Post on 09-Apr-2017
Motor & Drive Systems; January 21, 2016
Accurate Power Conversion Measurements on High Power Motor Drives
Presented by:Ian WalkerGMW Associatesian@gmw.com
Interconnections for the test of a low power AC Motor with Variable Speed Drive
DC or Single Phaseor Three Phase AC Input
Inverter
Motor Load
Speed and Torque Meter
Test Cell
From: Yokogawa
Current and Voltage Transduces provide electrical isolation in testing high power Variable Speed Drives
DC or Single Phaseor Three Phase AC Input
Inverter
Motor Load
Speed and Torque Meter
Test Cell
Current SensorI
itypical i = I/1000
Voltage SensorV
vtypical v = V/100
From: Yokogawa
๐๐ =๐ผ๐ผ๐๐
๐ฃ๐ฃ =๐๐๐๐โฒ
Voltage and Current Waveforms on one phase of a low power, variable speed AC Motor Drive
From: Yokogawa
V
I
Voltage and Current Spectra for the previous Voltage and Current Waveform
From: Yokogawa~200 harmonic
Power MeasurementFor any voltage and current phase pair:
๐๐๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก = โ1 ๐๐ ๏ฟฝ0
๐๐๐๐ ๐ก๐ก โ ๐ผ๐ผ ๐ก๐ก ๐๐๐ก๐ก
When Voltage and Current Transducers are used:
๐๐ ๐ก๐ก = ๐๐โฒ โ ๐ฃ๐ฃ ๐ก๐ก with ๐๐โฒ typically about 100๐ผ๐ผ ๐ก๐ก = ๐๐ โ ๐๐ ๐ก๐ก with ๐๐ typically about 1000
๐๐๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก = ๐๐ โ ๐๐โฒ โ1 ๐๐ ๏ฟฝ0
๐๐๐ฃ๐ฃ ๐ก๐ก โ ๐๐ ๐ก๐ก ๐๐๐ก๐ก
This calculation provides True Power measurement of any waveform, including all the harmonic content, limited by the bandwidth of the transducers and the processing instrument.
Note also: ๐๐๐๐ (๐ก๐ก)๐๐๐ก๐ก
= 1๐๐โฒ
๐๐๐๐ (๐ก๐ก)๐๐๐ก๐ก
and ๐๐๐๐ (๐ก๐ก)๐๐๐ก๐ก
= 1๐๐
๐๐๐ผ๐ผ (๐ก๐ก)๐๐๐ก๐ก
dramatically reducing the capacitive and inductive coupling from long cables.
The Total Power can also be calculated from the harmonic content
๐๐๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก = ๐๐0 โ ๐ผ๐ผ0 + ๐๐1 โ ๐ผ๐ผ1 โ ๐๐๐๐๐๐๐๐1 + ๐๐2 โ ๐ผ๐ผ2 โ ๐๐๐๐๐๐๐๐2 +
๐๐3 โ ๐ผ๐ผ3 โ ๐๐๐๐๐๐๐๐3 + โฏ + ๐๐๐๐ โ ๐ผ๐ผ๐๐ โ ๐๐๐๐๐๐๐๐๐๐
or
๐๐๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก = ๐๐0 โ ๐ผ๐ผ0 + ๏ฟฝ1
๐๐๐ก๐ก๐๐๐๐๐๐ โ ๐ผ๐ผ๐๐ โ ๐๐๐๐๐๐๐๐๐๐
V0 and I0 are the dc components of Voltage and Current. or
๐๐๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก = ๐๐ โ ๐๐โฒ๐ฃ๐ฃ0 โ ๐๐0 + ๐๐ โ ๐๐โฒ ๏ฟฝ1
๐๐๐ก๐ก๐๐๐ฃ๐ฃ๐๐ โ ๐๐๐๐ โ ๐๐๐๐๐๐๐๐๐๐
Voltage and Current Transducers must have accurate amplitude andphase response for all the harmonics that contribute to ๐๐๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก. Any โFalseโ harmonics, ๐ฃ๐ฃ๐๐ or ๐๐๐๐ , introduced by cross-talk, will generate an error in the ๐๐๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก๐ก if ๐๐๐๐๐๐๐๐๐๐is โ 0 and may be significant if ๐๐๐๐ approaches 0 and ๐๐๐๐๐๐๐๐๐๐ is = 1.
Cross Talk Mechanisms
For a variable speed motor drive used in transport applications, the voltage signal rise and fall times can be as short as 50ns, implying significant spectrum components to 6MHz. The wavelength of the electromagnetic radiation at 6MHz is about 50m. In a Motor Drive Test Cell, the dimensions of possible โantennasโ within the signal measurement cables are typically less than 5m so simple capacitance and inductive coupling models, rather than electromagnetic wave coupling, can be used for a simplified analysis.
