DC or AC Drives
DC or AC Drives
DC or AC Drives
Load
~
~
Load
The annual growth rate for variable-speed drives (abbreviated to VSDs in the following
text) is approx. 6 %, while the growth rate for AC drives is around 8 % p.a., with the market's
volume for DC drives remaining more or less stable.
This overview is intended to outline to users, plant managers, industrial design engineers
or the persons responsible for a particular process the features offered by DC drives as
compared to AC drives.
DCs],
Drive
component
objectively
DC thyristor converter
DC motor
AC PWM converter
PAC = 0.5 kVA ... 2500 kVA; UAC = 380 V ... 690 V
AC asynchron. motor
DC Drive
requirements/processes.
AC Drive
space requirements
C
Load
Technological/Innovative aspects:
Load
STOP, etc.
Fig. 1
Fig. 2
up-to-the-future DC technology
D
the drives:
protection
service; "on-the-spot" repairs
E
(basic depiction)
(basic depiction)
DC Drive
AC Drive
M
MN
M
MN
2,0
2,0
Current limit of
thyristor converter
G
F
n
G
n1
1,5
=
=
=
=
Current limit of
frequency converter
1,5
Motor with
forced ventilation
1,0
1,0
Breakdown
torque limit
of motor
Self-ventilated motor
Commutation limit
of motor
0,5
0,5
n
n
F
nG
n1
n
n
nG
Fig. 3
Fig. 4
DC
and
AC Motor
P
PN
2,0
1,5
= DC Motor
= AC Motor
1,0
n 1 DC
n 1 AC
0,5
G
nG
n
n
Fig. 5
A comparison of operating characteristics of DC and AC motors shows that the direct-current motor is advantageous to the
asynchronous motor for continuous operation at low speeds and for high setting ranges at constant power.
The possible overload in short-time duty depends not only on the motor parameters but to a high degree on the dimensioning
of the associated DC thyristor converter / AC frequency converter as well .
The larger the speed range in which a motor can output its maximum power, the better the motor in question can be adapted
to suit processes which require a constant drive power in a wide speed range.
Typical application: coilers
The basic technical and design-related differences between DC and AC standard motors in magnetic-field formation and powerloss dissipation also entail different sizes (
^ shaft height H) for the motors and different mass moments of inertia J
=
rotor
for the rotors, with reference to the same torque; see the Comparison Table 1 below.
in kgm
Comparison Table 1:
Mass moments of inertia for the rotors, sizes/shaft heights and weights for
DC
AC Standard Motors
and
(examples)
elpmaxE
DC Motor
P
DC Motor
kW
rpm
Type
Nm
Shaft
rotor
2
kgm
height H
IP23
71
15
2000
DMP112-4L
0.05
112
110
579
125
2000
DMP180-4LB
0.69
180
455
1570
329
2000
DMI225S
3565
560
1500
DMA+315M
AC Motor
AC Standard
Motor Type
Weight kg
3.00
225
1032
10.68
315
2100
IP54
1252
2595
rotor
2
kgm
Shaft
Weight
height H
kg (IP54)
115
180M4
0.161
180
175
575
315SMA4
2.30
315
870
355SMA4
8.20
355
1800
450LG4
25.00
450
3980
DC motors have a significantly lower shaft height H and weight than do AC motors, with the mass moment of inertia of the
rotor J
rotor
consequently being substantially smaller with DC motors as well. But this mass moment of inertia is an important
variable for highly dynamic applications, such as test rigs, flying shears, and reversing drives, since it has a marked influence
on the ramp-up time t and the motor's dynamic response in four-quadrant operation (driving and braking modes).
a
1 /2
[kgm ]
Ramp-up time:
(J
+ J
mot
external
MA x
) x
n
[sec]
9.55
for:
Ex. 1:
=
=
=
=
=
MA
Jmot
Jexternal
=
=
=
= M
Ramp-up time t
for:
Ex. 1:
71
x 9.55
external
^
2
= motor moment of inertia = 0.161 kgm
= 0.619 sec
= 0.946 sec
Table 2:
Ramp-up times t based on the above motor data in the basic speed setting range
Example
( = Ex.)
