U N W E g S f T I I OK H U S S O H c m m m a y s s a

UTHM

*300000021fi1574*

UNIVERSITI TUN HUSSEIN ONN MALAYSIA

BORANG PENGESAHAN STATUS TESIS*

JUDUL: THREE PHASE INDUCTION MOTOR INVERTER APPLICATION FOR MOTION CONTROL

SESIPENGAJIAN: 2007/2008

Saya M O H D RUSMI BIN ABDUL GHANI (HURUF BESAR)

mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah)* ini di simpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hakmilik Universiti Tun Hussein Onn Malaysia. 2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi

pengajian tinggi. 4. ** Sila tandakan (V)

• • • SULIT (Mengandungi maklumat yang berdarjah keselamatan atau

kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972)

TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

TIDAK TERHAD

Disahkan oleh:

(TANDATANGAN PENULIS)

Alamat Tetap:

A925.KG.HULU TAKJR, SEBERANG TAKIR, 21300 KUALA TERENGGANU. TERENGGANU

TARIKH: APRIL 2008

(TANDATANGAN PENYELIA)

P.MADYA DR. ZAINAL ALAM BIN HARON

TARIKH: 2 - ^ A P R I L 2008

CATATAN: * Potong yang tidak berkenaan. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak

berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan dikelaskan sebagai SULIT atau TERHAD.

• Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertai bagi pengajian secara kerja kursus dan penyelidikan atau Laporan Projek Sarjana Muda (PSM).

"I hereby declare that I have read this thesis and in my opinion this thesis is sufficient in

term of scope and quality for the award of the degree of

Master of Electrical Engineering ".

Signature

Name of Supervisor : P.Madya DR. ZAINAL ALAM BIN HARON

Date APRIL 2008

THREE PHASE INDUCTION MOTOR INVERTER APPLICATION FOR

MOTION CONTROL

MOHD RUSMI BIN ABDUL GHANI

A project report submitted in partial

fulfillment of the requirement for the award of the

Degree of Master of Electrical Engineering

Faculty of Electrical and Electronic Engineering

Universiti Tun Hussein Onn Malaysia

APRIL 2008

ii

I declare that this report on "Three Phase Induction Motor Inverter Application for

Motion Control" is the result of my own project except for works which have been cited

in the references. The report has not been accepted any degree and not concurrently

submitted in candidature of any other degree.

Signature

Name of Author : MOHD RUSMI BIN ABDUL GHANI

Date : APRIL 2008

For my dearest wife Salina,

My beloved daughters NurAfifah Nabilah and NurAisyah Najihah,

My beloved sons M.Aqil Hanis and M.aiman Hakimi

&

My family for their encouragement and blessing

i v

ACKNOWLEDGMENT

In the name of Allah, the most Gracious and most Compassionate

First of all, I am greatly indebted to Allah SWT on His blessing to make this

project successful.

I would like to express my gratitude to honourable Prof. Madya Dr. Zainal Alam

bin Haron, my project supervisor for his guidance and help rendered throughout this

project.

Special thank and appreciation goes to all my friends, technicians and others

whose name could not be mentioned here one by one. Your encouragement, help and

concern is greatly appreciated.

My warmest thanks go to my parent and parent-in-law for their support. My

highest appreciation goes to my loving wife, Salina Salleh and my beloved daughters

Nur Afifah Nabilah, Nur Aisyah Najihah, my beloved sons M.Aqil Hanis and M.Aiman

Hakimi for their unconditional support and love that continuously fed my strength desire

to succeed.

Finally, I wish to thank everyone who has helped in one way or another towards

the successful implementation of this project.

XI

ABSTRACT

The aim of this project is to become familiar with the operation and use of the

Toshiba VFFS1 Inverter to reduce motor starting current and also to improve on the

quality of the motion executed motor-driven equipment. Various methods exist to

reduce the high starting currents of three phase induction motors. A low starting current

not only reduces stresses on the power utility but also decreases stresses on the motor

and the driven equipment. As designed, inverters can reduce the starting current,

especially by programming the motion to follow a trapezoidal or s-curve profile. A

trapezoidal motion profile reduces jerky motion while the s-curve profile totally

eliminates it. The challenge in motion control is always how to achieve precise motion

with minimum jerk, and overshoot in position as well as velocity. There are four

methods that can be used to connect the inverter to a motor, namely, by control panel,

using a controller computer, remote terminal box, or a PLC. A number of induction

motors were tried with the inverter to observe their response to the different motion

profiles programmed into the inverter. The results are reported and discussed in this

work.

vi

ABSTRAK

Matlamat projek ini ialah untuk menyesuaikan dan menggunakan operasi

penyongsang Toshiba VFFS1 untuk mengurangkan arus permulaan motor dan juga

melakukan pembaikan gerakan peralatan pacuan motor. Terdapat pelbagai kaedah yang

digunakan untuk mengurangkan arus permulaan yang tinggi bagi motor aruhan tiga fasa.

