CHAPTER 3

METHODOLOGY


3.1 INTRODUCTION

In this chapter three, the methods and techniques used to conduct this project are
deliberated step by step with clear figures. Methodology is a vital part where it
precisely describes and discusses the methods to achieve and accomplish the objectives
of this project. This system consists of four sections. The sections explained clearly in
flow chart system.

3.2 FLOW CHART OF SYSTEM

In first section, prepares suitable raw materials for mechanical parts and electrical
components for electrical parts. In this section, also need to prepare bill of material list
to clarify all the required components and materials are enough to proceed to second
section.

In second section, need to design all the required electrical circuit using Protheus,
Multisim and Fritzing software and mechanical parts using CATIA software. In details
for electrical part, need to design dual power supply circuit, PWM signal wave
generating circuit using discrete components included with three-phase sine wave
generation circuit, triangular wave generating circuit, comparator circuit, gate drive
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optocoupler circuit and driver circuit of IGBTs and also closed-loop controller circuit.
In mechanical part, need to design shaft of the sensor and protective box for whole
circuit boards.

In third section, process of fabrication will continue. Here, first all the
mechanical part will be assembled and then electrical circuit board will be fixed on
assembled mechanical parts.

Finally, in section four, test the all the parts and run the experiment. During
experiment run, need to collect the data and analysis data for chapter 4.Then, make the
final thesis report. This flow of process is shown in figure 3.1.



Figure 3.1: Flow chart of system
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3.2 SYSTEM BLOCK DIAGRAM

Figure 3.2 shows the system block diagram of the adjustable speed drive of
three-phase induction motor using discrete components. When power is supplied,
rectifier rectifies the supplied power AC to DC. The power processing unit consist of
IGBT enables the induction motor to run and drive the load (induction motor). The
optical encoder calculate the rotation per minute (RPM) of the induction motor. So,
when there are any changes needed in speed, it goes to closed-loop controller. The
controllers embody the control laws governing the load and motor characteristics and
their interactions. There are strategies have been formulated for adjustable speed drives
and controllers implement their algorithm through PWM signal wave generating circuit,
triangular circuit, optocoupler circuit and IGBT driver circuit.



Figure 3.2: System block diagram of ASD of three-phase induction motor using
discrete components


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3.3 ADJUSTABLE SPEED DRIVE OF THREE-PHASE INDUCTION
MOTOR USING DISCRETE COMPONENTS

3.3.1 Electrical Part

In this part, There are several type of circuits was used in this study such as
power supply circuit, PWM signal wave generating circuit, three-phase inverter bridge
circuit and closed-loop PID controller circuit

3.3.1.1 Power Supply Circuit

The design of circuit using Multisim software and the hardware of a 15V
regulated dual power supply circuit is shown in figure 3.3 and 3.4 respectively. The
circuit is built using LM7805 and LM7905 IC which steps down their input voltage to
regulated Dual 15V DC. The output of the circuit is +15V and -15V DC. The 220V to
12V center tap transformer is used to step down the mains voltage. The bridge rectifier
KBP306 performs the process of rectification which will convert 12V AC to 12V DC.
The 2200uF capacitor is used to filter the voltage coming from the diodes, and other
capacitors in the circuit are used for decoupling.



Figure 3.3: Design circuit of 15V regulated dual power supply

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Figure 3.4: Hardware of 15V regulated dual power supply circuit

The design of circuit using Multisim software and the hardware of a 9V regulated
dual power supply is shown in figure 3.5 and 3.6 respectively. The circuit is built using
LM7809 and LM7909 IC which steps down their input voltage to regulated Dual 9V
DC. The output of the circuit is +9V and -9V DC. The 220V to 9V center tap
transformer is used to step down the mains voltage. The bridge rectifier KBP306
performs the process of rectification which will convert 12V AC to 12V DC. The
2200uF capacitor is used to filter the voltage coming from the diodes, and other
capacitors in the circuit are used for decoupling.



Figure 3.5: Design circuit of 9V regulated dual power supply

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Figure 3.6: Hardware of 9V regulated dual power supply circuit

Complete hardware of dual power supply circuits with transformers are shown in
figure 3.7 below.