๐๐~๐๐๐๐
~3 ๐ฅ๐ฅ 108
6 ๐ฅ๐ฅ 106 ~12
ร 102~ 50๐๐
Capacitive Cross Coupling from the high voltage, high current cables
For ๐ ๐ ๐ต๐ต = 2ohm, I =500A peak, ๐๐(t) = 500mA peak๐ฃ๐ฃ ๐ก๐ก = ๐ ๐ ๐ต๐ต๐๐ ๐ก๐ก = 1000mV peak
At low frequency, ~10kHz, capacitive cross-coupling is low with ๐ถ๐ถ๐ถ๐ถ~100pF and ๐๐๐๐ ~100Vat 10kHz, ๐ง๐ง๐ถ๐ถ~200kohm.
๐๐โฒ ๐ก๐ก ~ ๐๐๐๐๐ง๐ง๐ถ๐ถ+๐ ๐ ๐ต๐ต
~ 100๐๐200k
~ 0.5mA
๐ฃ๐ฃโฒ ๐ก๐ก ~๐ ๐ ๐ต๐ต๐๐โฒ ๐ก๐ก = 2 ๐ฅ๐ฅ 0.5mA~1mV peak
~0.1% of the โtrueโ current output signal of 1000mV peak.
๐๐๐ ๐ + ๐๐๐ถ๐ถ๐๐๐ ๐ + ๐๐๐ถ๐ถ
๐ฃ๐ฃ ๐ก๐ก = ๐ ๐ ๐ต๐ต๐๐ ๐ก๐ก๐ฃ๐ฃ๐ฃ ๐ก๐ก = ๐ ๐ ๐ต๐ต๐๐๐ฃ(๐ก๐ก)
๐๐๐ฃ(๐ก๐ก)
DCCT 1:1000
๐๐(๐ก๐ก)
V(t) I(t)
๐ถ๐ถ๐ถ๐ถ ๐ง๐ง๐ถ๐ถ = 12๐๐๐๐๐ถ๐ถ๐๐
~ 200k at 10kHz for 100pF
๐๐ ๐ก๐ก + ๐๐๐ฃ(๐ก๐ก)
๐๐๐ฃ(๐ก๐ก)
๐ ๐ ๐ต๐ต
๐๐(๐ก๐ก)
High impedancecurrent source
๐๐๐ฃ(๐ก๐ก)
Capacitive Cross Coupling from the high voltage, high current cables
For ๐ ๐ ๐ต๐ต = 2ohm, I =500A peak, ๐๐(t) = 500mA peak๐ฃ๐ฃ ๐ก๐ก = ๐ ๐ ๐ต๐ต๐๐ ๐ก๐ก = 1000mV peak
At high frequency, ~1MHz, capacitive cross-coupling is high with ๐ถ๐ถ๐ถ๐ถ~100pF and ๐๐๐๐ ~100Vat 1MHz, ๐ง๐ง๐ถ๐ถ~1kohm.
๐๐โฒ ๐ก๐ก ~๐๐๐๐
๐ง๐ง๐ถ๐ถ + ๐ ๐ ๐ต๐ต
๐ฃ๐ฃโฒ ๐ก๐ก ~๐ ๐ ๐ต๐ต๐๐โฒ ๐ก๐ก =๐ ๐ ๐ต๐ต๐๐๐๐
(๐ง๐ง๐ถ๐ถ + ๐ ๐ ๐ต๐ต) ~2 ร 100
1k ~100mV peak
~10 % of the โtrueโ current output signal of 1000mV peak.
Note that ๐ฃ๐ฃโฒ ๐ก๐ก on the current signal is approximately in phase with V ๐ก๐ก .
๐ฃ๐ฃ ๐ก๐ก = ๐ ๐ ๐ต๐ต๐๐ ๐ก๐ก๐ฃ๐ฃ๐ฃ ๐ก๐ก = ๐ ๐ ๐ต๐ต๐๐๐ฃ(๐ก๐ก)
๐๐๐ฃ(๐ก๐ก)
DCCT 1:1000
๐๐(๐ก๐ก)
V(t) I(t)
๐ถ๐ถ๐ถ๐ถ ๐ง๐ง๐ถ๐ถ = 12๐๐๐๐๐ถ๐ถ๐๐
~ 200 at 6MHz for 100pF
๐๐ ๐ก๐ก + ๐๐๐ฃ(๐ก๐ก)
๐๐๐ฃ(๐ก๐ก)
๐ ๐ ๐ต๐ต
๐๐(๐ก๐ก)๐๐๐ ๐ + ๐๐๐ถ๐ถ
High impedancecurrent source
๐๐๐ ๐ + ๐๐๐ถ๐ถ
๐๐๐ฃ(๐ก๐ก)
Capacitive Cross Coupling from the high voltage, high current cables
Capacitive Cross Coupling from the high voltage ๐๐ ๐ก๐ก on the motor drive cables can be substantially reduced by shielding the drive-to-motor cables in the vicinity of the Current Transducer and signal cables. Self adhesive copper tape can be wrapped around the cables for a length of greater than three Current Transducer Head diameters. The shielding must be grounded at one end only and near the AC Drive so that the shield high frequency current, ๐๐๐ฃ(๐ก๐ก), is returned to the AC drive in a short, low inductance path.
