Frequency converter working principle

Harnessing high efficiency and energy savings in industrial settings, especially those involving induction motors, necessitates the integration of advanced frequency converter systems. Modern frequency converters, essential in the realm of electrical frequency converters, are adept at feeding AC motors with controlled power. Despite their widespread utility and ease of installation, one critical challenge associated with these systems is their non-sinusoidal output voltage. This has led to increased motor losses, excessive noise, vibrations, and negative impacts on both the insulation system and motor bearings.

Introduction to Frequency Converter Technology

Adapting induction motors to variable speeds poses a significant challenge. The synchronous speed of an AC motor, as defined by the formula ns = 120 * f / p, hinges on the power grid frequency and the pole number. To modify motor speed for a specific pole number, altering the frequency is key, underlining the importance of understanding the frequency converter working principle.

The Core Principle and Diversity of Frequency Converters

The basic mechanism of a frequency converter involves first rectifying AC power into DC, and then inverting this DC back into AC at the desired frequency. This involves several components – the rectifier, the DC-link, and the inverter.

PWM Voltage Source Inverter (VSI): Predominantly used in the frequency converter industry, this type operates on Pulse Width Modulation and is adaptable for a wide range of powers, from several hundred watts to megawatts. Modern PWM converters typically utilize Insulated Gate Bipolar Transistors (IGBTs).

Current Source Inverter (CSI): A simpler, cost-effective design compared to PWM. It employs thyristors or SCRs, making it more affordable and rugged. Its design ensures short-circuit proofing, due to large inductors in the DC link. However, its requirement to match the load makes it less flexible than PWM.

Flux Vector Control (FVC): This sophisticated frequency converter type is used in applications requiring precise control. FVC converters are equipped with feedback loops, though they are generally more expensive.

The Influence on Motors and Addressing the Issues

Connecting an induction motor to a frequency converter alters its power supply to a non-sinusoidal voltage. This can lead to several issues, including rotor losses and additional heating. Advances in power semiconductors and microprocessors have helped in tailoring switching patterns to mitigate these disadvantages.

Considering Frequency Converter Repair and Application

Regular maintenance and prompt frequency converter repair are crucial for long-term functionality and safety. Ensuring that the frequency converter is correctly specified for its application, whether it’s a power frequency converter, an electronic frequency converter, or a mains frequency converter, is vital to prevent potential operational hazards.

Selecting the Appropriate Frequency Converter

Choosing the right frequency converter involves multiple considerations. Understanding the material that the sensor will be in contact with, the operational environment, and the specific requirements of the application, such as whether a voltage to frequency converter or frequency to frequency converter is needed, is essential.

Conclusion: Effective Integration of Frequency Converters

Integrating a frequency converter into an industrial operation requires thorough consideration of various factors, including the impact on motor insulation and bearing life. Decisions on the use of frequency converters, taking into account their working principle and application, must be made carefully to ensure optimal performance and safety.