4

The cycloconverter

f1
S

T2

T1

T1

T1

n2

n1 B

iA i+ u+ uiS iR uR ie uS uT iT

SM
3

f2

Figure 7 Basic circuit diagram of the Cycloconverter fed synchronous motor

S i+,i-,u+,uT1, T2 n1 ie n2 iR , iS, iT SM uR , uS, uT A, B f1 f2

= Circuit-breaker = Output current and voltage = Converter transformer = Stator converter = Excitation current = Excitation converter = Stator currents = Synchronous motor = Stator voltages = Three-phase bridges connected in antiparallel = Mains frequency = Frequency of synchronous motor

4.1

Design and principle

The Cycloconverter is a frequency changer which converts a polyphase voltage with the frequency f1 into a single or polyphase voltage with a different, lower frequency f2. Energy can be transferred in either direction directly without a D.C. link. Consequently, the Cycloconverter is classified in the group of linecommutated converters. By virtue of its design, the Cycloconverter consists of reversible, usually suppressed-half Thyristor converters as known and used for years with D.C. drive. The basic unit is generally a three-phase bridge with which a three-phase voltage can be converted into a direct voltage. In this way, the converter output is a positive, rectified voltage in rectifier operation or a negative, rectified voltage in inverter operation. By means of phase-angle control this voltage can be continuously varied from zero to roughly the maximum phase-to- phase a.c. voltage, both in the positive and the negative polarity.

Figure 8 Operating range of a Cycloconverter (for one phase)

If the output current of such a converter is controlled to obtain a sinusoidal shape with a given frequency like it is shown on Figure 9, the arrangement acts as a frequency converter and is called a Cycloconverter. The reactive power of commutation required for the current transfer between the individual legs of each bridge is obtained from the power system. Only one of the antiparallel bridges is in operation at a time, so that circulating currents are entirely excluded. When the current reverses, i.e. when the current commutates to the antiparallel bridge, a short dead time is observed before this antiparallel bridge is fired.

Figure 9 Mains and Output voltage and Mains Output frequency of a Cycloconverter in Sinusoidal operation

Since the output frequency of the Cycloconverter is derived from the main frequency, it must be lower than the latter. In practice the output frequency f2 can be continuously varied from zero to about 50 percent of the system frequency. The maximum speed attainable by the drive thus amounts to nearly half the synchronous speed referred to the system frequency. In view of this physical limit, the Cycloconverter is used for low-speed drives typically like Ball Mills. The maximum attainable speed can be calculated from the following formula: f1 n max < 60 where: f1 p = = [r/min] p power - system frequency [Hz] number of pairs of poles of the motor

4.2

Methods of Controlling the Cycloconverter

Two different modes of operation are used to control the entire speed range (i.e. frequency range) of the drive: -Sinusoidal operation -Trapezoidal operation In the sinusoidal mode for the lower speed range, the machine voltages, and therefore the voltages to be generated by the Cycloconverter, are low. The converters always operate with partial firing angles and the output voltages retain their mean sinusoidal characteristic. This operating mode is possible as long as the converters do not attain their natural control limits as the output voltage amplitudes increase (rectifier and inverter in their end position). One drawback is the relatively high reactive power required for control. At low speeds, this results in a correspondingly low power factor for the mains. To improve the mains power factor the trapezoidal mode is employed in the upper speed range, where the Cycloconverter also has to supply higher voltages. This mode also utilizes the static converters more effectively with respect to the voltage. In the trapezoidal mode the static converters are operated at their firing limits for as long as possible in the low-frequency cycle 1/f2, i.e. during operation as a motor with the rectifier in its end position and during operation as a brake with the inverter in its end position. The control angle only deviates from this in the area where the polarity of the converter output voltage changes. Since there is no star connection between the machine and the Cycloconverter, the machine voltages still retain their sinusoidal shape.

A B

Figure 10 Mains and Output voltage and Mains Output frequency of a Cycloconverter in Trapezoidal operation

The longer the converters are operated with a full firing angle over one cycle of the machine frequency f2, the better the mains power factor. The slopes of the trapezoidal characteristic do have a certain limit. If the voltage system of the synchronous machine is to remain controllable, not more than one converter may ever be operated with the full firing angle at any one time. This condition is satisfied when each converter is in its end position for no longer than /3 in a half-cycle of f2. This makes utilization of the Cycloconverter more effective with respect to the voltage. In this mode the peak value of the machine voltage for the fundamental oscillation is 15% higher than the maximum instantaneous value of the converter output voltage. 4.3 Physical design of the Cycloconverter

In order to operate in harmful dusty areas, the complete Cycloconverter and the auxiliaries of the motor, such as cooling, and of the ball mill, such as bearing, lubrication etc., are housed in a closed container. The container provides adequate protection against ingress of dust and water. Picture 2 shows Cycloconverter and auxiliaries incorporated in a container with IP55 protection degree.

Picture 2 Shows Cycloconverter and auxiliaries incorporated in a container with IP55 protection degree.

An additional and important advantage of this concept is that all necessary components are already installed, cabled and tested prior to shipment. This means that installation and subsequent commissioning at site requires only the connection of external cables and checking of external signals. As a consequence only a very short commissioning time is required.

4.2.4

Efficiency

Efficiency definition of a drive system is only correct if the overall efficiency of the drive system is defined. The overall efficiency takes into account all individual efficiencies such as those for the transformer, the converter, the motor, etc. Gearless Mill Drives are recognized by their generally high efficiency. The following efficiency calculation is based on an operating point of 95 % of the speed. The values given in table 3 and used for the following efficiency calculation are based primarily on measured values. P output (kW) Equipment Main transformer Excitation Transformer Cycloconverter Excitation converter Motor ventilating and wind age loss Motor core and stray load loss Motor I2 R loss Total: Losses (kW) 69.1 3.3 54 2.3 40 36 129 333.7
Table 3 Losses for efficiency calculation

(shaft power)

5613

Poutput h = * 100 Poutput +Plosses

5613 [kW] h = = 94,3 % 5613 + 333.7 [kW]

Efficiency = 94.3 %

5.

Sistem Advantages

A Gearless Drive offers the following intrinsic advantages compared to other drive systems: No gear box No lubrication system for gear box Minimum number of mechanical components Minimum number of electrical components It operates virtually wear free No inching drive Minimum space requirements Variable speed, base condition for process optimization Minimum maintenance High availability / reliability Minimum spare parts requirements Smooth start up Accurate positioning without auxiliary equipment Bi-directional operation possible without any extra cost Big air gap between the motor and the stator (low sensitivity for deformations or displacements of the mill body) continuous air gap monitoring between rotor and stator gives clear indication of critical operating conditions, allowing timely shut down before damage occurs

Summary Bosowa Cement experience is a clear breakthrough leading to the optimal lay-out of Cement Grinding installation with capacity of 150 T/H capacity and above. The ideal lay-out from technical, operation and economical point of view added to friendly environmental installation would be the closed grinding circuit including Ball mill with Gearless Motor, high efficiency separator and an Electro-filter Precipitator (EP). Our experience on Cement Grinding configuration with GMD demonstrates highest operational availability