CHAPTER-6 MEASUREMENT OF SHAFT VOLTAGE AND BEARING CURRENT IN 2, 3 AND 5-LEVEL INVERTER FED INDUCTION MOTOR DRIVE
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1 12 CHAPTER-6 MEASUREMENT OF SHAFT VOLTAGE AND BEARING CURRENT IN 2, 3 AND 5-LEVEL INVERTER FED INDUCTION MOTOR DRIVE 6.1. INTRODUCTION Though the research work is concerned with the measurement of CM voltage, as a spillover the shaft voltage and the bearing current has been measured. Due to the CM voltage at the star point of stator winding of an IM, a voltage is induced in the rotor because of capacitive/inductive coupling. Since the rotor conductors are short circuited the current will circulate in the rotor and also tries to flow to the general ground through the bearing. The fast switching action of the inverter devices can cause high frequency noise voltage transients which induce capacitive coupling from rotor to the ground through the bearing and hence called the capacitive currents. These high frequency currents from the rotor will flow through the bearing to the ground [23, 36 & 61]. These currents through the bearing causes electrical discharge machining (EDM) in the inner surface of the bearing and in turn reduce the life of the bearing. This chapter presents the experimental measurement of the rotor shaft voltage and bearing current for a modified 3- phase squirrel cage IM connected to an inverter. Experiments have been carried out on 2- level, 3-level and 5-level inverter fed IM drives in SVM scheme. PIC µ- controller was used to generate SVM pulses along with other associated electronic interface circuits to operate the 2-level, 3- level and 5-level
2 121 inverter. Necessary converter circuits were fabricated and tested for giving the proper DC voltage to the inverter. Standard current probe, LISN, high frequency 4-channel MSO with differential probes were used to measure the shaft voltage, bearing current and other parameters. The graphs were plotted showing Frequency vs shaft voltage in Volts & dbµv and the bearing current in dbµa using the signal analysis software and compared the results LITERATURE SURVEY It was observed by the researchers that the occurrence of bearing failures among IM driven by inverters is much more frequent than those driven by 5/6 Hz utility supply [26]. A survey conducted by references [1,3, 4, 5 & 24] indicates that the inverter-fed motors have a greater probability of bearing breakdown than the 5/6 Hz line-fed motors. The concept of bearing currents in variable speed drive systems using Converter-Inverter is due to the existence of CM voltage and also by fast switching ON and OFF of the inverter devices has been reported for almost a decade [23, 36 and 43]. Annette Muetze et al. [5] reports that the induced bearing currents, the ground currents can be from the influence of CM voltage and the capacitance between stator and rotor windings with high dv/dt at the input to the IM terminals [1,3 & 67]. D. Busse, et.al [25] has also explained about the characteristics of induced shaft voltage in the IM due to converter-inverter adjustable speed drive system.
3 122 Due to the recent advancement of adjustable-speed drives, with VSI, mechanism of inducing shaft voltages and bearing currents are due to the voltage transients exist at the star point of the stator winding of an IM and the ground. As summarized by Chen et. al. [23], [61], there is three general types of motor bearing currents (stator to rotor bearing current, stator winding to ground current, rotor to shaft current) that can be associated with PWM VSI drive. [3, 5 & 67] 6.3. PROPOSED METHOD OF MEASUREMENT OF SHAFT VOLTAGE & BEARING CURRENT The modified IM is shown in the Fig.6.1. [7, 8] The inner diameter of the end plates of the existing motor is slightly increased by machining. Proper insulation is used to isolate the end plates from the main body of the IM. The fixing bolts of the end plates are also made of nonconducting material. Hence the whole rotor is isolated from the main body of the IM [7]. Fig 6.1. Modified IM (Rotor & stator Isolated)
4 123 With this modification, the rotor is floating and the connections to the ground through the current probe are done as shown in the Fig.6.1 [9]. The shaft voltage with respect to the ground and the bearing current in terms of voltage (using current probe) were recorded using the DSO. Fig.4.2. in Chapter-4 Shows the circuit diagram of a 3-level inverter and the corresponding switching states of each phase of the inverter is listed in Chapter-4, Table 4.1. The switching sequence of the 3-level inverter is similar to that of 2- level inverter as discussed in chapter - 2. The circuit diagram of a 5-level NPC inverter is shown in chapter-5, Fig.5.1, and the corresponding switching states of each phase of the inverter are listed in chapter-5, Table 5.1, 6.4. HARDWARE IMPLEMENTATION The hardware implementation of the 2-level, 3-level and the 5-level has been discussed in the chapters 2 to 5. The output of the inverter bridge is given to the IM (3Phase,.37kW, 415VL, 139 rpm, 5Hz, star connection) stator terminals. The, line voltage,cm voltage, shaft voltage, and the bearing current using current probe (in terms of voltage) has been monitored and recorded using 4 channel DSO (5MHz) along with necessary differential probe (2:1). The actual bearing current can be computed from the current probe output voltage is as follows.
