1.

MOTION
2. DRIVES

What are variable-speed drives?

Nov. 1, 2022
Drives can improve manufacturing processes and increase
energy efficiency
Shawn Cox





An inverter, a dc bus, a rectifier and a regulator/controller make up the

majority of the parts in a variable-speed drive (VSD). In order to create dc
power, the rectifier would convert ac power. A capacitor on the dc bus
would store the energy and reduce power sags and output voltage swells.
The inverter would change the dc energy into ac energy, and the
controller would handle all control operations.

In order to perform the VSD operation, a fixed-frequency input supply is

changed into a variable-frequency output. High frequency can therefore
be used for faster speeds while low frequency can be used for slower
speeds.

Also read: 4 changes on the horizon for motor and drive use

By allowing the motor to produce more or less torque in accordance with

the demand, we can change the output.

Mechanical variable-speed drives: The mechanical variable-speed

drive would employ mechanical means to change a motor's output from
fixed speed to variable speed. Both traction drives and drives with
variable pitch are included in this group.

It is possible to change the diameter of one or both pulleys in pulley-and-

belt drives with variable pitch. The power would be transmitted through
metal rollers in a traction drive. Moving the rollers will alter the contact
path's diameter, allowing you to modify the input and output. When
comparing this type of variable speed drive to an electronic drive, it is less
effective.

Hydraulic variable-speed drives: In this kind of drive, the transmission

medium for the torque would be hydraulic oil. This device experiences
significant mechanical and hydraulic losses when compared to other kinds
of variable speed drives.

Also read: Why do I want to use a VFD?

Hydrostatic, hydrodynamic, and hydro-viscous drives are the three

categories of hydraulic variable-speed drives. A hydraulic motor and pump
make up the hydraulic drive. Speed can be adjusted by varying the
displacement of the pump or motor.

The hydrodynamic drives would use oil to transmit torque between a rotor
on the variable-speed output shaft and an impeller on the constant-speed
input shaft. One or more discs connected to the output shaft make up the
hydroviscous type of VSD.
Electric variable-speed drives: The process of variable-speed drive is
done in four major steps. In Step 1, there is a rectifier that transforms the
incoming three-phase ac power into dc power. In Step 2, capacitors
receive dc power, which smooths the wave and creates a pure dc supply.
In Step 3, the required voltage and current for the motor are determined
by the variable-speed drive. After that, dc power is fed into an inverter,
which generates ac power with the exact voltage and current required. In
Step 4, only the power that the motor requires is provided by the variable-
speed drive, which continuously calculates and adjusts the frequency and
voltage.

For our daily operations to run smoothly, electric motors are required.
Practically speaking, they move and operate everything we need for
either work or play. They require the necessary amount of electrical
energy to produce the torque and speed required.

Also read: Demanding motion applications often transcend industrial

contexts

Mechanical controls will be applied to slow down the shift or control the
outcome if the torque or speed becomes too high or low. The energy and
raw material wasted as a result are significant. For the process'
requirements, the motor's speed should be accurate. In the absence of a
better speed-control method, energy is frequently lost, which is bad for
business for everyone.

VSDs to control torque or speed: Variable-speed drives can increase

the energy efficiency of your various applications, including pump, fan,
conveyor and compressor systems. Because the system controlled by
drives can be automated, no manual labor is required, saving time and
money on labor costs. Variable-speed drives operate the motors at partial
load, utilizing only the necessary amount of energy, which can reduce the
drive system's energy consumption.

Within months of installation, the VSD investment in pump and fan

applications will pay for itself quickly, thanks to the immediate reduction
in electricity consumption. Finally, with drives, it is possible to reduce the
stress placed on mechanical equipment during startup and operation,
extending the equipment's lifespan.

These kinds of significant gains can be made not only in big industrial
operations, but also in smaller installations.

Variable-speed drives not only improve processes, which saves money,

but they also can increase energy efficiency. Any size organization can
benefit from variable-speed drives. As technology grows, so will the use of
drives.

Also read: Smart components improve changeover speeds

About the Author
Shawn Cox | Contributing Editor
Shawn Cox is a licensed master electrician/PLC programmer. He was co-
owner/operator of Bobby Cox Electric for 15 years and is currently
employed by BMW Manufacturing as an ESA. Contact him
at brianshawncox@yahoo.com.

Email

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1. MOTION
2. DRIVES

VFDs: more than just ac-motor

regulators
June 3, 2024
Variable frequency drives offer energy savings, compact form
factors, heightened reliability and safety features
Joey Stubbs





In manufacturing, where every Watt counts and downtime is the enemy of

profit, the spotlight is firmly fixed on efficiency, reliability and safety. And
in this pursuit, one technology has emerged above others: variable
frequency drives (VFDs).

