Processing spindles, turbo blowers or compressors, gas turbines, expanders or vacuum pumps: For these and many other applications in which output frequencies of over 2,000 Hz are required, KEB Automation now offers a solution with the newly developed “High Speed Drives”. In combination with the Combiline Z2 sine filters, motors are particularly protected at high speeds and the system efficiency is increased effectively. Innovative simulation methods are available for the fast and resource-saving commissioning of the High Speed Drives.
In high-speed applications, motors have to reach 100,000 revolutions per minute and more – this can be achieved efficiently with the new High Speed Drives from KEB. With an output of up to 450 kW and switching frequencies from 2 kHz to 16 kHz, the robust and particularly compact inverters are optimized for demanding applications. “The High Speed Drives enable high output frequencies of up to 2,000 Hz. Thanks to a special 3C3 coating on the circuit board, the devices are designed for use in harsh environmental conditions, such as in sewage treatment plants,” says Fabian Fischer, Team Leader Application Sales at KEB Automation. “In addition, liquid-cooled and air-cooled versions of the inverter are available. This allows us to respond flexibly to the individual needs of our customers.” The liquid-cooled version of the drive is also characterized by a high inlet temperature of 55 degrees Celsius. Like the air-cooled version, it also offers the option of supplying magnetic bearing controllers via the DC link voltage. This effectively protects the sensitive magnetic bearings even in the event of voltage dips. Sensorless speed control is available for all common high-speed motor types – from IPM and PM to asynchronous or synchronous reluctance motors.
Filter technology for high-speed applications
In combination with the Combiline Z2 sine filters, users benefit from a system solution with coordinated components. The output filters consist of a motor choke and a capacitor and can be flexibly adapted to different applications thanks to the modular concept. “The motor choke is available separately for less sensitive motors. Machine and system manufacturers also have a high degree of freedom when installing the filters in the control cabinet,” says Fischer. The high-speed filters in the Z2 series have a high efficiency of more than 99.9% and significantly reduce harmonic losses in the motor. Last but not least, the filters improve the EMC behavior of the overall drive and enable cable lengths of more than 100 meters. “Compared to multilevel converters, our customers achieve higher system efficiency at comparable or even lower costs and increased performance in the field weakening range with the KEB system consisting of a 2-level drive controller and sine filter,” says Fischer, summarizing the advantages of the solution.
Simulation saves expensive practical tests
The company relies on Matlab/Simulink for the optimal interaction of all high-speed components. The software is an established standard for modeling and simulating complex, dynamic systems. Based on the available motor data, reliable predictions can be made about the static and temporal progression of the speed or voltage, among other things. Complex practical tests are no longer necessary due to the extensive simulation options. The company also uses virtual drive design by means of “Hardware in the Loop” (HIL). Commissioning is simulated in advance on the basis of the motor, sine filter and inverter data, without the need for real components. Variations of the system-related parameters are therefore possible at any time without risk and the finished parameterization is already available for the subsequent real commissioning. This results in tangible time and cost savings throughout the entire project phase.
Source: KEB
