Apparatus and method for starting and stopping an AC induction motor

An apparatus for controlling the starting and stopping of an AC induction motor, the apparatus comprises a first and a second magnetic permeable portions having a plurality of legs wherein a magnetic control flux of the second magnetic has an opposite magnetic polarity to the magnetic control flux of the first magnetic permeable portion; anon-spacer separating the first and second magnetic permeable portions to prevent magnetic control flux cancellation between the first and second magnetic permeable portions; a first and second AC power phase windings; and a first and second group of DC excitation control windings.

TECHNICAL FIELD

The invention concerns an apparatus and method for controlling the starting and stopping of an AC induction motor.

BACKGROUND OF THE INVENTION

An AC induction motor is a type of electric motor for powering driven equipment. They are robust, reliable, and inexpensive and standardized throughout the world. Starting an AC induction motor requires a careful compromise between the cost of the motor starter apparatus, starting performance and the electric supply authorities regulations.

A basic method of starting an electric motor is by closing a contactor to allow the motor to start at full voltage as a direct-on-line starter. Although it is a compact and inexpensive method, it is not the best method to use. Direct-on-line starting is marked by inrush current surges of six to eight times the motor's full load ampere value, resulting in electrical surge transients as well as mechanical strain on driven equipment. It results in a fast breakaway and acceleration up to full speed in an uncontrolled fashion.

The effect upon a hydraulic pump is mechanical stress applied on the rotating components followed by surges in the hydraulic system. This may include a high initial flow rate causing a vacuum to be drawn on the suction side, pump cavitations and pressure pulsations at the pump discharge, Similar effects are found with mechanical loads such as conveyers (driven by a motor) which when subjected to sudden jerks or severe applications of torque, may lead to load displacement, conveyor belt slippage or breakage.

Equally, when stopping the rate of deceleration is totally uncontrolled, this leads to further mechanical stress on pipelines for pumping applications, mountings and check valves from the inertia of the flowing fluids. It also produces pressure surges in the hydraulic circuit leading to pipeline rupture and leakage of product.

To maintain continuity and quality of the supply of electricity, electric supply utilities apply service rules and regulations that limit the kW size of motors that can be connected with the direct-on-line method of starting which may affect other electric power consumers.

For large motors, from 35 kW up to 5000 kW, the supply authorities may require the application of reduced inrush current starting to limit the starting current surge to a low value.

Although there are numerous variations of motor starting with a reduced voltage, the prior art auto-transformer starter is the most efficient and common methodology for starting a large motor, because it is the only reduced voltage starter that can provide maximum starting torque with minimal line current; this is due to the transformation ratio of the number of turns of the primary and secondary windings of the auto-transformer.

Other known non-electronic types of reduced voltage starters are the primary reactor and primary resistance starters. Both primary reactor and primary resistance starters have similar starting characteristics and disadvantages as the direct-on-line starting methodology which causes transient current and torque peaks when changing from reduced voltage to full fine voltage.

SUMMARY OF THE INVENTION

In a first preferred aspect, there is provided an apparatus for controlling the starting and stopping of an AC induction motor, the apparatus comprising;a first magnetic permeable portion having first, second and third legs;a second magnetic permeable portion arranged relative to the first magnetic permeable portion such that a magnetic control flux of the second magnetic permeable portion has an opposite magnetic polarity to a magnetic control flux of the first magnetic permeable portion, the second magnetic permeable portion having fourth, fifth and sixth legs;a non-magnetic spacer separating the first and second magnetic permeable portions to prevent magnetic control flux cancellation between the first and second magnetic permeable portions;a first AC power phase winding wound around the first and fourth legs;a second AC power phase winding wound around the third and sixth legs;a first pair of DC excitation control windings mounted around the first magnetic permeable portion; anda second pair of DC excitation control windings mounted around the second magnetic permeable portion;wherein a magnetic power flux opposes the magnetic control flux in the first magnetic permeable portion and a magnetic power flux assists a magnetic control flux in the second magnetic permeable portion during a first half cycle, and a magnetic power flux assists a magnetic control flux in the first magnetic permeable portion and a magnetic power flux opposes a magnetic control flux in the second magnetic permeable portion during a second half cycle, such that the impedance of the AC power phase windings is changed by an equal and symmetrical variation of the density of the combined magnetic fluxes in each of the magnetic permeable portions during a complete power cycle to produce a balanced voltage with a symmetrical waveform from each of the AC power phase windings.

