Driving means formed by induction motor and method for starting the same

Abstract: An induction motor as driving apparatus includes two stators (9) in which two rotor cores (3,4) each formed in a squirrel cage type are rotatably mounted on a common rotary axis (2); two stators (14,15) which respectively surround the two rotors (9) and on which stator windings (12,13) are respectively wound; and a switching device (20) which supplies power by sequentially switching between one side of either the one stator winding (12) or the other stator winding (13) and both the sides of the two stator windings (12,13). Starting characteristics and operation characteristics of an induction motor are improved thereby enlarging applications of the induction motor, enhancing operation efficiency, and reducing power consumption.

Description: BACKGROUND OF THE INVENTION (1) Field of the Invention The present invention relates to a driving means which is formed by a single induction motor integrally having two stators and two rotors, or which is formed by two induction motors for driving a common load, and a method for starting the operation of such driving means. (2) Description of the Related Art An induction motor having a single rotor and a plurality of stators which can start smoothly and output a high driving torque in a wide range from a low speed range to a high speed range, is described in EP-A-0 421 656. Generally, there have been known a line-starting method and a star-delta connection method as the starting method of an induction motor for driving a load. The line-starting method achieves a sufficient torque but, on the other hand, a large current flows at the starting operation in the case of a large capacity motor so that the electrical installation cost is inevitably very large. In the case where the star-delta starter is used, although the current at the starting operation can be limited to be low, the starting torque is also lowered. Because the starting torque is lowered, it becomes necessary to use a larger capacity induction motor, resulting in raising the cost of the induction motor. Here, with respect to the case where a star-delta starter of a general kind is used, the resulting torque current and input characteristics are shown in Figs. 7, 8 and 9. Methods for starting an induction motor have been disclosed in, for example, Japanese Patent Application Kokai Publication Nos. Sho 51-104513 and Sho 52-54112, and a number of methods for starting the motor by appropriately switching the stator windings between the star- and delta connection are known. In these methods, the stator windings are constituted by a plurality of circuits (windings) and, during the starting operation, the starting current is controlled to be low by the switching of these windings respectively to star-connections or delta-connections. Each of the above described methods enables the limiting of the starting current but it remains as a star-delta starting method so that, due to the reduction of the starting current, the starting torque is inevitably lowered. Thus, the device that employs the star-delta starting cannot be applied other than to such loads as a load having square-law decreasing characteristics in which a load is smaller than the starting torque in the star-connections for the star-delta starting so that, although the motor is an induction motor, its application is limited to and the motor cannot serve as a general purpose induction motor. Further, the induction motor employing the above starting methods lacks characteristics of intermediate torque which is larger than the starting torque and which enables the continuous operation. In a prior art example wherein there are a plurality of individual stator windings provided on a single stator-core, when power is supplied only to one of these stator windings, the deterioration in magnetomotive force waves is caused, resulting in various defects such as fluctuations of torque characteristics, starting failure, and lowered operation efficiency, and the resulting structure cannot be used in practice. The induction motor that is started by the line-starting method is used mostly for a load in which a load is very small or an inertia is large, and thus it embodies a method that is dictated by the starting torque of the induction motor. However, the period in which the load having a large inertia requires a large torque is up to the time when the rotation speed reaches its rated speed. Once the rated rotation speed is reached, the rotation speed is unlikely to change especially because of the large inertia so that a smaller torque is sufficient after the starting operation. However, despite the fact that only the small torque is needed subsequent to the starting, the output cannot be lowered after the starting only because the induction motor is of the line-starting type and, under the existing state, unnecessary power is being wasted. Thus, there is a demand for the development of a driving device by an induction motor and a method for starting the same in which the starting current is reduced during the starting operation and yet to generate a large torque, and which enables the power-saved operation during the rated operation. To meet this demand, a starting compensator operation (condorfer starting) and, recently, an inverter starting operation are available, but each of these involves a device with a very large cost. The induction motor is often used by being connected to an emergency electric generating installation. The induction motor is then used as a motor for driving an emergency fire extinguishing installation such as a pump. As to a prime mover constituting a private power generating installation for emergency purposes and a generator driven by the prime mover, the size of the prime mover and the capacity of the generator are selected based on a coefficient which is calculated on a load current change rate and an input change rate with respect to the