Figure 3.7: Complete hardware of dual power supply circuit



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3.3.1.2 PWM signal wave generating circuit

The figure 3.8 shows the full hardware of PWM generation circuit which
consisting of three-phase sine wave generator, triangular waveform generator,
comparator and optocoupler circuit. The design of this circuit is drawn using Multisim
software. The complete PWM signal wave generating circuits drawn using Multisim
can be refer in Appendix.



Figure 3.8: Hardware of PWM signal wave generating circuit

3.3.1.2.1 Three-phase sine wave circuit

The three-phase sine wave generation circuit generates three-phase sinusoidal
waveforms according to the commanded normalized synchronous frequency, 50Hz and
the commanded normalized voltage. The circuit is designed using low cost, low noise
and high speed J-FET quad operational amplifier TL074 IC and some discrete
components. The design is drawn using Multisim software and shown in figure 3.9. The
real hardware circuit is shown in figure 3.10.

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Figure 3.9: Design of three-phase sine wave circuit



Figure 3.10: Hardware of three-phase sine wave circuit

3.3.1.2.2 Triangular Waveform Generation Circuit

The three-phase inverter was designed to operate at a switching frequency of f
S
=
1.37 kHz. Therefore, the output of a carrier frequency generation circuit has the same
frequency. Figure 3.11 and 3.12 shows the triangular carrier waveform generator circuit
and hardware of circuit respectively, which is formed around ICTL082CD.
FIRST-PHASE
SINE WAVE (0)
OUTPUT
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Figure 3.11: Triangular wave generator circuit

This circuit produces a triangular waveform, V
tri
, with a frequency of f
b
, which is given
by
f
b
=

According the formulae given, we can get frequency of f
b
about 1.3kHz. The 10K ohm
potentiometer is used as variable component to adjust the carrier frequency. So that, can
get the accurate frequency needed.



Figure 3.12: Hardware of triangular wave generator circuit
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And has peak-to-peak amplitude, V
m
, given as,
V
m
=

Where V
max
is the maximum output voltage of ICTL082CD with 7V, and an
offset of V
of,

V
of
=

3.3.1.2.3 Comparator Circuit

Figure 3.13 shows the comparator circuit in Multisim which use three ICLM311.
LM311 is highly flexible voltage comparator. The ability to operate from a single
power supply of 5.0 V to 30 V or 15 V split supplies, as commonly used with
operational amplifiers, makes the LM311 a truly versatile comparator. Moreover, the
inputs of the device can be isolated from system ground while the output can drive
loads referenced either to ground, the VCC or the VEE supply. This flexibility makes it
possible to drive DTL, RTL, TTL, or MOS logic. The output can also switch voltages
to 50 V at currents to 50 mA. Thus, the LM311 can be used to drive relays, lamps or
solenoids. In this part, the comparator circuit produce three-phase PWM wave. As in
figure 3.13, the three-phase PWM block comprised of three ICLM311. Each of the
three-phase sine waves is compared with the common triangular carrier waveform with
three complementary comparators to produce the three-phase PWM signals. The
outputs of the comparator are drive signals for the succeeding optocoupler and gate
drive circuit. Figure 3.14 shows the hardware of comparator circuit.

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Figure 3.13: Design of comparator circuit



Figure 3.14: Hardware of comparator circuit




INPUT OF FIRST-PHASE
SINE WAVE (0)

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3.3.1.2.4 Gate Drive Optocoupler Circuit

Gate drive optocoupler are widely used in motor drive applications because they
provide high-output current and fast switching speed. They increasingly show up in
renewable energy converters as well because they offer IGBT-protection features,
including under-voltage lock-out (UVLO), desaturation (DESAT) detection, and an
active miller clamp. Besides using gate drivers, designers employ other methods of
IGBT protection that include current sensors on the output phases and on dc buses. To
detect over-currents and overloads, they may use isolation amplifier (iso-amp) current
sensors featuring fast fault detection in conjunction with current measurement.
Optocouplers are commonly used in such systems to galvanically isolate the control
circuits and help protect against damage caused by high voltages in the dc bus. Another
primary purpose of these devices is to provide a high degree of common-mode rejection
(CMR) and help prevent the fast switching of the pulse-width modulation (PWM)
signals from erroneously driving the IGBT.