The apparatus may further comprise a third AC power phase winding wound around the second the fifth legs.

The DC excitation control windings may all have the same number of turns.

Each magnetic permeable portion may comprise:an upper cross-bar yoke connecting an upper portion of each leg, anda lower cross-bar yoke connecting a lower portion of each leg.

Each AC power phase winding may have substantially equal magnetic saturation levels.

The AC power phase winding may be a single continuous winding with a plurality of voltage taps.

The AC power phase winding may be at least two separate coils having an equal number of turns, each coil having a plurality of voltage taps.

The apparatus may further comprise a switch connected at a 50% voltage tap of each AC power phase winding to reduce stress on insulation of the AC power phase winding.

The apparatus may further comprise a third magnetic permeable portion, the third magnetic permeable portion omitting DC excitation control windings.

The third magnetic permeable portion may have an air gap and is isolated by non-magnetic spacers to prevent magnetic control flux cancellation between the first and second magnetic permeable portions.

The DC excitation control windings may be a plurality of control windings for inducing magnetic control fluxes in the magnetic permeable portions, and the flow of magnetic control flux in the magnetic permeable portions have substantially equal flux densities and the magnetic flux flows in the first magnetic permeable portion in opposition to the second magnetic permeable portion.

The first pair of DC excitation control windings may be wound around the upper cross-bar yoke of the first magnetic permeable portion between the first and second legs and between the second and third legs, and the second pair of DC excitation control windings is wound around the upper cross-bar yoke of the second magnetic permeable portion between the fourth and fifth legs and between the fifth and sixth legs.

The first pair of DC excitation control windings may be connected in series and supplied with DC amperes, and the DC amperes induce a magnetic control flux to flow in an upwardly direction on the second leg, and in a downwardly direction on the first and third legs

The second pair of DC excitation control windings may be connected in series and supplied with DC amperes, and the DC amperes induce a magnetic control flux to flow in an downwardly direction on the fifth leg, and in a upwardly direction on the fourth and sixth legs

The apparatus may further comprise:an input connection to the AC power phase windings for connection to a three phase AC power system;an output connection to a load from selected reduced voltage taps of the AC power phase windings;a common connection to each A.C. power phase winding for connection to a common circuit point; andan input connection to each pair of DC excitation control windings.

It is an advantage of at least one embodiment of the present invention to use impedance of a variable reactor to symmetrically ramp-up the available voltage to the motor terminals during the second starting stage and control deceleration of the driven load during a motor stop sequence.

The progressive increase of impedance of the present invention and also an improved magnetic core assembly symmetrically reduces the available voltage to the motor terminals. This allows a motor stop with a ramp-down from the motors full load speed in a controllable manner.

Another advantage of at least one embodiment of the present invention is that the continuously variable, control of reactor impedance values for the second step allows a wider range of motor kW sizes to be utilized for a given physical size of a variable reactor/auto-transformer apparatus.

A further advantage of at least one embodiment of the present invention is having the first step as a reduced voltage auto-transformer apparatus, and a second starting step that includes an improved means of DC control. The improved magnetic core assembly enables a smooth switch-over into a variable reactor control connection.

One feature of the present invention is that pairs of DC control windings are connected in series opposition such that any AC induced in these DC control windings by the AC power phase windings cancels out and the resultant voltage across the excitation circuit is substantially zero.