motor rating during the starting operation period from the time when the motor which becomes the load of the electric generating installation starts to the time when the rated operation speed is reached. Therefore, as a matter of course, a study has been made not only for reducing starting current during the starting operation but also for reducing the rates of load current and input variations in the star-delta switching during the starting operation. This is because, by the reduction of the required capacity of the generator and the prime mover, it is possible to reduce the installation cost. Also, the fire extinguishing installation such as a pump which is operated in an emergency is one in which the time required for reaching the rated operation is made as short as possible. To this end, it is desired that an induction motor as a driving apparatus be developed in which, while the load current change rate and the input change rate are given due consideration, the starting torque is made large-and the starting operation period is made short to the fullest extent, and yet the structure of the apparatus be made simpler as possible. The starting methods with which the attempt has been made to realize the desire includes a closed star-delta starting, a reactor starting, and a condorfer starting including a special type of condorfer starting. Where the induction motor is used in, for example, a compressor in which the operation is frequently started and stopped or undergoes frequent changes between high and low loads, the induction motor repeats frequent stopping and re-starting operations and, due to the starting current during the re-starting operation, the induction motor suffers from an intense rise of temperature thus causing the motor to become inoperable. In a large induction motor, a star-delta starting operation has been used in order to limit the starting current during the starting period, but the star-starting frequently fails the re-starting because of the low starting torque, and this requires the use of an induction motor of a higher ranking in its capacity. Also, for driving a compressor, an unload type motor is available in which the motor is constantly rotating and unnecessary air is appropriately being exhausted but, since the motor is constantly rotated, the running cost becomes high. For the above reasons, each of the conventional induction motors as described above has been such that unnecessary power is consumed because of a large inertia or that, although the motor is for general purposes, a special starting device is required in order to limit the starting current, and this has rendered the motor to be that for special use and no longer that for general purposes. Thus, there has been a demand for the development of technology enabling the provision of an induction motor as a driving apparatus which is low in cost and which, as a motor that can cope with a large inertia without requiring any such special high cost starting device as required in general purpose motor, as a motor that can be used in a private power generating installation, and as a motor that can be used in a compressor that repeats starting and stopping operations and is differently used depending on a loaded state and an unloaded state, can be used efficiently for any purposes while fully exhibiting its capability as an induction motor. The selection of an output of an ordinary general purpose induction motor which is constituted by a single rotor and a single stator and which has characteristics of the starting torque being smaller than those of the rated torque, is not based on the rated torque as reference but is based on the starting torque of the induction motor with reference to the load torque and, especially when the motor is star-delta started, the starting torque inevitably becomes small thereby requiring a kind of motor whose output is of a higher ranking, that is, a higher capacity. This requirement is more conspicuous when the load during the starting operation is high. Thus, there is a demand for techniques for developing an induction motor as a driving apparatus and a method for starting the operation of the same, which is constituted by a general purpose induction motor but which can be used in connection with a variety of loads without the need of selecting a kind of induction motor in which its output is unnecessarily ranked up. SUMMARY OF THE INVENTION Therefore, an object of the invention is to overcome the problems existing in the conventional driving means and to provide an improved driving means in which starting characteristics and operation characteristics of an induction motor are improved. According to the invention, there is provided a method for supplying power to an induction motor having a first power generation means constituted by a first rotor and a first stator which surrounds the first rotor and on which a first stator winding is wound and a second power generation means constituted by a second rotor and a second stator which surrounds the second rotor and on which a second stator winding is wound, the first and second power generation means being connected to a common load, the method comprising the following sequential steps: a first step of supplying power to the first and second stator windings after both the windings are respectively connected in a star-form; a second step of supplying power to the first and second stator windings after a connection of the second stator winding is changed into a delta-form while a connection of the first stator winding remains as the star-form; and a third step of supplying power to the first and second stator windings after the connection of the first stator winding is changed into a delta-form while the connection of the second stator winding remains as the delta-form. According to a further embodiment of the invention, the induction motor may comprise a first induction motor formed by the first rotor and the first stator