In particular, gate drive optocouplers are widely used to drive IGBTs because
they can provide high output current for precise switching while at the same time giving
conversion efficiency. Precise switching is also necessary to keep the high and low
sides of an IGBT from turning on simultaneously, thus causing a short circuit. Figure
3.15 shows typical schematic of Gate drive optocoupler circuit in Multisim. In this part,
the circuit builds with EL 4N25. EL 4N25 known as Gallium Arsenide Diode Infrared
source optically coupled to a Silicon npn phototransistor. It also contains high direct-
current transfer ratio and base lead provided for conventional transistor biasing. EL
4N25 provides high-voltage electrical isolation about 1.5-kv, or 3.55-kv rating and have
high speed switching. Figure 3.16 shows hardware of Gate drive optocoupler circuit.

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Figure 3.15: Design of Optocoupler generator circuit



Figure 3.16: Hardware of Optocoupler generator



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3.3.1.3 Three-phase Inverter Bridge

It is built around mainly from two things:-

1) Driver circuit for IGBTs
2) IGBTs Bridge

3.3.1.3.1 Driver Circuit of IGBTs

Many electrical appliances such as convertors, UPS and motor drive contain
MOS gated transistors that operate up to 600volts. So, they need a driver, and a driver
should have following characteristics:-

1) The drive signal should have amplitude of 10 volts 15 volts.
2) Floating outputs to drive the high side switches.

The IR2130 is used to drive the power MOSFETs and IGBTs with high and
low output channels, provide the floating channel for boot strap operation. Figure 3.17
shows IR2130 driver schematic in Proteus software. The six input signals
(h
1
,h
2
,h
3
,l
1
,l
2
,l
3
) given to the IC and correspondingly get the six output signals, upper
three output drives the high side MOS gate transistors to resolve the issue of floating on
the other hand the lower three inputs (l
1
,l
2
,l
3
) are directly connected to the output.
Figure 3.18 shows the hardware of driver circuit for three modules of IGBTs.

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Figure 3.17: IR2130 driver circuit



Figure 3.18: Hardware of IR2130 driver circuit

3.3.1.3.2 IGBTs Bridge

The bridge inverter has six switches that are controlled from PWM signals in
order to generate three-phase AC output from DC bus. The phase voltage is determined
by the duty cycle of PWM signals. While the motor is running, a maximum three
switches will be on at any given time; either one upper and two lower switches or one
lower and two upper switches. When the switches are on, current flows from DC bus to
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the motor winding. The output of the inverter is three phase of AC as shown in figure
3.19 which is drawn using Protheus software and figure 3.20 shows the block with three
IGBT modules. The model of IGBT module used is SKM200GB123D.These three
phases are apart from each other with the angle of 120. It contains some harmonics.
These harmonics can be reduced for the smooth running of motor. While some
harmonics filters the stator winding due to inductive nature.



Figure 3.19: IGBTs Bridge circuit



Figure 3.20: Hardware of IGBTs Bridge
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The highly inductive in nature of motor windings hold electric energy in the form
of current and this current opposes any sudden change until all the energy stored in the
windings is dissipated while switches are off. To facilitate this, diodes are connected
across each switch. These diodes are known as freewheeling diodes. A dead time is
given between the upper and lower switches on or off of the same half bridge to prevent
DC bus supply from being shorted.

3.3.1.4 THREE-PHASE INDUCTION MOTOR CIRCUIT

Figure 3.21 shows the output of the inverter is three phase of AC is directly
connected to the input of the IM to turn on the motor. Y-connection is used at the IM
part.



Figure 3.21: Three-phase induction motor circuit

3.3.1.5 CLOSED-LOOP PID CONTROLLER CIRCUIT

Figure 3.22 shows complete hardware circuit of closed-loop PID controller
circuit consisting of LCD screen, Arduino and frequency to voltage converter circuit
using LM2907N-8 (8 pins) IC.