5 EXPERIMENTAL RESULTS Fig.6.2. shows the 2-level inverter CM voltage, Line voltage, Vector sum of phase current and the bearing current (in terms of voltage using the current probe). Fig.6.2. is taken from the published result [7] for the same modified IM to show the bearing current. Fig.6.3, ch.3 shows the shaft voltage of 2-level inverter fed IM when the shaft is not grounded. Fig.6.4 shows the 3-level inverter shaft voltage (ch.3) when there is no flow of bearing current. Fig.6.5. ch.4 shows the 3-level inverter bearing current (in terms of voltage using the current probe). Fig.6.6 shows the shaft voltage (ch.3,1:1)at the instant when shaft is grounded through the bearing and bearing current (ch.4)in terms of voltage using current probe for the 5-level NPC inverter. Fig.6.7. shows the shaft voltage (2:1, ch.2) and the CM voltage (2:1, ch.3) when there is no flow of bearing current. From the above recorded waveforms it is easy to measure the magnitude of voltages and it is found to be 142.5Vpeak, 135Vpeak and 13Vpeak for 2,3 and 5-level inverter. Figs 6.8, 6.9 and 6.1 shows the FFT of IM shaft voltage of 58Vpeak, 43Vpeak and 36Vpeak for 2, 3 and 5-level inverter respectively. It is observed from the FFT plots that IM shaft voltage is reduced in 5-level inverter when compared to 3 & 2- level inverters. Similarly Figs. 6.11, 6.12 and 6.13 shows the shaft voltage FFT plots for 2, 3 and 5 level inverters in dbµv respectively which can be used for comparing the results with FCC and CISPR standards in future. It is also observed that the IM shaft voltage is reduced in 5-level inverter
6 125 when compared to 3 & 2- level inverters. Hence it is concluded that as the inverter level increases the shaft voltage reduces. Fig.6.2 DSO recorded waveform (2-level inverter [7]) Ch 1: CM voltage ( diff. probe 2:1), Ch 2: line voltage (diff. probe 2:1), Ch 3: 1 : 1 vector sum of phase current, Ch 4: 1 : 1 bearing current alone using current probe. Fig.6.3. DSO recorded waveforms.(2-level inverter) Ch 3. 2 : 1. Shaft voltage
7 126 Fig DSO recorded waveforms.(3-level inverter) Ch 1: 2 : 1 Phase voltage.ch 2: 2 : 1 wave form of Line voltage Ch 3: 2 : 1 Shaft Voltage with respect to ground. Fig DSO recorded waveforms.(3-level inverter) Ch 1 2 : 1 Phase voltage. Ch 2 2 : 1CM voltage. Ch 4. 1 : 1 Bearing current using the current probe.
8 127 Fig.6.6. DSO recorded waveforms (5-level inverter) Ch 1. 2: 1 line voltage to IM Ch 2: 2 : 1 wave form of CM voltage at IM. Ch 3:1 : 1 shaft voltage of IM Ch 4: 1 : 1 Bearing current Fig.6.7. DSO recorded waveforms (5-level inverter) Ch 1. 2:Phase voltage to IM. Ch 2. 2:1 shaft Voltage. Ch. 3. 2:1 CM Voltage.