and a second induction motor formed by the second rotor and the second stator. Also, a switching device is arranged such that both the stator windings can respectively be switched over between star connections and delta connections with respect to the power source. With the above described switching device, it is possible to provide, at low cost, means which can be used when, for example, a load has a large inertia or it is needed to make small the magnitude of current/input changes during the connection switching. This is made possible by a starting method in which firstly the power supplying is made by respectively star-connecting the two stator windings, secondly one of the stator windings is delta-connected, and thirdly the power supplying is made by respectively delta connecting the two stator windings. First, since the induction motor as the driving apparatus according to the invention comprises two squirrel cage type rotors which are rotatable on a common rotary axis, two stators which respectively surround the two rotors and on which stator windings are wound, and a switching device which supplies power by sequentially switching between one and the other of the stator windings or switching to one of the stator windings, it is possible to use this induction motor as a general purpose induction motor, which can be operated in a power saving manner after a line-starting operation, or can make a star-delta starting operation. Moreover, since there are provided two sets of the stators and two sets of the rotors, the supplying power only to one of the sets thereof enables the continuous operation with an intermediate torque. This has not readily been realized by the conventional induction motor. The induction motor structure as the driving apparatus comprises two induction motors which are connected for driving a common load and a switching device which supplies power by sequentially switching between stator windings of one of the two induction motors and stator windings of the other of the two induction motors, or switching to the stator windings of either of the two induction motors. Thus, not only is it possible to use each of the motors, as it is, as general purpose induction motor, it is possible to make the starting with one of the induction motors as a line-starting operation, in which case the starting torque of this one induction motor becomes larger than when an induction motor having the same total output as two of such induction motors is star-delta connected for the starting operation. Also, in no cases will the starting current exceed the rated current as being the total of the two induction motors. The switching device is so arranged that both the stator windings can switched over between the star-connections and the delta-connections with respect to the power source, and this enables the induction motor as the driving device to cope with all kinds of load torques. Moreover, this switching device can be constructed using a simple switch having a capacity about half that of a conventional switch, with the number of such switches being only two to five and also the rating being half that of the conventional switch, thus enabling the realization of the switching device at a low cost. Other functions, for example, the switching control of the switching device which is made by sequential switching based on such values as the number of revolutions, time periods and load torques, can be realized by conventional techniques. The method for the starting of operation in which the switching device operates such that, firstly the two stator windings are parallel-star-connected with the power supplying being made to both the stator windings, secondly either one of the stator windings is delta-connected, and thirdly the two stator windings are parallel-delta-connected, is best suited to a square-law decreasing load such as a disaster prevention pump or a disaster prevention fan which becomes a load of a private power generating installation. That is, when the starting is made by the parallel-star-connections, the ratio is 1/3 both in the current and the torque as compared with that of the torque under the parallel-delta connections. The operation begins with the parallel-star-connections and, at the intersection with the load torque, one of the stator windings is delta-connected, followed by the switching to the delta-connections and the star-connections in parallel. At this switching, the current of the independent delta-connections is 1/2 that of the parallel delta-connections and the current of the independent star-connections is 1/6 that of the parallel-delta-connections so that the current ratio changes from 1/3 to 4/6. Further, the operation takes place by the parallel-star-delta connections and, at the intersection with the load torque, the switching is made to the next parallel-star-delta connections. At this time, the current ratio changes from 4/6 to 1. The current ratio change at the first switching is from 1/3 to 4/6, and this is incomparably small when compared with a large change of 1/3 to 1 during the conventional star-delta switch starting operation. The current change to take place at the next switching is from 4/6 to 1. When this switching takes place, the number of revolutions has already approached close to the rated revolutions and the load current has been reduced to a small value, so that any influence this change from 4/6 to 1 may bring about is extremely small as compared with that in the prior art. Similarly, the change in the input is reduced to an extremely small value as compared with that in the conventional star-delta switching. This is accountable, as already explained, by the fact that, since the two sets of the stators and the rotors are provided, the induction motors made up of the respective sets thereof effectively funotion to produce a consolidated torque. Moreover, assuming that each of them is constructed by a motor having the same capacity, the