How do variable frequency drives affect my business?

Posted on 1st Nov 2022

In industrial settings, there are two main approaches to regulate motor speed: either by adjusting frequency or voltage. Due to the consistent flux density, altering frequency typically provides better control when comparing the two.

Variable Frequency Drives are useful in this situation.

A variable frequency drive (VFD), sometimes referred to as a variable speed drive or an adjustable frequency drive, is a motor controller that regulates speed and torque in electro-mechanical drive systems by altering the voltage and frequency of the electricity supplied to the electric motor.

In order to manage the speed of the induction motor, VFDs are power conversion devices that transform fixed frequency and voltage input power into variable voltage and frequency output power.

It consists of power electronic components, a high-speed central controlling unit, and optional sensor components.

More than 25% of the electrical energy used globally is consumed by electric motors in industrial applications.

Centrifugal load service VFDs can be used to control this, which helps to assure efficiency.

VFDs are utilised in drive systems that have three primary subsystems: an AC motor, a main drive controller component, and a drive/operator interface.

There are many different low and medium voltage, AC-AC, and DC-AC topologies available for VFDs.

VFD Use in Industrial Environments

VFD applications in various machines are growing daily as the demand for improved automation and more energy-efficient equipment rises.

Small machine tools and large-scale compressors alike employ VFDs in industrial plants for a variety of equipment.

There is a significant need for improved functionality in locations where VFDs are employed, particularly in locations where there is a strong need for machinery that can execute complicated automation duties.

A VFD functions by collecting power from the supply side, inverting it, storing that voltage, and then using an internal component known as an IGBT to produce a controllable sine wave-like form.

The converter is the variable frequency drive's initial stage.

Six diodes make up this device, which allows electricity to flow in only one direction—typically the direction denoted by the arrow in the diode symbol.

For instance, the diode will open and the A-phase diode will close when the A-phase voltage is higher than the B or C phase voltages.

The A-phase diode will close as the B-phase diode opens if the B-phase becomes more positive than the A-phase.

On the negative side, this procedure is comparable to that of the other three diodes.

Given that each diode opens and closes, this is what causes the six current pulses.

A six pulse VFD is what this is known as.

Darwin Motion VFD are crucial for industrial businesses.

Energy savings are possible when using variable torque loads with a VFD.

Therefore, by simply controlling the motor using a VFD, energy expenses can be decreased if a firm has an application that doesn't require the maximum speed to run.

A company may exactly match the load requirements to the speed of a motor-driven equipment by using variable frequency drives.

In industrial plants, more than 60% of the electricity is used by electric motor systems.

Utilizing the available motor control systems by installing or upgrading to variable frequency drives will help your facility consume between 30 and 35 percent less energy overall.

Additionally, using VFDs lowers production costs and enhances product quality.

Increased output as a result of improved process control: When using VFDs, errors are typically reduced or eliminated, especially if the business's motors are run at the most efficient speed for the application.

As a result, production levels increase and a company's revenues rise.

It helps eliminate jerks at startup on both belts and conveyors, enabling high throughput.

Controlled Acceleration: VFD starts at zero speed and gently accelerates on a customizable ramp, in contrast to AC motors that start across the line.

For the load and the motor that are mechanically connected, this serves to lessen mechanical shock, which in turn helps to lessen wear and tear.

Equipment can increase speed smoothly with a moderate ramp-up in power as opposed to experiencing an abrupt shock to full power.

In an industrial application, a variable frequency drive also offers the following advantages:

Less power disruptions

Lower initial power requirements

Variable torque restriction

Regulated stopping

Lower costs for maintenance

The need for pricey mechanical driving components is gone

It's crucial to make sure that your staff is adequately informed on how to use and maintain your VFDs in order to improve comprehension of these drives, increase overall productivity, and lengthen the lifespan of your VFDs.