Institute Nikola Tesla

THE INDUSTRIAL APPLICATION OF POWER CONVERTERS IN

MECHATRONIC SYSTEMS FOR CONTROL OF VIBRATORY
CONVEYING AND DOSING OF PARTICULATE MATERIALS

eljko V. Despotovi PhD.E.E, IEEE Senior Member

Institute Mihajlo Pupin-University of Belgrade, Volgina 15,
Belgrade, Serbia , zeljko.despotovic@pupin.rs
 Vibratory Conveying

The most efficient way to

transporting and finishing
of granular and particulate
materials

The base operation in

various technological
processes to production of
medicaments, meat,
cement, steel
 Basic Types of Operations in VC

conveying along to the horizontal surface

conveying along to the slightly inclined surface
conveying along to the spiral elevator
vibratory dosing; loading and (or) discharging
vibratory finishing; pulverization and separation
vibratory compaction
vibratory rapping (electrostatic precipitators)
conveying along to the horizontal surface
conveying along to the slightly inclined surface

conveying along to the spiral elevator

vibratory dosing; charging and (or) discharging
vibratory finishing; pulverization and separation

vibratory compaction (compact table)

vibratory rapping (Electro Static Precipitators Installations)

alternative position of vibratory actuators

vibratory tables

vibratory bags

vibratory tubes

In addition to this presentation there will be shortly and simply

exposed kinematics and dynamics of the vibratory conveyance
Vibratory Conveyance KINEMATICS
Conveying process is based on a
sequential throw movement of particles

Vibrations of tank, i.e. load-carrying

element (LCE), in which the material is
placed, induce the movement of material
particles, so that they resemble a highly
viscous liquid and the material becomes
easier to transport and to dose

The conveying material flow directly

depends on the average value of particles
throw movements, being on a certain LCE
working vibration frequency.

This average value, on the other hand,

depends on vibratory width (VW) i.e.
doubled amplitude oscillation of the LCE
 Vibratory Conveyance DYNAMICS

basic dynamical equations

n
m p av = Fi = m p g + N t
i =1

av = a L sin = X m 2 sin sin t

FN = m p ( g X m 2 sin sin t )

X m -amplitude oscillation of LCE surface

-excitation frequency K<1

X m 2 sin K= 1
K=
g
conveyor operation regime factor K>1
 Vibratory Conveyance Optimisation
The most rational regime is provided by a continuous micro-throw of the particle,
so that time of its pass is equal or multiple to the total oscillation period of the
vibratory conveyor

tp = n T
2
cos 2 n 2 2 n 2 1
K = + 1
2 n sin 2 n

REALITY 3.297 > K > 1.1

 The Vibratory Conveying Speed

1
vt = ( K1 K 2 sin t ) X m 1 2 cos
K

K1 , K 2 - empirical coefficients

t - inclination angle of VC ( = 0 for horizontal VC )

- amplitude oscillations of vibratory tank i.e. LCE

Xm
- excitation frequency

- vibration angle

K - operation regime factor of VC

The Empirical Coefficients K1 and K2
are depending upon physically properties of the conveying material
 The Diapasons Application of Vibratory Machines

AMPLITUDE [mm] FREQUENCY [Hz]

vibratory conveyors 2 100 5 150

vibratory dosators 1 10 100 1000

Vibratory Conveying Drives

MECHANICAL
-eccentrics
-centrifugal
-inertial

ELECTRICAL
-rotary electric motion
-linearelectromagnetic
Eccentric Vibratory Conveying Drive
 Centrifugally Vibratory Conveying Drive

(a)- eccentric drive with one mass , (b)- eccentric drive with two masses
 When a reciprocating motion has to be electrically produced, the
use of a rotary electric motor with a suitable transmission is really a
rather roundabout way of solving the problem

It is generally a better solution to look for an incremental-motion

system with magnetic coupling, so-called electromagnetic vibratory
actuator (EVA) , which produces a direct to-and-from movement