torque of each of them is 1/2 that in the conventional example, so that the capacity of the electric circuits to be incorporated therein can be smaller and the cost is lower accordingly, thus offering advantages in both quality and cost aspects. BRIEF DESCRIPTION OF THE DRAWINGS The above and other objects, features and advantages of the present invention will be apparent from the following description of preferred embodiments of the invention explained with reference to the accompanying drawings, in which: Fig. 1 is a sectional view of an induction motor as a driving means according to the invention; Figs. 2A - 2C are structural diagrams of another induction motor as a driving means according to the invention; Fig. 3 is a graph showing torque characteristics obtained by the respective connections according to the invention; Fig. 4 is a graph showing current characteristics obtained by the respective connections according to the invention; Fig. 5 is a graph showing input characteristics obtained by the respective connections according to the invention; Fig. 6 is a diagram showing connections according to the invention that are effective when a load is a pump or fan used in an emergency private power generating installation; Fig. 7 is graph showing torque characteristics obtained by the star-delta switching in a conventional induction motor; Fig. 8 is a graph showing current characteristics obtained by the star-delta switching in a conventional induction motor; and Fig. 9 is a graph showing input characteristics obtained by the star-delta switching in a conventional induction motor. PREFERRED EMBODIMENTS OF THE INVENTION A first preferred embodiment of the invention is explained with reference to Fig. 1. First the construction of an induction motor according to the invention is explained. In the induction motor represented by the numeral 1, two rotor cores 3 and 4 are axially mounted on a rotary shaft 2 with a predetermined space being provided therebetween, rotor conductors 5 and 6 are provided respectively on the rotor cores 3 and 4 and, at two sides of the rotor cores 3 and 4, the rotor conductors 5 and 6 are formed in a squirrel cage form by being short-circuited by short-circuiting rings 7 and 8, thereby forming a unitary rotor structure 9 having the two rotors. Further, stators 14 and 15 comprise stator cores 10 and 11 that are provided so as to surround the respective rotor cores 3 and 4 with predetermined spaces being provided therebetween and stator windings 12 and 13 that are wound respectively on the stator cores 10 and 11. On the two sides of the machine frame 16 on which the stators 14 and 15 are provided, there are provided a bearing 19 containing bearing balls 17 and a bearing 20 containing bearing balls 18 and, due to these bearing balls, the shaft 2 of the rotor structure 9 that is axially supported rotates coaxially with the stators 14 and 15. Also, the stator windings 12 and 13 of the induction motor are connected to a switching device 25, and the induction motor forms a driving apparatus. According to the invention, in order to realize a compact induction motor, two rotors and two stators are provided in parallel in one machine frame, which can also be handled at an installation site in the same manner as for the conventional induction motor. A second preferred embodiment of the invention is explained with reference to Fig. 2. Fig. 2 shows an induction motor structure as a driving apparatus in which two general purpose induction motors are used for driving a common load. Fig. 2A shows an arrangement in which the induction motors 23 and 24 are coupled to a load 22 from its two sides through respective coupling members 27, and the induction motors 23 and 24 are electrically connected to a power source 26 through a switching device 25. Fig. 2B shows an arrangement in which the induction motor 23 drives the load 22 through the coupling members 27, and the induction motor 24 drives the load through a pulley 28 and a belt 29. The connection between the induction motors 23 and 24 and the power source 26 is the same as that explained with reference to Fig. 2A. Fig. 2C shows an arrangement in which both the induction motor 23 and the induction motor 24 are coupled to the load 22 for driving it through the pulley 28 and the belt 29. Here, the connection between the induction motors 23 and 24 and the power source 26 is also the same as that explained with reference to Fig. 2A. In the above cases, the motors required are two general purpose induction motors each of which may only have half the capacity that is required for the load. Thus, the cost of the induction motors, that is, the total cost of the two induction motors each having half the required capacity, will not exceed the cost of the induction motor having the required capacity. Now, Fig. 7 is referred to for explaining the switching device 25 which is constructed as a unit with the induction motor 1. In controlling the switching in this switching device, the effective controlling methods include those in which, by detecting changes due to the load to the induction motor in any of or in combination of values of revolutions, load currents, temperatures and times, the switching is made based on the detected values. Where the switching device employs a simple sequence and use is made of, for example, only the times or the revolutions for the switching operation, the handling of the switching device will be exactly the same as that for the prior art induction motor. It is also possible to use the switching device in combination with other control devices or control boards (not shown) for the controlling of the switching device. The etator windings 12 and 13 in the switching device 25 and various connections between the stator windings 12 and 13 and the switches S are shown in Fig. 7. Changes in torques and currents due to the switching are shown in Figs. 3 to 5. Since the two induction motors 23 and 24 and the switching device 