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Optimal Generation of Output Torque for Industrial Motors Using Variable Frequency Drive and Gearbox Drive

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Optimal Generation of Output Torque for Industrial Motors Using Variable Frequency Drive and Gearbox Drive International Journal of Recent Technology and Engineering (IJRTE) ISSN: 2277-3878, Volume-8 Issue-4, November 2019 Optimal Generation of Output Torque for Industrial Motors using Variable Frequency Drive and Gearbox Drive S.Joseph Francis, S.Karthikeyan, S.Balasundaram, L.Kalaivani, M.Gengaraj, used to control the drive speed by decreasing the frequency Abstract: This paper depicts the exploration of output torque of and the appropriate voltage to satisfy the requirement of Gear reduction drive and variable frequency drive (VFD) with electric motor load. If any application required the speed detailed analysis report for the various load conditions. The right requirement, as VFD can increase or decrease the motor selection of VFD will depend on the load requirement and application. The higher the load therefore more torque needed in speed to meet the specified speed requirement. [2]. an application, the higher the current draw of the motor will be. In order to reduce the mechanical components and to Since VFDs are rated by their continuous output current (amps), improve the overall maintenance, the VFD is proficient it is important to select a drive with adequate current to the motor to changing the output speed of the drive without the for optimal performance. The property of Torque is converse effect of gear reduction. By means of gear ratio, the output torque need for any mechanical pulleys. Though, VFD has a is increased by developing the torque with reduced efficiency distinct feature that it has the capability to save the losses. On the other hand, in some applications the gear reduction economy of the user through its unique nature to save play a vital role in reduces the speed while increase the torque and energy by controlling only the power that is required for in many other applications it uses to increase speed with reduced the application. By means of power conversion only, a VFD torque. In recent era, many industrial drives are designed as such can accomplish. As like traditional electric motor, a VFD is that to run at 60% to 100% of rated load. In this scenario the drive would get optimum efficiency is generally obtained nearly 75% of attached, that convert the power to the usable form. The rated load. Thus, a 20 horsepower (HP) electric drive has a principle behind the induction motor in which the electrical satisfactory load range of 12 to 20 HP with optimum efficiency is supply is given to its stator and the given input electrical at 7.5 HP. A motor’s efficiency tends to decrease dramatically power is converted to mechanical output power through the below about 50% load. Hence it’s very important to choose the rotating magnetic field and that produced torque by means of drive for the proper application with different loading conditions. slip. In other words a VFD, will convert its incoming power, a fixed voltage, and frequency, to a variable voltage and Keywords: Torque coefficient, Variable frequency drive, Load, frequency [3]. This feature of VFD is used to vary the speed I. INTRODUCTION of the industrial drive without the need any additional mechanical pulleys of gearboxes. The fig. 1 shows the block diagram of variable frequency drive fed motor. n modern era, the Variable Frequency Drive (VFD) is I finding a variety of applications over the industrial field. It is used to drive the industrial electric motor by controlling the frequency and voltage applied to the motor. Simply it s a type of motor controller that controls the performance parameter of the industrial drive. VFD can be otherwise called as adjustable speed drive, adjustable frequency drive, AC drive, micro drive, and inverter depends upon the application where it is used [1]. The relationship between the Frequency (Hz) and the motor’s speed (RPMs) is linear in other words it is directly proportional. In general, if the Fig. 1. Block Diagram of VFD. frequency is faster this yields the motor speed as faster. If any application which doesn’t require the rated speed the VFD is The vital reason to acquire the VFD is speed control. The major advantage of this type of speed control is for the purpose to process, operation and economic benefits with Revised Manuscript Received on November 15, 2019 proper energy consumption. While considering maintenance * Correspondence Author the VFD is the suitable choice because it not having any S.Joseph Francis, EEE Department, National Engineering College, Kovilpatti, India. Email: [email protected] carbon brushes or mechanical components like pulleys and S.Karthikeyan, EEE Department, National Engineering College, gearboxes etc., Fans and Pumps are the apparent profitable Kovilpatti, India. Email: [email protected] benefits of VFDs. The relationship of the power and velocity S.Balasundaram, EEE