Arus permulaan yang rendah bukan saja dapat mengurangkan tekanan pada peralatan

kuasa, ia juga dapat mengurangkan tekanan pada motor dan pemacu. Penyongsang

direka bagi mengurangkan arus permulaan, terutama oleh pengatucaraan gerakan untuk

mengikut profil trapezoid atau lengkuk-s. Satu profil gerakan trapezoid mengurangkan

gerakan sentakan dan lengkuk-s dapat menghilangkan sepenuhnya sentakan. Cabaran

dalam kawalan gerakan adalah untuk mencapai gerakan yang lancar dengan sentakan

minima dan dalam kedudukan terlajak serta halaju. Terdapat empat kaedah yang boleh

digunakan untuk menyambung penyongsang ke sebuah motor, iaitu, oleh panel kawalan,

menggunakan sebuah komputer pengawal, kotak pangkalan jauh, atau satu PLC.

Sejumlah motor aruhan telah dicuba dengan penyongsang untuk memantau kawalan

gerakan penyongsang yang berbeza arahan. Hasilnya telah diapor dan dibincangkan

dalam keija ini.

TABLE OF CONTENTS

CHAPTER CONTENTS PAGE

THESIS STATUS CONFIRMATION

SUPERVISOR'S CONFIRMATION

TITLE

TESTIMONY

DEDICATION

ACKNOWLEDGEMENT

ABSTRACT

ABSTRAK

TABLE OF CONTENTS

LIST OF FIGURES

LIST OF TABLES

LIST OF SYMBOLS / ABBREVIATIONS

LIST OF APPENDIXES

CHAPTER 1 INTRODUCTION 1

1.1 Starting of Induction Motor 1

1.2 Type of Starter Motor 2

1.2.1 D.O.L Starter 2

1.2.2 Star/Delta Starter 2

1.2.3 Soft Starter 3

i

ii

iii

iv

v

vi

vii

xi

xiv

XV

xviii

1.2.4 Inverter 3

1.3 Background of the Study 4

1.4 Problem statement 6

1.5 Aim of the study 6

1.6 Objectives of the study 7

1.7 Research Scopes 7

1.8 Report Outline 8

CHAPTER II LITERATURE REVIEW 9

2.1 Motion Control 9

2.2 Elements of Motion Control 10

2.2.1 Position Control 10

2.2.2 Velocity Control 10

2.2.3 Acceleration/Deceleration Control 11

2.2.4 Torque Control 12

2.2.5 Jerk 12

2.2.6 Trapezoid and S-Curve 13

2.3 Basic Theory of Inverters 15

2.3.1 Voltage Source Inverter 15

2.3.2 The Three-Phase Bridge VSI 16

2.3.3 Current Source Inverter 17

2.3.4 The Three-Phase Current Source

Bridge Inverter 17

2.4 Speed Control of Induction Motors 18

2.4.1 Speed Control by Changing the Line

Frequency 19

2.4.2 Speed Control by Pole Changing 22

2.5 The Frequency Converter 23

2.5.1 The Rectifier 25

2.5.2 Full-wave Controlled Rectifier 26

2.5.3 The Intermediate Circuit 28

2.5.4 The Inverter 31

2.5.5 Transistor 34

2.5.6 Pulse Width Modulation PWM 36

Review of Important Research Works on 40

Motion Control

CHAPTER III METHODOLOGY 43

3.1 Research Flow 43

3.2 Toshiba VF-FSI Instructions Manual 45

3.3 Simplified Operation of the VF-FS1 Inverter 45

3.3.1 Local Mode and Remote Mode 46

3.3.2 How to Start and Stop 47

3.3.3 Start and Stop using the Operation

Panel Keys (CNOD=l) 48

3.3.4 RUN/STOP of an External Signal

to the Terminal Board (CNOD = 0) 48

3.3.5 Coast Stop 48

3.3.6 How to set the Frequency 49

3.3.7 Setting the Frequency using the

Operation Panel (FNOD=3) 50

3.4 How to Operate the VF-FS 1 50

3.5 Setting Program for Inverter 51

3.5.1 Setting the Controller Computer

to Panel Inverter 52

3.5.2 Setting Remote Terminal Box to

Panel Inverter 53

3.5.3 Setting Controller Computer to

XI

PLC and to Panel Inverter 54

3.6 Setting CX-Program for PLC 56

3.7 Serial Communication 58

3.8 Setting the Controller Computer 58

3.8.1 Parameters Listed in the Table 61

3.8.2 Parameter Setting, Import, and

Export are Executed 62

3.8.3 Monitoring Display 63

3.8.4 Open/Save as 68

3.9 Setting Acceleration/Deceleration Time 69

3.9.1 Automatic Acceleration/Deceleration70

3.9.2 Manually Setting

Acceleration/Deceleration Time 72

3.9.3 Acceleration/Deceleration Time 2 73

3.9.3.1 Linear Acceleration /

Deceleration 73

3.9.3.2 S-pattern Acceleration /

Deceleration 1 74

3.9.3.3 S-pattern Acceleration /

Deceleration 2 74