25 shown in Fig. 2 are the same as those in the first embodiment of the invention, the explanation to follow hereunder is omitted for the second embodiment. Fig. 6 shows an example of connections in which the stator windings 12 and 13 and the switches S are connected in the switching device 25. Here, one side of the 3-phase stator windings 12 is connected to power sources R, S and T through a main switch S1 while the other side of the 3-phase stator windings 12 is connected to a switch S2 for star-connections. The 3-phase stator winding 12 is delta-connected through the switch S4. One side of the 3-phase stator windings 13 is connected to the power sources R, S and T through the 3-phase stator winding 12 through the switch S1. The other side of the 3-phase stator winding 13 is connected to a switch S5 for star-connections. Also, the 3-phase stator winding 13 is delta-connected by a switch S6. Therefore, the 3-phase stator winding 12 results in star-connections by the switch S2 and in delta-connections by the switch S4. Further, the 3-phase stator winding 13 results in star-connections by the switch S5 and in delta-connections by the switch S6. Next, the explanation is made for the case in which, by using the induction motor with the switching device as shown in Fig. 6, the starting operation takes place in a square-law decreasing load such as a pump or a disaster prevention fan which becomes a load of a private power generating installation. In this case, the starting is made by the switching device in the following manner. In the state in which all the switches are opened, firstly the switches S2 and S5 are closed so that two stator windings 12 and 13 are parallel-star-connected and then the switch S1 is closed so that the power supply is made to the two 3-phase stator windings 12 and 13. Secondly, the switch S2 of one stator winding 12 is opened and is delta-connected by closing the switch S4. Thirdly, the switch S5 of the 3-phase stator winding 13 is opened and the switch S6 is closed whereby the two 3-phase stator windings 12 and 13 are parallel-delta-connected. The torque changes by the switching of the connections and the resulting current and input characteristics are as follows. That is, when the starting is made by the parallel-star-connections, the ratio becomes 1/3 both in the current and the torque as compared with those in the parallel-delta connections. The operation takes place in the parallel-star-connections and, at the intersection A (Fig. 3) with the load torque, one side 3-phase stator winding 12 is delta-connected and is switched in parallel with the star-connections of the other side 3-phase stator winding 13. At the switching at this time, the current of the 3-phase stator winding 12 of the independent delta-connections is 1/2 of that in the parallel-delta-connections and that of the 3-phase stator winding 13 of the independent delta-connections is 1/6, and this means that the current changes from the ratio 1/3 to the ratio 4/6. Further, the operation takes place under the parallel-star-delta-connections and, at the intersection B with the load torque, the switching is made to the next parallel-delta-connections. The current then changes from the ratio 4/6 to the ratio 1. The current change at the first intersection A is from 1/3 to 4/6. This change is incomparably smaller than a large change from the ratio 1/3 to the ratio 1 in the conventional star-delta switching start operation. At the next intersection B, the current change is from 4/6 to 1 and, since this switching takes place at a point when the speed is already close to the rated number of revolutions, the value of the load current is very small so that any influence that the change from the 4/6 to 1 may bring about is very small when compared with the prior art. Also, if, by the switching device 20, the torque by the single delta-connections alone is added to the next torque of the parallel-star-connections, the change ratios of the input and the current can further be made smaller. These advantages result because, as already explained, the two sets of 3-phase stator windings constitute two induction motors which function effectively as a unit for producing the necessary torque. Furthermore, if the two motors are of the equal capacity, the rated capacity of each of them can be 1/2 that of the conventional motor, and the circuits to be incorporated may employ those of proportionally lower capacity and cost so that there are significant advantages in both the aspects of performance and cost. In the above embodiment, by using, for example, the connections as shown in Fig. 6, if the switch S2 is closed with the connections being changed to single star-connections, the torque characteristics will become half those of the parallel star-connections shown in Fig. 3, thus providing the torque characteristics which are better suited to the square-law decreasing characteristic load. The conventional induction motor of the kind to which the present invention relates has been such that it consumes unnecessary power for a large inertia or that, although the motor is for general purposes, a special starting device is required in order to limit the starting current, thus making the motor a special use motor and no longer a general purpose motor. The present invention provides an induction motor which is low in cost and which can be used efficiently for any purposes while fully exhibiting its capability as an induction motor, that is, as a motor that can cope with a large inertia without requiring any such special high cost starting device as required in the conventional general purpose motor, as a motor that can be used in a private power generating installation, and as a motor that can be used in a compressor that repeats starting and stopping operations and is differently used depending on a loaded state and an unloaded state. The present invention also provides a method for starting the operation of the induction motor.