There will still be some capacitive coupling between the Drive-to-Motor cables and signal cables giving rise to a cross coupling current ๐๐โฒโฒ ๐ก๐ก with ๐๐โฒโฒ ๐ก๐ก << ๐๐โฒ ๐ก๐ก . This can be reduced by shielding the signal cables.
๐๐๐ ๐ + ๐๐๐ถ๐ถ๐๐๐ฃ๐ฃ(๐ก๐ก)
DCCT 1:1000
๐๐(๐ก๐ก)
V(t) I(t)
๐ถ๐ถ๐ฃ๐ถ๐ถ
๐๐ ๐ก๐ก + ๐๐๐ฃ๐ฃ(๐ก๐ก)๐ ๐ ๐ต๐ต๐๐๐ฃ(๐ก๐ก)
๐๐๐ฃ๐ฃ(๐ก๐ก)
๐๐๐ฃ๐ฃ(๐ก๐ก)
๐ฃ๐ฃ ๐ก๐ก = ๐ ๐ ๐ต๐ต๐๐ ๐ก๐ก๐ฃ๐ฃ๐ฃ๐ฃ ๐ก๐ก = ๐ ๐ ๐ต๐ต๐๐๐ฃ๐ฃ(๐ก๐ก)
๐๐๐ ๐ + ๐๐๐ถ๐ถ
Capacitive Cross Coupling from the high voltage, high current cables
The Current Transducer to Burden Resister signal cable should be a twisted pair (to reduce magnetic pickup) with the outer shield returned to the AC drive in a short, low inductance path.
๐๐๐ ๐ + ๐๐๐ถ๐ถ๐๐๐ ๐ + ๐๐๐ถ๐ถ
DCCT 1:1000
๐๐(๐ก๐ก)
V(t) I(t)
๐ ๐ ๐ต๐ต๐๐๐ฃ(๐ก๐ก)
๐ถ๐ถ๐ฃ๐ถ๐ถ ๐๐๐ฃ๐ฃ๐ฃ(๐ก๐ก)
๐ฃ๐ฃ ๐ก๐ก = ๐ ๐ ๐ต๐ต๐๐(๐ก๐ก)
๐๐๐ฃ๐ฃ๐ฃ(๐ก๐ก)
Capacitive Cross Coupling from the high voltage, high current cables.
Addition of a Common-Mode Choke to a Signal Pair.
Even with a shielding of the drive-to-motor cables and shielded signal cables, there still can be a residual cross-talk, particularly at higher frequencies. A common-mode choke is effective in providing a relatively high impedance to a current on only one line of the signal pair. Single turn, clamp-on, common-mode shunts can have an impedance of about 10ohm at 1MHz and 30ohm at 6MHz to give a reduction of spurious signals at a 2ohm Burden Resistor of between 5 and 15 times. This demonstrates one benefit of using a current source Current Transducer with a remote, low resistance Burden Resistor, ๐ ๐ ๐ต๐ต .
๐๐๐ฃ๐ฃ๐ฃ(๐ก๐ก)
DCCT 1:1000
๐๐(๐ก๐ก)
V(t) I(t)
๐๐ ๐ก๐ก๐ฃ๐ฃ ๐ก๐ก = ๐ ๐ ๐ต๐ต๐๐(๐ก๐ก)๐ ๐ ๐ต๐ต
๐ถ๐ถ๐ฃ๐ถ๐ถ
๐๐๐ ๐ + ๐๐๐ถ๐ถ๐๐๐ ๐ + ๐๐๐ถ๐ถ
๐๐๐ฃ(๐ก๐ก)
๐๐๐ฃ๐ฃ๐ฃ ๐ก๐ก
Inductive Cross Coupling from the High Current Motor Drive Cables.
Signal induced in a small โpick-upโ loop at the Burden Resistor.
