XI International PhD Workshop

OWD 2009, 17–20 October 2009

Some Aspects Of Pulse Voltage Regulation For Induction

Motor Soft Starting And Braking In Electric Drives
Of Crane Travel Mechanisms

Vasilyev Dmitry, Belorussian National Technical University

(01.12.2006, prof. Firago Bronislav, Belorussian National Technical University)

Abstract 4) Reduction of impact torques and starting

In this paper the application of pulse voltage currents in mechanical gears.
regulation for soft starting and braking of induction Nowadays frequency converters with the
motors of crane traveling mechanisms is discussed. induction motors are widely used in the variable
Shortcomings of phase voltage regulators - thyristor speed electric drives of crane mechanisms – crane
softstarters - and advantages of pulse voltage traveling and hoisting mechanisms. Such a controlled
regulators (PVR) are analyzed. Three types of PVR electric drive undoubtedly meets most of the
power circuit structures are described and compared. mechanism’s operating requirements but on the
Quasi-frequency control at underspeed operation of other hand is considerably more expensive than the
a crane induction motor supplied with PVR is uncontrolled one because of the frequency converter
considered. The research of soft starting and braking price which is three-five times higher the price of an
modes as well as quasi-frequency control of a crane induction motor.
induction motor has been performed with the help When there is no need in full conformity with the
of Matlab simulation model of a thyristor softstarter above mentioned technological requirements (such
and PVR based on three mains power switches and a as speed control ability) for a certain crane
shunt diode bridge. mechanism, for example, crane trolley traveling
mechanism, cheaper and technologically simple soft
1. Introduction to the problem starter device can be used as an alternative to a
frequency converter.
Crane equipment is widely used in various fields
of industry, for example, in metallurgical production,
2. Phase voltage regulation of an
port terminals, warehouses and etc. A certain field of
induction motor
application determines crane mechanism
construction features, functional characteristics and Thyristor softstarter operation is based on phase
also operating requirements. However crane regulation of an induction motor supply voltage at
equipment has some common features and therefore constant mains frequency (Fig.1).
can be defined by a number of general requirements.
Since all the technological operations of crane
mechanisms are performed by means of electric
drives, crane equipment functionality requirements
first of all refer to crane electric drives. Basic
requirements include high production efficiency,
reliability, fail-safe operation and maintenance
simplicity.
These basic requirements can be extended further
to comply with the following technical conditions:
Fig.1. Phase regulation of an induction motor s upply
1) Operation at steady underspeeds which can voltage (phase A ).
be achieved with stiff speed-torque characteristics of
With the help of such a softstarter a value of
the electric drives,
stator voltage is changing during starts and stops in
2) Soft starting and breaking with set
relation to a certain law, for example, linear or
acceleration and deceleration during operation at any
exponential law.
speed of working range,
A typical circuit of a softstarter consists of three
3) Efficiency of starting/breaking modes and
pairs of inverse-parallel connected thyristors and
speed regulation,

403
allows controlling softstarter output voltage by losses in the induction motor transients than during
changing the thyristor firing angle. Power circuit of its phase voltage regulation.
such a thyristor softstarter is presented in Fig. 2.

Fig.3. A half-period exa mple of PVR output voltage

curve (for med with 5 pulses).