My first exposure to VFDs was in 1987 while in the U.S. Navy. I didn’t
realize then the significance of their technology and what a game changer
they were compared to standalone ac motors. Although they were
originally invented in the 1960s, they began making their appearance in
automation and other industries in the early 1980s and have remained an
industry staple ever since. Much has changed since then, but what are
they, and what are the latest advancements in this fantastic technology?

A VFD’s purpose is to regulate the speed of an ac electric motor by

adjusting the frequency and voltage of the power supplied to the motor
instead of running with a fixed input voltage and frequency as is common
with ac motors. This means they can precisely match the connected
motor's speed to the task at hand, eliminating the need for energy-
wasting throttling mechanisms. Over the past decade, VFDs have
undergone a remarkable transformation, offering unparalleled energy
savings, compact form factors, heightened reliability and advanced safety
features that are helping revolutionize the manufacturing industry.

In the past few years where “sustainability” has not just become a
buzzword, but a business imperative, VFDs have emerged as the poster
child for energy efficiency in manufacturing. The past decade has
witnessed a quantum leap in efficiency, thanks to advancements in power
electronics and control algorithms. Variable frequency drives boast
efficiency ratings that were once deemed unattainable, helping
manufacturing facilities slash their energy bills while reducing their carbon
footprints. With energy consumption often being one of the largest
operational expenses, the significance of this cannot be overstated.

Additionally, as with many electronic technologies, VFDs have become

more compact over the years. Denser electronic packages, smaller and
more powerful power electronic components, multi-layer printed circuit
boards (PCBs) and more compact integrated circuit chips have all driven
the size of VFD packages down. This translates into a smaller VFD
footprint, enabling more of them to be populated into the same enclosure,
or the ability to use a smaller enclosure for the same number of drives.
Both of these result in money savings.
At the same time, they are getting smarter with enhanced ease of use and
user-friendly troubleshooting features. Fault codes and onboard
troubleshooting tips help the customer replace the right part and get it up
and running sooner. In the high-stakes world of manufacturing, downtime
is not just an inconvenience, it is a costly nightmare. This is where the
reliability of VFDs comes into play. Traditionally, concerns lingered around
the longevity and robustness of these devices, but recent years have seen
monumental strides in reliability and improved mean time between
failures (MTBF).

Variable frequency drives are built to withstand the rigors of industrial

environments, with enhanced thermal management systems, robust
enclosures and advanced diagnostic capabilities. Predictive maintenance
features, enabled by the integration of sensors and cloud-based analytics,
allow for proactive identification of potential issues before they become
catastrophic failures.

Furthermore, the advent of fault-tolerant designs has added an extra layer

of resilience, ensuring that manufacturing processes remain uninterrupted
even in the event of certain component failures. This reliability translates
directly into increased uptime, driving productivity and maximizing
profitability.

Of course, in the manufacturing industry safety is paramount. And while

VFDs have long been lauded for their energy-saving attributes, recent
advancements have ushered in a new era of safety features that prioritize
the well-being of both personnel and equipment.

From integrated motor and load protection to comprehensive fault

detection and emergency-stop functionalities, VFDs are equipped with a
suite of safety features designed to mitigate risks and ensure compliance
with stringent safety standards. Moreover, advancements in insulation
technology and fault-clearing capabilities have bolstered the safety profile
of VFDs, minimizing the likelihood of electrical hazards and catastrophic
failures.

Additionally, VFDs are now coming equipped with the same Safety
Integrity Level (SIL) functional safety commands that were originally
developed for and found on servo drives. A suite of safety-rated
commands allows the drives to not only safely stop, but maintain a safe
speed or a safe torque. Additional safety instructions will most certainly
be added to the next generation of VFDs.

As we look to the future, the trajectory of VFDs is poised for even greater
innovation. From the integration of artificial intelligence and machine-
learning algorithms for predictive maintenance to the proliferation of IoT-
enabled connectivity for remote monitoring and control, the possibilities
are boundless.
The evolution of VFDs over the past decade has been nothing short of
extraordinary. From energy savings to reliability and safety
advancements, these devices have helped reshape the manufacturing
landscape, driving efficiency, productivity and sustainability. As
engineering departments and decision-makers plan the course for their
manufacturing facilities, one thing is abundantly clear: with VFDs, the
future looks brighter than ever before.

About the Author

Joey Stubbs | contributing editor
Joey Stubbs is a former Navy nuclear technician, holds a BSEE from the
University of South Carolina, was a development engineer in the fiber
optics industry and is the former head of the EtherCAT Technology group
in North America.

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