变频调速交流感应电机

A VFD controls motor speed by adjusting the output frequency and voltage supplied to the motor. The drive converts 60 hertz AC input to DC power using a rectifier, then uses a DC to AC inverter with pulse width modulation to generate AC output at the desired frequency. Since motor speed is proportional to input power frequency, changing the frequency directly controls motor speed.

The voltage to frequency ratio, or V/f ratio, is the relationship between output voltage and frequency maintained by a VFD. This ratio is approximately proportional to the stator magnetic field and motor speed. By maintaining a constant V/f ratio, VFDs preserve motor performance and efficiency. For example, a motor rated at 208 volts and 60 hertz has a V/f ratio of 3.5 volts per hertz that must be maintained during speed adjustments.

Soft starting gradually increases motor speed to the desired level instead of instantly turning it on to full speed. This eliminates high starting torques and surge currents, reducing mechanical stresses on equipment. Soft starts increase equipment life and reliability while decreasing maintenance costs. Additionally, adjusting motor speed even slightly can save considerable energy since load torque and power vary with the square and cube of speed respectively.

Open loop control outputs constant drive power without feedback or adjustments, maintaining a preset V/f ratio for speed regulation. Closed loop, or vector control, uses a microprocessor that receives feedback about the motor's magnetic field and torque, then continually adjusts VFD power according to a control algorithm. Most VFDs use open loop control when operating motors at or below rated voltage for simplicity and cost-effectiveness.

When operating above rated frequency, VFDs restrict output to the motor's rated voltage to prevent damage. This precaution avoids exceeding voltage or current limits of the motor's insulation and coils. For example, a motor rated at 208 volts and 60 hertz would not receive 460 volts when frequency increases to 120 hertz; instead, the VFD limits output to the rated 208 volts while maintaining safe operating conditions.

VFDs are used in fans, pumps, compressors, drills, and machining equipment like drill presses, lathes, and milling machines. In ventilation systems, VFDs allow fans to respond to temperature controls by increasing speed when temperatures are high or decreasing speed when temperatures are low. For machining, VFDs enable equipment versatility by allowing low-speed operations for plastics to prevent charring and high-speed operations for hard metals like steel.

A DC to AC inverter uses pulse width modulation to switch DC power on and off in a specific pattern. A low pass filter then transforms this pulse stream into a roughly sinusoidal waveform, generating AC output power at the chosen frequency. The sinusoidal waveform is necessary because most induction motors are designed to operate with power from AC mains, requiring smooth AC output rather than pulsed DC.