Power circuit of a pulse voltage regulator consists

of a certain number of supply mains power switches
and shunt power switches. The latter are used for
shunting of the induction motor stator windings
during the off-state of the supply mains power
Fig.2. Power circuit of a typical thyristor so ftstar ter. switches. Each power switch is a pair of inverse-
As a result of the thyristor softstarter application parallel connected IGBT transistors with bypass
a negative impact of electromagnetic transients on diodes.
the induction motor performance is weakened with Depending on the number of power switches
the reduction of impact torques and starting used for pulse voltage regulation and induction
currents. However due to the delayed start-up of the motor shunting various operational PVR power
induction motor supplied with a softstarter and its circuits can be built. The authors of this paper have
extended total starting time energy losses during the considered three variants of PVR power circuit
induction motor transients tend to increase if structures.
compared with its direct starting with nominal mains The first one consists of six power switches:
voltage [1]. 3 supply mains power switches, 3 shunt power
Other shortcomings of a thyristor softstarter switches - one for each induction motor winding.
involve substantial distortions of a sinusoidal voltage Such a power circuit is completely symmetrical in
waveform supplying the induction motor and a lag relation to the output phase voltages and currents
shift angle for the first current harmonic. The output although rather expensive due to the increased
voltage curve of a thyristor softstarter contains number of power switches.
higher harmonics leading to the power factor The second type of PVR power circuit includes
decrease [1]. four power switches (2 supply mains power switches,
Better harmonics content of the output voltage, 2 shunt power switches for interphase motor
absence of a lag shift angle in the first current windings shunting) and therefore is more cost-
harmonic waveform, less energy losses and therefore effective than the previous one. This power circuit
greater number of switching frequency can be has asymmetrical structure and therefore causes
obtained with the use of a pulse voltage regulator output phase voltages and currents asymmetry.
(PVR) operated on full-controlled power switches The third type of PVR power circuit consists of
such as IGBT. three supply mains power switches (one for each
supply mains phase), a diode shunt bridge with one
3. Pulse voltage regulation of an unidirectional transistor to operate the shunting
induction motor process. This type of PVR power circuit has
combined the advantages of the previous two
Pulse regulation of the induction motor supply structures. It is symmetrical but at the same time
voltage is carried out by changing the width (in consists of a fewer number of power switches hence
relation to a certain law) and number of voltage is less expensive.
pulses, i.e. IGBTs switching frequency. Half-period The power circuit of the pulse voltage regulator
of PVR output voltage curve formed with 5 pulses is with three power switches (transistors T1-T6), a
shown in Fig. 3. From [2] one can draw a conclusion shunt diode bridge D1-D6 and one unidirectional
that better harmonics content of the PVR output transistor T7 is shown in Fig. 4. Operation of the
voltage can be achieved by increasing the number of supply mains transistors T1-T6 provides energy
voltage pulses. The higher harmonics amplitudes are exchange between the load and the mains. When
decreased significantly with growth of the switching they are switched off transistor T7 shunts the
frequency. The author’s research in [2] also proves induction motor windings with the diode bridge.
that the application of PVR provides less energy

404
 Thyristor softstarter output voltage curve during
quasi-frequency control of an induction motor is
shown in Fig. 5. The formation of the induction
motor supply voltage consists of a series of positive
and negative supply mains voltage half-waves, which
are formed according to the alternating sign
switching function.

Fig.4. PVR with thr ee power s witches and a shu nt

diode bridge.

Further research and simulation of the induction

motor soft starting and breaking as well quasi-
frequency control study is based on the latter PVR
power circuit structure.
For a more detailed description and comparison
of possible PVR power circuit structures please refer
to [3].

4. Quasi-frequency control of an Fig.5. Thyristor sof tstart er o u tput voltage curve

during quasi-frequ enc y contr ol.
induction motor supplied with
pulse voltage regulator The sign of this switching function defines
Functionality of a pulse voltage regulator is output voltage curve polarity during the quasi-
extended with the application of an induction motor frequency control. The period of the switching
quasi-frequency control ability. Such an improved function sets the number of positive and negative
soft starter device would allow not only the supply mains voltage half-waves in it.
reduction of impact torques and starting currents but The formation of the PVR output voltage curve
also provide the operation of an induction motor at for phase A during quasi-frequency control is shown
underspeed. PVR with this feature can be used in the in Fig. 6. According to the PVR power circuit
crane electric drives for smooth stopping and precise structure in Fig. 4 transistors T1, T2 take part in the
positioning of the crane traveling mechanisms formation of the PVR voltage pulses for phase A,
instead of an expensive frequency converter. while transistor T7 performs shunting of the motor.

Fig.6. PVR output voltage curve during quasi-frequency control.

405
Transistor T7 operates only as a shunt when either switches and a shunt diode bridge (Fig. 7). The
T1 or T2 is in off state so that the circuit current parameters of the special crane induction motor
could decrease to zero. The same switching 4MTKF160LB8 (11kW, 380/220V, 40% duty cycle)
algorithm during quasi-frequency control is applied designed for intermittent operation mode have been
to the remaining power switches of phase B and C. used during the simulation.
In general the formation of any PVR output Pulse voltage regulation of the crane induction
voltage curve during quasi-frequency control of an motor 4MTKF160LB8 has been performed
induction motor is performed with a certain according to the linear and exponential 1st harmonic
switching sequence of the mains and shunt IGBT voltage variation.
transistors according to the desired quasi frequency. PVR output voltage and current curves are
To variate quasi-voltage value one should change the presented in Fig. 8. The induction motor
supply mains transistors pulse width. 4MTKF160LB8 speed curves for various starting
current limitation settings are presented in Fig. 9.
5. Simulation results The authors have also performed simulation of
The research of the induction motor soft starting the crane induction motor 4MTKF160LB8
and braking for phase and pulse voltage regulation underspeed operation at quasi-frequency of 8,33 Hz
has been performed via Matlab simulation models. for the same PVR power circuit structure.
PVR simulation model has been developed The results of quasi-frequency control simulation are
according to the power circuit with three power presented in Fig. 10.