Electromagnetic drives offer easy and simple control for the mass
flow conveying materials

In comparison to all previously mentioned drives, these have a

more simple construction and they are compact, robust and reliable
in operation

The absence of wearing mechanical part, such as gears, cams belts,

bearings, eccentrics or motors, makes electromagnetic vibratory
conveyors and feeders most economical equipment
Electromagnetic Vibratory Actuator (EVA)

1-Load Carrying Element (LCE)

2-Active section
3-Elastic parts
4-Reactive section
5-Flexible parts (leaf springs)
6-Inductor
Types of electromagnetic VCD-s 7-Armature
(a)-one mass, (b)-pending, (c),(d)- two masses, 8-Exciting coil
(e)-eliptical, (f)-multi drive
Construction of conventioanal vibratory actuator : MV G 50 - 10 AEG
 CEMENT INDUSTRY
Vibratory bunker
Vibratory exctractor
Vibraratory feeder

EXCITATION PART
Typical types of ash and particulate material conveying-
PNEUMATIC TRANSPORT

PNEUMATIC CONVEYING
Typical types of ash and particulate material conveying-
HYDRAULIC TRANSPORT

HYDRAULIC CONVEYING
MECHANICS of VIBRATORY HOPPER

Resultant vertical
vibration force Fv

Resultant horizontal
force Fh=0

Excitation forces
F1,F2 and F3

Driving current
i1(t),i2(t) and i3(t)

EVA-
Electromagnetic
Vibratory Actuator
THE ELECTROMECHANICAL SYSTEM FOR EXCITING
VIBRATORY HOPPER

(a)-mechanical
construction

(b)-armature EVA
on the active side

(c)-armature EVA
on the reactive side
 EQUIVALENT ELECTRICAL MODEL OF
VIBRATORY DISCHARGER

EVA (i), i=13

THE MECHANICAL PART OF THE SYSTEM
PROBLEM: Degradation of elastic elements (springs)

BREAKING OF SPRINGS!!!!

SOLUTION:
FIBERGLASS SPRINGS
k1
k1
100Hz6000 osc/min360 000 osc/h
1106 osc/ day (mean value)
PER YEAR 360106 cycles
-drift of spring characteristics
-decrease of stiffness k1
-change resonant frequency
-decrease of resonant frequency
-decreasing of amplitude oscillation
Electromagnetic Vibratory Conveyor with
Fixing Inductor
Electromagnetic Vibratory Conveyor with Fixing
Inductor and Directional Exciting Force

CI-Center Inertia of vibratory through

REACH HARMONIC EXCITATIION harmonics of excitation force

FORCE HARMONICS : fo, 2fo, 3fo....20fo (first five are dominant)

SPRING LOSSES ARE BIGGER (veliki problem kod elinih
slojevitih opruga), ALTERNATIVE: FIBERGLASS COMPOSITE

50Hz3000 osc/min180 000 osc/h0.5106 osc/ day (average value )

ANNUAL NUMBER OF CYCLES 180106
Typical construction of a vibratory conveying system having
electromagnetic vibratory actuator
1-Load Carry Element
(LCE)
2-Flexible elements (leaf
springs) are made of a
fiberglass composite
material.
3-Base
4-Rubber mounts
5-Magnetic core
6-Coil
7-Armature
Electromagnetic Vibratory Actuator 8-Vibratory trough
EVA 9-Non contact inductive
sensor
 Analytical Model of Electromagnetic Vibratory
Conveyor