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Figure 3.22: Hardware circuit of closed-loop PID controller

3.3.1.5.1 Interfacing Arduino and LCD screen

The Arduino UNO interfaced with LCD screen to display the speed of the
induction motor in rotational per minute (rpm). The connection of wire to interface
Arduino UNO with LCD screen is shown in figure 3.23.This circuit is drawn using
Fritzing software. The hardware of circuit to interface Arduino UNO with LCD screen
is shown in figure 3.24 below.



Figure 3.23: Interfacing connection of Arduino and LCD screen

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Figure 3.24: Hardware of interfacing connection of Arduino and LCD screen

3.3.1.5.2 Frequency to Voltage converter circuit

Frequency to voltage converter, LM2907N-8 (8 pins) IC is associated with
optical encoder to convert the input speed signal in frequency into voltage. The optical
encoder (speed sensor) used is shown in figure 3.25 and 3.26 respectively. This optical
encoder is used to generate the input speed (RPM) signal. The details about the optical
encoder explained in table.



Figure 3.25: RE08A Optical Encoder Kit

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Figure 3.26: Optical encoder (Speed sensor) board



Figure 3.27 shows that +5 pin is connected to the +5V source. The GND pin is
connected to the ground. The Signal pin which gives the pulses as output is connected
to the counter pin at DAQ (Arduino) through interrupt approach. These pulses represent
the rotation of the induction motor. We have to count these pulses in one minute to get
the speed in rpm.



Figure 3.27: Input speed signal generator

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The Arduino code uses interrupts to count the pulses of the encoder and then
sends the velocity serially every second. The wheel radius and rate of velocity
calculations can be adjusted as desired. The 5v and ground pins can use the Arduinos
built in supply, and the signal pin is connected to digital pin 2 in Arduino board. The
Arduino code can be refer at Appendix.

For the LM2907N-8 (8 pins) in the configuration seen in figure 3.28 below, a
frequency signal is applied to the input of the charge pump at pin 1. The voltage
appearing at pin 2 will swing between two values which are approximately:-
(V
CC
) V
BE
and (V
CC
) V
BE
The voltage at pin 3 will have a value equal to:-
V
CC
* f
IN
* C
1
* R
1
* K
Where K is the gain constant and normally 1.0.



Figure 3.28: Configurations of LM2907N-8 (8 pins)

The circuit is R
1
, C
1
fixed, only to change the input signal frequency. In
addition, also can change the fixed time constant input frequency:-
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f = R
1
C
1

The output voltage is proportional to U
o
and t. This can be divided into the
following two cases to be discussed:-
1. Using the measured capacitor C
x
to replace C
1
. When the fixed R
1
, C
x

change, there is relationship U
a
C
x
. Using this principle may constitute a
multi-range analog capacitance table.
2. The measured resistance R
x
to replace R
1
. In the fixed C
1
, R
1
changes,
there is relationship U
oa
R
1
.
This may constitute a multi-range linear ohmmeter, still used as an 8V to 10V
DC voltage meter indicator. Figure 3.28 shows the hardware of frequency to voltage
converter circuit.



Figure 3.29: Hardware of frequency to voltage converter circuit.

3.3.2 Mechanical Part

In this mechanical part, the shaft is made to be fixing with the slotted disc of
optical encoder and three-phase induction motor. Perspex was used for the protective
box of whole circuit board .The materials undergo some machining operations to
fabricate before the set up of the electronic boards. Figure 3.30 shows design of shaft in
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CATIA software. The 3D printer machine used to make the part and the design in
MAKERBOT software is shown in figure 3.31. While figure 3.32 shows the final
output of the shaft.



Figure 3.30: Design of shaft in CATIA software



Figure 3.31: Design of shaft in MAKERBOT software



Figure 3.32: Shaft to connect slotted disc and induction motor
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Figure 3.33 and 3.34 shows the design of protective box of whole circuit boards
and the final output part of the protective box.



Figure 3.33: Design of protective box