Another feature of the invention is that the physical construction and electrical engineering requirement for manufacture does not depart from typical transformer construction techniques used by prior art auto-transformer starters. In other words, the construction may utilize a 3-coil set of windings, identified as a “wye (star point)” configuration with one set of coils per phase. This allows balanced load sharing between the three phases or utilizes 2-coil set of windings where the central phase does not include a coil set of windings. This results in a slight imbalance compared with the above mentioned 3-coil set construction. The 2-coil set of windings is identified as an “open-delta” configuration.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring toFIG. 1, a perspective view of a 2-coil variable reactor/auto-transformer apparatus10according to a first embodiment is shown. The apparatus10is used in a motor starter (not shown) to supply starting current to a polyphase induction motor.

The apparatus10may be used for starting, and stopping the motor with deceleration.

The apparatus10generally comprises a magnetic core assembly having magnetic properties that is assembled from transformer core laminations arranged in an “EI” arrangement. The apparatus10has at least two magnetically permeable portions or part cores20,40made of a magnetic material having a magnetization curve with a pronounced knee. The first and second part cores20,40are separated by a non-magnetic spacer30. The first part core20is arranged relative to the second part core40such that a magnetic control flux of the first part core20has an opposite magnetic polarity to a magnetic control flux of the second part core40. This enables symmetrical control of the output waveform of the AC to the induction motor. The components of the magnetic core assembly are held in position by upper brackets11and lower brackets12.

Each part core20,40has three legs. The first part core20has two lateral legs21,23and a central leg22. The second part core40also has two lateral legs41,43and a central leg42. The lateral legs21,23,41,43have equal cross sectional areas and have respective AC power phase windings90,100of AC phase coils mounted on them. The AC power phase windings90,100have voltage taps similar to prior art auto-transformers. The first AC power phase winding90is wound around the first pair of lateral legs21,41. The second AC power phase winding100is wound around the second pair of lateral legs23,43. The AC power phase windings90,100are interlinked by the magnetic flux in the lateral legs21,23,41,43they are mounted on.

A pair of DC excitation coils70,80is mounted around the first pad core20. Another pair of DC excitation coils50,60is mounted around the second part core40. The pairs of DC excitation coils50,60,70,80enable the magnetic control flux in each part core20,40to be varied. The DC excitation coils70,80of the first part core20are connected in series and have the same number of turns as each other. The DC excitation coils50,60of the second part core40are connected in series and have the same number of turns as DC excitation coils70,80of the first part core20. The windings of the DC excitation coils50,60,70,80are interlinked by the magnetic flux in the respective part core20,40they are mounted around. Thus, the first part core20has a set of DC excitation coils70,80and the second part core40has a set of DC excitation coils50,60. Each pair of DC excitation coils50,60,70,80are connected with an opposite polarity.

The DC excitation coils70,80of the first part core20and the DC excitation coils50,60of the second part core40are connected to a DC source for inducing a magnetic control flux to flow in each of the part cores20,40since they are closed magnetic circuits. The direction of flow of the magnetic control flux in the part cores20,40are in opposite directions to each other such that any AC induced in those DC excitation coils50,60,70,80by the AC power phase windings90,100cancels out and the resultant voltage across the excitation DC control circuit is substantially zero. A magnetic power flux opposes the magnetic control flux in the first part core20and a magnetic power flux assists a magnetic control flux in the second part core40during a first half cycle. A magnetic power flux assists a magnetic control flux in the first part core20and a magnetic power flux opposes a magnetic control flux in the second part core40during a second half cycle. This causes the impedance of the AC power phase windings90,100to be changed by an equal and symmetrical variation of the density of the combined magnetic fluxes in each of the part cores20,40during a complete power cycle to produce a balanced voltage with a symmetrical waveform from each of the AC power phase windings90,100.

