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Common mistakes make by frequency converter designers
Designers must fully understand the mechanical systems that the frequency converter is driving. The effects of friction, temperature, and gearing are all crucial to the proper application of inverters. In many installations, frequency converters need to be protected from electrical noise and unreliable input power. The proper usage of branch protection, line reactors, and semiconductor fuses is often learned only after a frequency converter failure.
Frequency converter designers should consider adding simplified PLC functions. This is particularly useful for applications where a PLC (or programmable relay) might enhance efficiency and process productivity but would not be cost effective.
Choosing the wrong type of frequency converter for an application can greatly affect productivity (how to selection a frequency converter?). An example of this would be using a volts-per-Hertz inverter where the accuracy and extended speed range of a flux vector frequency converter would allow more consistent results. Also, incorrectly sizing a frequency converter can cause nuisance tripping and unwanted shutdowns. Peak overload and the frequency converter's overload capacity should be taken into account.
One potential mistake that designers can make is not considering speed regulation of the frequency converters they are choosing. Tighter speed regulation (typically ±0.05%) is often the benefit of an encoder-based frequency converter, but costs more up front. Lower speed regulation (typically -3% to -5%), which is offered by various ac induction motor systems, may suit the application fine, while saving costs for the designer. Matching the required speed regulation of the product to the application always leads to increased productivity.
Inexpensive frequency converters use small IGBTs with fast switching times and simple filters. The fast switching times translate into an increased efficiency for the IGBTs themselves, but on the downside, cause electrical noise that can harm motors. Improperly filtered noise combined with long cables can cause motor problems and lower productivity.
Frequency converter designers should consider adding simplified PLC functions. This is particularly useful for applications where a PLC (or programmable relay) might enhance efficiency and process productivity but would not be cost effective.
Choosing the wrong type of frequency converter for an application can greatly affect productivity (how to selection a frequency converter?). An example of this would be using a volts-per-Hertz inverter where the accuracy and extended speed range of a flux vector frequency converter would allow more consistent results. Also, incorrectly sizing a frequency converter can cause nuisance tripping and unwanted shutdowns. Peak overload and the frequency converter's overload capacity should be taken into account.
One potential mistake that designers can make is not considering speed regulation of the frequency converters they are choosing. Tighter speed regulation (typically ±0.05%) is often the benefit of an encoder-based frequency converter, but costs more up front. Lower speed regulation (typically -3% to -5%), which is offered by various ac induction motor systems, may suit the application fine, while saving costs for the designer. Matching the required speed regulation of the product to the application always leads to increased productivity.
Inexpensive frequency converters use small IGBTs with fast switching times and simple filters. The fast switching times translate into an increased efficiency for the IGBTs themselves, but on the downside, cause electrical noise that can harm motors. Improperly filtered noise combined with long cables can cause motor problems and lower productivity.
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