3.9.4 Switching Acceleration /

Deceleration Time 1 and 2 75

3.9.4.1 Selection using Parameters 76

3.9.4.2 Switching by Frequencies 76

3.10 Testing Implementation 77

3.10.1 Puma Compressor 78

3.10.2 Crusher Machine 79

3.10.3 Circular Machine 80

3.10.4 Other Motor Testing 81

XI

CHAPTER TV RESULTS AND DISCUSSIONS 82

4.1 Result of Puma Compressor

4.2 Result of Crusher machine

4.3 Result of Circular machine

4.4 Results for Other Motor Testing

83

87

90

94

CHAPTER V CONCLUSIONS 95

REFERENCES 97

APPENDIXES 100

xii

LIST OF FIGURES

FIGURE TITLE PAGE

2.1 Trapezoidal model (a) and S-Curve model (b) 13

2.2 Comparison of Trapezoidal and S-Curve Velocity

Profiles 14

2.3 A Three-Phase Inverter 16

2.4 Circuit Diagram Three-Phase CSI 18

2.5 Variable-frequency speed control in an induction

motor 21

2.6 The method of change an a.c. motor speed 24

2.7 Simplified diagram of a frequency converter 25

2.8 Single and three-phase a.c. voltage 26

2.9 The mode of operation of the thyristor 27

2.10 The full wave controlled rectifier 27

2.11 Variable d.c. intermediate circuit 28

2.12 Constant or variable voltage intermediate circuit 29

2.13 Variable voltage intermediate circuit 29

2.14 The chopper transistors varies the intermediate

circuit voltage 30

2.15 Inverter for variable intermediate circuit current 3 2

2.16 Inverter for variable or constant intermediate

circuit voltage 33

2.17 Modulation of pulse amplitude or width 34

xiii

2.18 How the switching frequency affects the motor

current 35

2.19 The principle of the sine-controlled P WM 3 7

2.20 The output voltage at PWM 38

2.21 The output voltage can be increased by utilizing

the third harmonic 40

3.1 Flowchart of research work 44

3.2 The coast stop 49

3.3 Process the setting mode 51

3.4 Connection to setting controller computer to

inverter 52

3.5 Connection to setting the remote terminal box

to panel inverter 54

3.6 Connection from PLC port A to control circuit

terminal board 55

3.7 Connection controller computer to PLC and to

panel inverter 56

3.8 Ladder diagram circuit for forward and reverse

control 57

3.9 Starting of PCM001Z displays. 59

3.10 The main menu and Parameter Table 5 9

3.11 The setup of the RS-232C 60

3.12 The parameter setting value 62

3.13 (a): Monitoring display tab page screen 63

(b): monitor setting tab page screen 64

3.14 Monitor - Data display screen 65

3.15 Se tAUl to 1 or 2. 70

3.16 Manually setting AU1 = 0. 72

3.17 Linear acceleration/deceleration 73

3.18 S-pattern acceleration/deceleration 1 74

3.19 S-pattern acceleration/deceleration 2 75

X I V

3.20 Selection using parameters 76

3.21 Switching by frequencies 77

3.22 The puma compressor 78

3.23 The crusher machine 79

3.24 The circular machine 80

4.1 The waveform when setting AU1=1 84

4.2 The waveform when setting AU1=0 85

4.3 The comparison between AU1=1 and AU1=0 86

4.4 The waveform when setting AU1=1 88

4.5 The waveform when setting AU1=0 89

4.6 The comparison between AU1=1 and AU1=0 90

4.7 The waveform when setting AU1=1 91

4.8 The waveform when setting AU1=0 92

4.9 The comparison between AU1=1 and AU1=0 93

XV

LIST OF TABLES

TABLE TITLE PAGE

3.1 Step to Start and Stop the Inverter 47

3.2 Remote Mode Selection 47

3.3 FNOD Setting Procedure 49

3.4 Listed of Parameters 61

3.5 Conditions on Baud Rate 66

3.6 Parameter Setting 71

3.7 Methods of Setting Automatic Acceleration /

Deceleration 71

3.8 Selecting an Acceleration / Deceleration Pattern 73

4.1 Comparisons Testing with Inverter and without

Inverter for Puma Compressor 86

4.2 Comparisons Testing with Inverter and without

Inverter for Crusher Machine 89

4.3 Comparisons Testing with Inverter and without

Inverter for Circular Machine 93

LIST OF SYMBOLS/ ABBREVIATIONS

Symbols:

M

n

/ Tt

<f>

CO

9

s

C

k

L

m

M

T

N

P

P

V

t

Micro (106)

Ohm

Frequency (Hz)

Pi (180)

Flux

Omega

Phase displacement

Slip

Capacitance

kilo (103)

Inductor

mili (10"3)

Mega (106)

Switching period

Speed

Pole

Power

Voltage

Time

Abbreviations:

AC (a.c) - Alternating Current

DC (d.c) - Direct Current

e.m.f - Electric Magnetic Force

THD - Total Harmonic Distortion

UPS - Uninterruptible Power Supply

CVCF - Constant Voltage and Constant Frequency

KV - Kilo-Volt

BJT - Bipolar Junction Transistor

TTL - Transistor-transistor Logic

MOS - Metal Oxide Semiconductor

CMOS - Complementary Metal Oxide Semiconductor

IGBT - Insulated Gate Bipolar Transistor

MOSFET - Metal Oxide Semiconductor Field Effect Transistor

PWM - Pulse Width Modulation

IEEE - Electrical and Electronic Engineer

VSI - Voltage Source Inverter

CSI - Current Source Inverter

RCL - Rotor Core Losses

AG - Air Gap

sync - Synchronous

ACC - Acceleration

DEC - Deceleration

LIST OF APPENDIXES

APPENDIX ITEM PAGE

A SPECIFICATION, DATA FOR TOSHIBA

INVERTER 100

B PERMISSION LETTER 107

C DATA, SPECIFICATION AND THE WAVEFORMS

TESTING BY PUMA COMPRESSOR 110

D DATA, SPECIFICATION AND THE WAVEFORMS

TESTING BY CRUSHER MACHINES 113

E DATA, SPECIFICATION AND THE WAVEFORMS

TESTING BY CIRCULAR MACHINES 116

F DATA, SPECIFICATION AND THE WAVEFORMS

TESTING BY PRESSURE MACHINES 119

G DATA, SPECIFICATION AND THE WAVEFORMS

TESTING BY SIMULATION LOADS 124

CHAPTER I

INTRODUCTION

1.1 Starting of Induction Motor

In a three phase induction motor, the induced e.m.f. in the rotor circuit depends

on the slip of the induction motor and the magnitude of the rotor current depends upon

this induced e.m.f.[l][2], When the motor is started, the slip is equal to one as the rotor

speed is zero, so the induced e.m.f. in the rotor is large. As a result, a very high current

flows through the rotor. When an induction motor starts, a very high current is drawn by

the stator, on the order of 5 to 9 times the full load current. This high current can

damage the motor windings and because it causes heavy line voltage drop, other

appliances connected to the same line may be affected by the voltage fluctuation. To

avoid such effects, the starting current should be limited. A starter is a device which

limits the starting current by providing reduced voltage to the motor. [3] Once the rotor

speed increases, the full rated voltage is given to it.

2

1.2 Type of Starter Motor

Basically, they can be divided into two major groups; electromechanical starters

and electronic starters [4], The name electromechanical starters stems from the fact that

they employ electromechanical contactors, relays, resistances and transformers for

offering reduced voltage starting. Under this type of starters, methods such as direct

online starting (DOL), star-delta starting, stator resistance starting and autotransformer

starting are listed. As for the electronic starters, there are the AC voltage controller

(soft) starters and V/F starters (inverter). Choosing the type of motor starter for each

application depends on the motor characteristics, available space, load torque

requirements and overall cost. [5].

1.2.1 D.O.L Starter

A DOL starter connects the motor terminals directly to the power supply. Hence,

the motor is subjected to the full voltage of the power supply. Consequently, high

starting current flows through the motor. This type of starting is suitable for small

motors below 5 hp (3.75 kW). By using this method, there is a high probability of

producing jerk. Reduced-voltage starters are employed with motors above 5 hp.

1.2.2 Star Delta Starter

Star/Delta starters are probably the most common reduced voltage starters in the

50Hz world. They are used in an attempt to reduce the start current applied to the motor