Referring toFIG. 2, an electrical diagram of the apparatus ofFIG. 1is shown. An input connection200to each AC power phase winding90,100is provided for connection to an AC power system. There is an output connection210to a load from selected voltage taps of the AC power phase winding90,100. A common point connection220to each AC power phase winding90,100for connection to a common star point is provided. An input connection230to each pair of DC excitation coils50,60,70,80mounted on the part cores20,40is provided.

FIG. 3shows an exploded view of the magnetic core ofFIG. 1. The arrangement of the magnetic part cores20,40have substantially equal magnetic saturation levels.

FIG. 4is an exploded view of the magnetic core ofFIG. 1showing the direction of flow of the magnetic control flux. The direction of flow of the magnetic control flux through each of the part cores20,40is indicated by the arrows. When the first part core20is excited by applying DC excitation, a magnetic control flux is induced that flows in an upwards direction along the central leg22. The second part core40induces a magnetic control flux that flows in a downwards direction along its central leg42when DC excitation is applied. Since the non-magnetic spacer30is sandwiched between the part cores20,40, any magnetic coupling is reduced and cancellation of the two equal and opposite magnetic control fluxes is prevented.

The impedance of the AC power phase windings90,100is dependant upon the magnetic permeability of the magnetic core assembly. When DC is applied to the DC excitation coils50,60,70,80, the magnetic control fluxes in each part core20,40are varied. An increase in DC to the DC excitation coils50,60,70,80results in a decrease in the impedance of the AC power phase windings90,100because of the increase of core saturation. This reduces the permeability of the magnetic core assembly and the impedance of the AC power phase windings90,100.

The amplitude of the DC applied to the DC excitation coils50,60,70,80varies in relation to a desired electrical parameter that may be provided by a microprocessor based motor protection relay controller. The controller monitors the motor phase current during each stage of starting the motor. The controller has a memory to store a first predetermined current value which is indicative of a started motor and is able to compare the current levels with a second predetermined current value after the motor has started for causing the motor starter to switch to subsequent second stage as a variable reactor after a predetermined transition time/current value. The controller compares the current levels with a third predetermined current value after the motor has reached near operating speed for causing the motor starter to switch to full supply voltage. The controller switches a digital output for the transition from the auto-transformer connection for the first starting period. The controller also controls an analog DC output signal for the manipulation of DC excitation of the part cores20,40during the second starting period as a variable reactor unit. The motor controller manipulates the analog DC output signal for desired motor operating parameters for rate of change during starting and deceleration during a stop command.

The amplitude of the DC magnetic control flux saturates the part cores20,40. This in turn deeply controls the permeability of the magnetic core assembly and therefore the impedance of the AC power phase windings90,100.

The AC power phase windings90,100and the DC control windings50,60,70,80are disposed with respect to the magnetic core assembly so that the AC and DC induces an AC magnetic power flux and a DC magnetic control flux in each leg21,22,23,41,42,43of the magnetic core assembly. These fluxes assist each other or oppose each other when the AC has a positive or negative value respectively.

The pairs of DC control windings50,60,70,80are connected in series opposition such that any AC induced in those DC control windings50,60,70,80by the AC power phase windings90,100cancels out. Any resultant voltage across the excitation circuit is substantially zero.

Referring toFIG. 5, a 3-coil, variable reactor/auto-transformer apparatus110in accordance with a second embodiment is shown. The apparatus110is used in a motor starter to supply starting current to a polyphase induction motor (not shown).

The apparatus110may be used for starting the motor and stopping the motor with deceleration.

The apparatus110comprises a magnetic core assembly of transformer laminations of a magnetic material having a magnetization curve with a pronounced knee. The apparatus110is assembled into a typical EI construction with at least two part cores120,140. The first120and second140part cores have three legs121,122,123and141,142,143, respectively. The part cores120,140are separated by a non-magnetic spacer130. A pair of DC excitation coils170,180are wound around the first part core120. Another pair of DC excitation coils150,160is wound around the second part core140.