Nm
n = 2000 rpm
71
= M
external
n = 2000 rpm
J
m
ra
ta
n
DC
same J
external
Motor
AC Motor
kW
min-1
kgm
external
sec
sec
71
15
2000
0.161
0.619
0.946
579
125
2000
2.5
1.15
1.73
1570
329
2000
10
1.73
2.42
3565
560
1500
25
1.57
2.20
9.55
High speed setting range at constant power (field weakening operation or field control range):
For specialized drive jobs, like coiler drives, test rigs, winders and unwinders, etc., very large setting ranges at constant power
are stipulated. In these cases, conventional field weakening operation with an externally excited DC machine makes
implementation particularly cost-efficient. This means: the larger the speed range in which a motor can output its maximum
power (length of the horizontal section of the characteristic in Fig. 5, from n
can be kept P
max(motor)
/ P
max(load)
5 ... 360 kW (M
2900 Nm) is 1 : 3.
The maximum value for the field weakening range at compensated DC motors with a shaft height of
250 mm in the
(see Fig. 5)
max
max
Speed n (rpm)
500
1500
2500
Speed n (rpm)
500
1250
Power P (kW)
130
130
80
Power P (kW)
130
130
2483
2483
827
305
2483
2483
933
Torque (Nm)
Torque (Nm)
Motor maintenance:
Today, depending on the application involved, the useful lifetime of brushes in DC motors is at approx. 7000 ...
12000 hours (h), thanks to the sophisticated collectors, carbon brushes and optimized field supply units used.
Depending on the mechanical conditions involved, the relubrication intervals for the bearings of DC/AC motors may be shorter
than the useful lifetime of the brushes in DC motors.
The historical development of the DC motor as an electric variable-speed drive since the beginning of the twenties has meant
that DC motors are customarily used with internal/forced ventilation (approx. 85 % of VSDs
250 kW).
For variable-speed AC drives, asynchronous standard motors have predominantly been utilized since the 70s/80s, which mostly
feature surface ventilation (approx. 90 % of VSDs
250 kW). Thus the process of matching the three-phase standard motors
to the requirements applying for variable-speed drives with AC converters has not yet been concluded.
The fact that AC motors with ratings of up to approx. 1400 kW are supplied in degree of protection IP 54 as standard is a tribute
to their simple and sturdy construction. For drive jobs in hazardous areas, explosion-protected AC motors are used almost
exclusively. This means that the AC motor has won itself a firm position and proved its practical utility most especially in those
sectors of industry characterized by aggressive ambient conditions and a high degree of dirt and dust in the cooling air.
The DC motors' lower weight and smaller size (usual degree of protection IP 23) as compared to the AC motors (usual degree
of protection IP 54) are crucial for applications where the motor has to be moved together with the load (e.g. for large-size cranes
in the "trolley travelling winch"), or in systems where space is at a premium (drilling rigs, skilift installations, marine applications,
printing presses, etc.).
The motor constant makes it possible to design the nominal point of DC motors corresponding to the process requirements.
However the efficiency of AC motors is better (> 55 kW: approx. 1 ... 4 % depending on cooling method).
DC motors are often utilized according to insulation class
class
B.
AC frequency converter-block
diagramm
(one-quadrant drives)
diagramm
(one-quadrant drives)
a) with GTOs (=Gate-Turn-Off Thyristors)
Id
1
X k iL
5
U
V
W
ik
Ud =
uL
us
Fig. 7
R=0
4
Transistors)
Fig. 6
U
V
W
Fig. 8
Result:
The advantage of a user-selectable turn-on/turn-off point with AC frequency converters is offset by the
following disadvantages when compared to DC thyristor converters :
The commutation routines run faster and therefore generate a higher level of interference (HF
interference in the motor voltage, EMC problem).
More space required at comparable power
Continued:
one energy
conversion routine
(AC
and DC
(AC
DC).
DC
AC), i.e. the power loss is more than double that of DC thyristor converters.
^100
=
: DC
This results in an advantage for DC drives, whenever small space and low power losses are an
important feature (Cost for air conditioning).
In many drive applications and production processes, the drives have to be able to handle both directions of rotation (frequently
in regenerative mode), and also have to execute reversal from driving to braking mode "suddenly" or "extremely gently". Typical
examples here are: skilifts, elevators, cranes, mine drives, shears drives, reversing drives, etc. Two solutions are available here
which have proved their worth in sophisticated industrial drive applications.