From ๐ฃ๐ฃโฒ = โ๐ด๐ด๐ฃ๐๐02
๏ฟฝ๐ ๐ 2
๐๐3 ๏ฟฝ๐๐๐ผ๐ผ๐๐๐ก๐ก
๐ด๐ด๐ฃ~10 ร 10mm ~ 10โ4m2
๐ ๐ ~100mm ~ 10โ1m๐๐ ~1m๐๐๐ผ๐ผ๐๐๐ก๐ก ~
400A2ms ~2๐ฅ๐ฅ105 โ๐ด๐ด ๐๐๐ ๐ ๐๐ (๐๐~150Hz)
Then the voltage induced in the loop at the Burden Resistor is
๐ฃ๐ฃโฒ~ โ 10โ4 ๏ฟฝ4๐๐ ร 10โ7
2 ๏ฟฝ10โ2
1 ๏ฟฝ 2 ร 105
~ 0.1ยตV. At low frequencies and with good layout the direct magnetic coupling is small and the developed voltage leads the current I(t) by about 90ยฐ.
๐๐๐ ๐ + ๐๐๐ถ๐ถ
โpick-upโ loop area ๐ด๐ด๐ฃ
High current loop radius ๐ ๐
DCCT 1:1000
๐๐(๐ก๐ก)
V(t) I(t)
๐๐ ๐ก๐ก
2๐ ๐ ~200mm ๐๐~1m
10mm
10m
m ๐ฃ๐ฃ ๐ก๐ก = ๐ ๐ ๐ต๐ต๐๐(๐ก๐ก)๐ ๐ ๐ต๐ต
๐ถ๐ถ๐ฃ๐ถ๐ถ ๐๐๐ฃ๐ฃ๐ฃ(๐ก๐ก)
๐๐๐ฃ๐ฃ๐ฃ(๐ก๐ก)
๐๐๐ฃ(๐ก๐ก)
๐๐๐ ๐ + ๐๐๐ถ๐ถ
Capacitive Cross Coupling from the high voltage, high current cables.
โGroundingโ of high frequency capacitively coupled currents.
To minimize capacitive coupling from the high frequency voltages and for safety, it is often preferable to use shielded Drive to Motor Cables. The parasitic currents ๐๐๐ ๐ ๐ก๐ก +๐๐๐ถ๐ถ ๐ก๐ก are returned by the cable shields. However, to measure the phase currents requires the shields be broken so the parasitic currents return outside the Current Transducer aperture. A separate low impedance return from the Motor to the Drive must be added. This direct return combines with the safety grounds to generate a potentially large โground loopโ in which current can be induced by changing magnetic fields. As far as feasible the loop area should be minimized. High frequency current can be reduced by clamp-on ferrite on the safety ground leads.
๐๐๐ ๐ (๐ก๐ก) + ๐๐๐ถ๐ถ ๐ก๐ก return direct to the AC Drive Safety GroundSafety Ground
Clamp-On Ferrite
๐๐โฒโฒโฒ ๐ก๐ก return
DCCT 1:1000
๐๐(๐ก๐ก)
V(t) I(t)
๐๐ ๐ก๐ก ๐ฃ๐ฃ ๐ก๐ก = ๐ ๐ ๐ต๐ต๐๐(๐ก๐ก)๐ ๐ ๐ต๐ต
๐๐๐ฃ(๐ก๐ก)
๐๐(๐ก๐ก)
Safety Ground
Clamp-On Ferrite
Summary
1. In the measurement of power transfer in high power variable speed motor drives a significant source of error in the power calculation can be the generation of โfalseโ current harmonics arising from capacitive coupling to the current channel from the high frequency voltage harmonics.
2. Shield all cables carrying high voltage to reduce capacitive coupling to the Current Transducer and associated signal lines.
3. To minimize the effects of capacitive coupling from the high frequency voltage harmonics, use current source (high impedance) Transducers rather than voltage source Transducers. This is particularly important for the Current Transducers.
4. Locate Transducers near the Drive rather than the Motor to avoid magnetic fields from the Motor generating cross-talk signals in the Transducers.
5. Capacitively induced currents in the cable shields should be explicitly returned to the source common with short, low impedance return leads. Low frequency magnetic fields from the motor currents can be reduced by minimizing the area enclosed by high currents.
6. Grounding for electrical safety compliance should be separately considered from the return of high frequency, capacitively coupled currents.
7. High frequency currents reduced in ground loops can be reduced by clamp on ferrites on the safety ground leads.
References Page
โข Weston, David A. Electromagnetic Compatibility, Principles and Application. 2nd ed. CRC Press, 2001.
Thank You
Questions?
Ian Walkerian@gmw.com
www.gmw.com650-802-8292