All three pairs of legs121,141, and122,142and123,143have a respective AC power phase winding190,191,192. The three AC power phase windings190,191,192have voltage taps similar to prior art auto-transformers. A first AC power phase winding190is wound around the first lateral legs121,141. A second AC power phase winding191is wound around the central legs122,142. A third AC power phase winding192is wound around the third lateral legs123,143. The windings of the AC power phase windings191,192,193are interlinked by the magnetic flux in the legs121,122,123,141,142,143they are mounted on.

Referring toFIG. 6, an electrical diagram of the apparatus110ofFIG. 5is shown. An input connection300to each AC power phase winding190,191,192is provided for connection to an AC power system. An output connection310to a load from selected voltage taps of the AC power phase winding190,191,192is provided. A common point connection320to each AC power phase winding190,191,192for connection to a common star point is provided. An input connection330to each pair of DC excitation coils150,160,170,180mounted on the part cores120,140is provided.

The relationship of % reduced voltage and corresponding % starting current values and torque values are shown in the table below and also onFIG. 6;

Referring toFIG. 7, a schematic circuit diagram of the apparatus110ofFIG. 5is shown. The system400comprises a circuit that is similar to the prior art Korndorfer closed transition configuration. The system400has three (single coil) AC power phase windings190,191,192which are continuous (single). The system400also has a common point with a star switch408,409,410. There is also a main switch401, a bypass contactor402and motor overload relay403. The motor overload relay403may be a thermal or an electronic relay. There are transformer contacts404,405,406. The transformer contacts404,405,406may be a solid state type or electromechanical type.

Referring toFIGS. 8 to 10, a 3-coil, variable reactor/auto-transformer apparatus510in accordance with a third embodiment is shown. Turning toFIG. 9, a schematic circuit diagram of the apparatus510ofFIG. 8is shown. The system500comprises a circuit that is similar to the prior art Korndorfer closed transition configuration, and has two separate coils for each AC power phase winding. The two coils are an upper coil593,594,595with a plurality of voltage taps, and a tower coil596,597,598of equal number of turns as the upper coil593,594,595. There is a magnetic core assembly comprising at least two part cores520,540. A pair of DC excitation coils570,580is wound around first part core520. Another pair of DC excitation coils550,560is wound around second part core540. An input connection300to each upper coil593,594,595of AC power phase windings is provided for connection to an AC power system.

An output connection310to a load from selected voltage taps of the upper coil593,594,595of AC power phase windings and to centre switch terminals is provided. A common point connection320to each lower coil of AC power phase windings596,597,598for connection to a common star point is provided. An input connection330to each pair of DC excitation coils550,560,570,580mounted on the first and second part cores520,540is provided. An output connection315to centre switch terminals is provided. The centre switch terminals enable switching the circuit from the auto-transformer connection of the first starting step to the variable reactor connection of the second starting stage. There is also a main switch501, a bypass contactor502and motor overload relay503. The motor overload relay503may be a thermal or an electronic relay. There are transformer contacts505,506,507. The transformer contacts505,506,507may be a solid state type or electromechanical type. The system500also has a common point504that is hard wired.

Referring toFIGS. 11 to 13, a perspective view of a 2-coil variable reactor/auto-transformer apparatus610according to a fourth embodiment is shown. The system600comprises a circuit that is similar to the prior art Korndorfer closed transition configuration, with two separate coils for each AC power phase winding690A,690B,691A,691B. The two coils are an upper coil690A,690B with a plurality of voltage taps, and a lower coil691A,691B of equal number of turns. There is centre switch terminal to enable switching the circuit from the auto-transformer connection of the first starting step to the variable reactor connection of the second starting stage. There is also a main switch601, a bypass contactor602and motor overload relay603. The motor overload relay603may be a thermal or an electronic relay. There are transformer contacts605,606,607. The transformer contacts605,606,607may be a solid state type or electromechanical type. The system600also has a common point604that is hard wired.