9 128 I.M. shaft & gnd. voltage in volts Fig. 6.8 FFT of IM shaft Voltage (2-level inverter) (Published results in SPWM scheme)[7] I.M.shaft & gnd. voltage in volts Fig.6.9. FFT of IM Shaft voltage (3-level inverter)
10 129 4 Amplitude in volts Fig.6.1 FFT of IM shaft voltage in volts (5-level inverter) 25 2 Amplitude in dbµv Fig FFT of shaft voltage in dbµv (2-level inverter)
11 13 2 Amplitude in db µ volts Fig FFT of Shaft voltage in dbµv (3-level inverter) Amplitude in db µv Fig FFT of Shaft voltage in dbµv (5-level inverter)
12 131 Figs to 6.19 show the FFT of Bearing current in ma for 2, 3 and 5- level inverters which include the expanded views also. Here for the 2- level inverter the magnitude of bearing current is found to be 18mA for the fundamental frequency and for other frequencies it is around 1mA average. For 3-level inverter the magnitude of bearing current is found to be 17mA for the fundamental frequency and for other frequencies it is around.6ma average. Similarly for 5-level inverter the magnitude of bearing current is found to be 9mA for the fundamental frequency and for other frequencies it is around.4ma average. Figs. 6.2 to 6.24 show the FFT of Bearing current in dbµa for 2, 3 and 5-level inverters which include the expanded views also..2 bearing current in Amps Fig FFT of bearing current in ma (2-level inverter) (Published result)[7]
13 bearing current in Amps Fig FFT of bearing current in ma in expanded view (2-level inverter) (Published result)[7] 2 bearing current in ma Fig FFT of bearing current in ma (3-level inverter)
14 bearing current in ma Fig FFT of bearing current in ma in expanded view (3-level inverter) 1 bearing current in ma Fig FFT of bearing current in ma (5-level inverter)
15 bearing current in ma Fig FFT of bearing current in ma in expanded view (5-level inverter) 25 Bearing current in db µ A Fig.6.2. FFT of bearing current in dbµa (2-level inverter)
16 135 Fig.6.21 FFT of bearing current in dbµa (3-level inverter) 15 Bearing current in db µ A Fig FFT of Bearing current in dbµa (5-level NPC inverter)
17 136 6 Bearing current in db µ A Fig FFT of Bearing current in dbµa (5 level NPC inverter Expanded view Y -Axis) 6 Bearing current in db µ A Fig.6.24.FFT of Bearing current in dbµa (5 level NPC inverter Expanded view X -Axis)
18 CONCLUSION In this chapter the experimental measurement of the rotor shaft voltage and bearing current for the modified 3- phase squirrel cage IM connected to an inverter is discussed. Experiments have been carried out on 2-level, 3-level and 5-level inverter fed IM drives in SVM scheme. It is noted that from the recorded waveform of shaft voltage (Figs.6.3, 6.4 and 6.7) for 2, 3 and 5-level inverter is 142.5V peak, 135Vpeak and 13V peak respectively. From this it is noted that 5-level inverter shaft voltage is less by 5Vpeak with respect to 3-level inverter and 12.5Vpeak with respect to 2-level inverter. It is also observed from the FFT plots that the IM shaft voltage is 13 dbµv (Fig.6.13), 175dBµV (Fig.6.12) & 22 dbµv (Fig.6.11) for 5, 3 & 2-level inverters fundamental frequency. Similarly Figs 6.14 to 6.19 shows that the bearing current in ma (in the form of pulses) 18mA, 17mA and 9mA for 2, 3, and 5 level inverter respectively. Figs. 6.2, 6.21 and 6.22 shows the FFT plots of bearing current in dbµa for 2, 3 and 5 level inverters. The values are 22 dbµa, 14 dbµa and 1 dbµa respectively. It is observed that IM bearing current is less in 5- level inverter when compared to 3 & 2 level inverters. Hence it is concluded that as the inverter level increases the shaft voltage and bearing current reduces. Note:-Justification for Figs.6.4 and 6.5 Fig.6.4. gives the actual readings of the inverter output line voltage, CM voltage, shaft voltage and the bearing current measured in terms of
19 138 voltage. Observing the DSO recorded waveform, at the time of grounding the shaft voltage, there will be the flow of bearing current. Due to the flow of bearing current the CM voltage magnitude is diminished (ch.2). The ch.3 of Fig.6.4 is the shaft voltage which is shorted to ground is diminished, however the sharp pulses exists which is in agreeable with CM voltage peaks. Fig 6.4 clearly shows that once there is a flow of bearing current, which is decreasing the CM voltage due to capacitive flow of current and hence the CM voltage is also reduces in magnitude which can be seen in Fig. 6.4 ch. 2. Observing the DSO recorded wave form of Fig.6.5 ch.2 and Fig.6.4 ch.3 the CM voltage is agreeable in phase and magnitude with that of the shaft voltage before grounding the shaft.
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