2
T2a_pulse T1 T2
1 g g
E E
T1a_pulse C C
1
Usa 3
T1b_pulse Tm
4
T2b_pulse Tm

6 LOAD U1a
T4a_pulse T4 A
T3
5 g g m
E E U1b
T3a_pulse C C B
2
Usb 7 U1c
T3b_pulse C

8
T4b_pulse Crane Induction Motor
4MTKF160LB8
10 Shunt IGBT pulses
T6a_pulse T5 T6
9 g g Shunt IGBT T7
E E
T5a_pulse C C
3 OR g
E
Usc C
11
T5b_pulse
12
T6b_pulse
+

Shunt diode bridge

A

Fig.7. Matlab simulation model of PVR with 3 power switches and a shunt diode bridge.

To provide steady underspeed operation of the during this operating mode. Underspeed fluctuations
induction motor at the reduced frequency it is lead to the induction motor vibrations. Moreover
imperative to maintain flux linkage at constant level with the relatively high motor torque (close to its
by decreasing the quasi-frequency control voltage nominal value), current amplitudes during quasi-
proportionally to the reduced frequency. Otherwise, frequency control of the induction motor increase up
an oversaturation of the induction motor magnetic to 200% and even higher. Therefore quasi-frequency
system will occur. control should be applied for the induction motor
Quasi-frequency control results in the motor low speed operation for a short period of time.
underspeed fluctuations (Fig. 10) because of the
pulse nature of stator current and motor torque

406
Fig.8. Output phase voltages (a) and currents (b) of PVR with 3 power switches
and a shunt diode bridge.

Fig.9. 4MTKF160LB8 induction motor speed curves for 3 starting current

limitation settings.

407
 Fig. 10. 4MTKF160LB8 induction motor speed curve with underspeed operation
at 8,33 Hz during quasi-frequency control.

6. Conclusions
[2] Firago Bronislav, Vasilyev Dmitry, Pawlaczyk
Pulse voltage regulator based on a power circuit Leszek: Zastosowanie impulsowego regulatora napięcia
with 3 power switches and a shunt diode bridge has dla miękkiego rozruchu i hamowania silników, prace
a number of obvious advantages over the thyristor Naukowe Instytutu Maszyn, Napedow i
voltage regulator such as: Pomiarow Elektrycznych, nr 62, Studia i
- reduced energy losses in the induction motor Materialy nr 28, s. 378-386, Politechnika
transients due to symmetrical power circuit structure Wroclawska, Wroclaw, 2008
and lack of output voltages and currents phase [3] Strzelecki Ryszard, Supronowicz Henryk:
asymmetry; Wspólczynnik mocy w systemach zasilania pradu
- lowered impact on supply mains due to the przemiennego i metody jego poprawy, oficyna
better harmonic content of the PVR output voltage Wydawnicza Politechniki Warszawskiej,
and current curves; Warszawa, 2000. – 452 s
- increased power factor and lack of 1st harmonic
current shift angle; Authors:
- quasi-frequency control ability for the induction
motor steady operation at underspeeds. PhD student
PVR with quasi-frequency control ability if Vasilyev Dmitry
compared to thyristor voltage regulator can be Belorussian National
considered an improved softstarter device and is a Technical University
cheaper alternative to a frequency converter F. Skaryna 65
provided there are no strict speed control Minsk 220027
requirements for a certain technological mechanism. Belarus
For example, it would be reasonable and cost- email: dmy@tut.by
effective to apply such PVR in the crane electric
drive of a trolley traveling mechanism.
Prof. Firago Bronislav
Bibliography Belorussian National
[1] Firago Bronislav, Vasilyev Dmitry, Pawlaczyk Technical University
Leszek: Regulirovanie naprjazenija asinchronnogo F. Skaryna 65
dvigatelja impulsnymi metodami dlja mjagkogo puska i Minsk 220027
tormozenija, II mezdunarodnaja naucno- Belarus
techniceskaja konferencija ″Organizacionno- email: dmy@tut.by
techniceskoe upravlenie v mezotraslevych
kompleksach″, 20-21 nojabrja 2007, Belorusskij
Gosudarstvennyj Technologiceskij Universitet,
Minsk, s. 213-220

408