Claims: A method for supplying power to an induction motor having a first power generation means constituted by a first rotor (4,6) and a first stator (15) which surrounds said first rotor and on which a first stator winding (13) is wound and a second power generation means constituted by a second rotor (3,5) and a second stator (14) which surrounds said second rotor and on which a second stator winding (12) is wound, said first and second power generation means being connected to a common load, said method characterized by comprising the following sequential steps: a first step of supplying power to said first and second stator windings (13,12) after both the windings are respectively connected in a star-form; a second step of supplying power to said first and second stator windings (13,12) after a connection of said second stator winding (12) is changed into a delta-form while a connection of said first stator winding (13) remains as the star-form; and a third step of supplying power to said first and second stator windings (13.12) after the connection of said first stator winding (13) is changed into a delta-form while the connection of said second stator winding (12) remains as the delta-form. A method for supplying power to an induction motor according to claim 1, further comprising, after said second step, a fourth step of stopping the power supply to said first stator winding (13) of the star-form and supplying power only to said second stator winding of the delta-form. A method for supplying power to an induction motor according to claim 2, further comprising, after said fourth step, a fifth step of supplying power to said first stator winding (13) after it is again changed into the star-form while the power supply to said second stator winding (12) of the delta-form is being maintained. A method for supplying power to an induction motor according to any one of the claims 1, 2 and 3, further comprising, before said first step, a sixth step of supplying power only to one of said first and second stator windings (13,12) after it is connected into the star-form. A method for supplying power to an induction motor according to claim 1, wherein said induction motor is a single motor (1) in which said first and second rotors are mounted on a common rotary shaft (2) with a predetermined space being provided therebetween and said first and second stators are surroundingly facing said first and second rotors, respectively. A method for supplying power to an induction motor according to claim 1, wherein said induction motor comprises a first induction motor (23) formed by said first rotor and said first stator and a second induction motor (24) formed by said second rotor and said second stator. A method for supplying power to an induction motor according to claim 6, wherein each of said first and second induction motors (23,24) has a rotary shaft directly connected to said load (22). A method for supplying power to an induction motor according to claim 6, wherein said first induction motor (23) has a rotary shaft (2) directly connected to said load (22), and said second induction motor (24) has a rotary shaft (2) coupled to said load (22) through a transmission means (29). A method for supplying power to an induction motor according to claim 6, wherein each of said first and second induction motors (23.24) has a rotary shaft (2) coupled to said load (22) through a transmission means (29).

Inventors: HIDAKA MANABU, KUMAMOTO KAZUO, MASAKI TADASHI, SATAKE SATORU, HIDAKA, MANABU, KUMAMOTO, KAZUO, MASAKI, TADASHI, SATAKE, SATORU, Hidaka, Manabu, c/o Satake Corporation, Kumamoto, Kazuo, c/o Satake Corporation, Masaki, Tadashi, c/o Satake Corporation
Applicants: SATAKE ENG CO LTD, SATAKE CORPORATION
Application year: 1996
Main classification: H02P1
IPC codes: H02P1, H02K17, H02K16