making

2. Couch section (wire section)

3. Press section
4. Dryer section
5. Calendar section
6. Reel section

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The paper pulp with a moisture content of 98 to 99% is transferred through the wire mesh and
the rest is removed by suction., moisture content would have reduced to 80%.In the press
section sheet is pressed between woolen felts so as to squeeze out water from wet sheet and
web leaves the press section with a moisture content of 60 to 65%.In dryer section the sheet is
further dried by passing it over and over the heated

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CEMENT MILLS

DRY PROCESS

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WET PROCESS

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TEXTILE MILLS

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NOTE: THIS NOTES MATERIAL IS MADE AFTER REFERING TO THE PRESCRIBED
REFERENCE BOOKS PURELY FOR ACADEMIC PURPOSE AND THERE IS NO COMMERCIAL
INTEREST INVOLVED

REFERENCES

[1] Fundamentals of eclectic Drives- Gopal K Dubey

[2]A first course on Electric Drives- S.K.Pillai

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