Department, National Engineering College, that a pump or fan consumes is directly proportional to the Kovilpatti, India. Email: [email protected] Dr.L.Kalaivani*, EEE Department, National Engineering College, cube of the velocity. For Kovilpatti, India. Email: [email protected] example, if a consumer can run M.Gengaraj, EEE Department, National Engineering College, a fan at 80% of full speed; it Kovilpatti, India.,. Email: [email protected] Retrieval Number: D8195118419/2019©BEIESP Published By: DOI:10.35940/ijrte.D8195.118419 Blue Eyes Intelligence Engineering 12147 & Sciences Publication Optimal Generation of Output Torque for Industrial Motors using Variable Frequency Drive and Gearbox Drive hypothetically uses 51% of full load power [4]. C. Determinations of Motor loading At rated load, many conventional electrical drives are II. VARIABLE FREQUENCY DRIVE develop to run at 50% to 100% of rated load. About the half A. Correlation of Voltage and Frequency of the rated load the motor’s efficiency is considerably At rated frequencies, if the applied frequency of an Induction decreased. On the other hand, the choice of good efficiency motor is reduced, the applied voltage also should reduced to should ranges with individual motor drives and it will extend suppress the current drawn by the motor. over a wide range for large larger motors which is shown in (The inductive reactance of an AC magnetic circuit is directly fig 3. While the efficiency reduces significantly with reduced load, the motor drive is considered under loaded. [7]. proportional to the frequency according to the formula XL = 2πfL. Where: f = frequency in hertz, and L= inductive reactance in Henry) Fig. 3. Motor Efficiency ( as a function of % full load efficiency) The motor get overheat and it will lose some efficicecy it may called as overloaded motors. A service factor has been fixed for many industrial drives which allows intermittent overlaoding. Service factor is a value which indicates the motor overloading condtion under ideal situations. If we take, 20-hp motor with a 1.2 service factor can handle an 24 hp Fig. 2. Relationships of VFD with constant load for minimum periods without sustaining considerable torque and constant power with various damage. However many motors continously running above frequencies the rated load with the service factor of 1.15 which results in Fig. 2 shows the relationship between the frequency versus effeiciency and life span of motor decreases. When the voltage is below nominal value and the cooling is weaken by torque and power. In order to evaluate the relationship ratio elevation, high ambiernt heat or dirty motor surfaces the the applied voltage applied to the motor should divided by motor should be never operated. rated frequency. The ratio should be low at low frequencies and it will increased as the frequency increases.[5] To III. GEAR BOX maintain the constant volts/hertz ratio throughout the range several methods are adopted to adjusts the output voltage A. Gearbox Setup waveform such as microprocessor control , PWM control by Gears are the device which used to reduce the output speed simultaneously change the voltage and frequency. For the while increased the torque value for the electric motor drive above rated frequency, the voltage is kept constant for the or engine to obtain the required result. [8]. many AC variable speed drives. B. Calculation of Horse power for the Drive Power = Work / Time Power = (Force X Distance) / Time The power value of the drive has been calculated from the torque and speed of the motor. For example, if the drive motor have speed of 2000 RPM then the horsepower is calculated below. Horse power = (2,000 X 6) / 63,025 = 0.190 Here the constant value 63025 is a common constant which makes the unit conversion. [6]. This common constant has been obtained using the 33,000 ft-lbs /min = 1 horsepower. Though horsepower units are a derivative of the 33,000 Fig. 4. Gearbox setup arrangement for Motor ft-lbs/min, for the given speed and torque, it is not significant to accepting how to calculate motor horsepower. Watts is the common unit used for power. The conversion from watts to horsepower is 745.7 watts = 1 hp. Published By: Retrieval Number: D8195118419/2019©BEIESP Blue Eyes Intelligence Engineering DOI:10.35940/ijrte.D8195.118419 12148 & Sciences Publication International Journal of Recent Technology and Engineering (IJRTE) ISSN: 2277-3878, Volume-8 Issue-4, November 2019 The fig.4 shows the reduction of Gear exclusively refers to Fig. 5. Experimental setup of VFD fed Induction motor the speed of the rotary machine; by dividing of gear ratio Table- I: Specifications greater than 1:1 the rotational speed of the rotary machine is Parameter Induction Motor VFD reduced. With fewer numbers of teeth meshes and drives a Type 3 phase 3 phase large gear it need increased number of teeth. Voltage 415 V 415 V B. Reduction of Gearbox Current 7.6 A 8 A Frequency 50 Hz 50 Hz The property of Torque is converse effect of gear reduction.
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