4-quadrant-DC-drive
4-quadrant AC drive
~ ~
Fig. 9
Fig. 10
4-quadrant DC drive
4-quadrant AC drive
~ ~
Fig. 11
Fig. 12
4-quadrant AC drive
with IGBT controlled power supply,
for regeneration, for all requirements.
Fig. 12a
Output currents of the DC thyristor converters/AC frequency converters; noise generation in the motor;
load on the winding insulation, and electromagnetic compatibility (EMC):
DC Thyristor Converter
AC Frequency Converter
Voltage
Phase 1
Phase 2
+ UD
Phase 3
Uav
EMF
t
Current
- UD
Fig. 13
Fig. 14
case.
oscill
= 6 x f
line
ents, etc.) is thus concomitantly greater (exception: converters from ABB with DTC control).
(U
).
EMC:
EMC:
required
for
reducing
electromagnetic
emissions
(EMC
Mains pollution:
The line currents of DC drives with a 6-pulse thyristor bridge will always contain, in addition to the fundamental wave, the 5th,
7th, 11th and 13th harmonics with empirical values of 22 %, 14 %, 9 %, 7.6 %
case of several DC drives operating simultaneously on the mains, the different phase sequences of the harmonic currents will
produce a "statistical improvement" in the level of mains pollution.
Due to the dimensioning method adopted for the smoothing inductors, harmonic currents with contents of 40 %, 14 %, 9 %
and 7.6 % must be anticipated with AC drives featuring a 6-pulse diode bridge in 1-quadrant drives. Due to the identical phase
angle of the harmonic currents, several drives on the same mains can be regarded as one drive with the same total current.This
also applies for thyristor bridges in 4-quadrant operation.
Input bridges with IGBT switching elements enable the
create more
high-frequency
low-frequency
harmonics.
Reactive-power demand:
Both drive concepts (AC and DC) take reactive power from the mains. Its size is negligible in the case of AC drives, and is RPMdependent below the rated speed with DC drives. The AC drive is the more favourable option here.
is in
cos 0...0.9
cos 0...0.85
is in
1-quadrant applications
with diode bridge
cos
0.99
cos
0.9
4-quadrant applications
with thyristor bridge and
with energy recovery into the mains
tion job:
1.
good condition.
3.
tion:
4.
ficient?
2.
5.
10
motor)
Based on the present-day development status of DC and AC drive engineering, and taking into account all the
systems' advantages/disadvantages mentioned above, the following guideline figures can be given:
>40...60
kW
2004
2000
1995
DC Drives
AC Drives
Market volume
A comparison of the two drive systems in this short overview shows that the question of whether the DC drive or the AC drive is the
right choice for any particular user is entirely dependent on the individual application involved.
If the following requirements have to be met, then the use of DC drives should be examined:
a) 4-quadrant operation with regeneration ?
IP54 ?
No hazardous areas ?
i)
(>1:1.5) ?
The greater the number of "Yes"s in answer to these questions, the more urgently should you consider using a DC drive !
DC or AC is therefore the crucial question which must be examined and decided for every
single project.
ABB's drive philosophy groups under one roof both the tried-and-tested DC drives and the wide and successful range
of AC drives, integrating them into a holistically planned drive control and operating concept.
This has already been implemented in the DCS 400 / ACS 400; DCS 500 and DCS 600 / ACS 600 ranges since 1994,
continually optimized in line with the latest market and customer stipulations, and simplified for enhanced userfriendliness into the bargain.
11
Literature:
Gleichstrom- oder Drehstrom-Antrieb? Systemvergleich
und Entscheidungshilfe (1990), ZVEI, Fachverband
Elektrische Antriebe, D-W-6000 Frankfurt/M
Heinrich, Walter:
Stben, Heinz:
ABB Industry
ABB Industry
ZVEI offprint
ZVEI-Sonderdruck:
ABB Automation SA
Automation and Drives
Rue de General de Gaulle
BP N 3
F-77430 CHAMPAGNE S/SEINE, France
Telephone +33 1 60 74 65 00
Fax
+33 1 60 74 65 65
ABB Motors AB
Machines Division 394
ABB Industrie AG
Electrical Machines Division
Postfach 1180
D-68619 LAMPERTHEIM, Germany
Telephone +49 (0) 62 06 50 3-0
Fax
+49 (0) 62 06 50 3-60 9
*059R0201A1070000*
12
*059R0201A1070000*