Lagragian of system
= ( Eki E pi )
i

Lagrange equation of motion

d
+ = Fqi
dt qi qi qi
i=1, 2 , . . , nss ; nss = 4

m11 m12 m13 m14 q1 b11 0 0 0 q1 k11 0 0 0 q1 F

m m22 0 m24 q2 0 b22 0 b24 q 2 0 k 22 0 k 23 q 2 0
21 + + =
m31 0 m33 m34 q3 0 0 b33 b34 q3 0 0 k 33 k 34 q3 0

m41 m42 m43 m44 q4 0 b42 b43 b44 q 4 0 k 42 k 43 k 44 q 4 0

M Z + B Z + K Z = F Z = [q1 q4 ] = [p w ]
T T
q2 q3 u
 DETAILED EXPLANATION OF MATHEMATICAL MODEL REVC
IS
GIVEN IN RELEVANT REFERENCE:
Z.V.Despotovic, Dj.Urukalo, M.Lecic, A.Cosic, "Mathematical modelling of
resonant linear vibratory conveyor with electromagnetic excitation: simulations
and experimental results", Applied Mathematical Modeling, ISSN: 0307-
904X, Vol.41, No.1, pp.1-24, January 2017,
http://www.sciencedirect.com/science/article/pii/S0307904X16304802.

m11 m12 m13 m14 q1 b11 0 0 0 q1 k11 0 0 0 q1 F

m m22 0 m24 q2 0 b22 0 b24 q 2 0 k 22 0 k 23 q 2 0
21 + + =
m31 0 m33 m34 q3 0 0 b33 b34 q3 0 0 k 33 k 34 q3 0

m41 m42 m43 m44 q4 0 b42 b43 b44 q 4 0 k 42 k 43 k 44 q 4 0

M Z + B Z + K Z = F

Z = [q1 q4 ] = [p w ]
T T
q2 q3 u
THE SIMPLIFICATION of EMVF MECHANICAL RESONANT SYSTEM

p + 2 0 p + 02 ( p p0 ) = K p 02 F

k -resonant frequency
0 =
m
= (b / m) / 0 -damping factor

Kp = 1/ k - static gain
 EVA like as a Generator of Force
o N 2 A i2 Electro
F = Magnetic
4( D + d + p ) 2
Force (EMF)

mechanical equation
ai i 2
m z + b z + k [ z ( D + d )] = 2
e
1
e
1
e
1
z
electrical equation
di
L(z) + R c i + e ( z , z , t ) = u ( t )
dt

(a)-mechanical model, (b)-magnetic circuit,

(c)-equivalent electrical circuit
static characteristic
 MODEL OF ELECTROMAGNETIC VIBRATORY
ACTUATOR (EVA)
di L( z ) dz
L( z ) + + Ri = u
dt z dt
1 L( z ) 2 L( z ) = L0
z0
F= i
2 z z
If the short excitation current pulse
for EVA is synchronized with the
z max > z d instant when the armature is
passing through the equilibrium
position ( z = z = D + d )
0
di
L0 + Rc i = u
dt
dp L
Rc = Rc + Rc i << u
dt p p = p
0

(a) electromechanical part, (b) electromagnet of

actuator, (c) equivalent electrical scheme. di u
=
predominantly inductive nature of EVA!!! dt L0
The Role of Mechanical Resonance in Vibratory
Conveying Systems

The mechanical models of electromagnetic resonant vibratory conveyors

(a)-movable inductor, (b)- static inductor , (c)-equivqlent electrical model
 1
X 2dm = X 2st
(1 2 ) 2 + 4 2 2

2 stX 2 =
st
F F m

= = X = 2
m2 m02
0 2m 2 0 m
2
2
0

Fm
X d
=
2 2 0
2m

The controllable limitation of

amplitude oscillation can be
achieved by an active control of
the exciting force i.e. current of
EVA
In this way, it is possible to provide operation of the VCS in the region of
the mechanical resonance
Resonance is highly efficient, because large output displacement is provided
by little input power of exciting force
 Traditional Solution for The Vibratory
Conveying Control

(a)-potentiometer

(b)-auto transformer

(c)-variable inductivity

(d)-magnetic amplifier

These ways of the control are coarse and they are followed by big energy losses ,
what affects the rise of cost, as well as increase the size of the regulation equipment
An important way how to overcome the
disadvantages of traditional ways of control has been
showed by development of the semiconductor power
converters

Application of electromagnetic vibratory drive in

combination with the power converters provides
flexibility during work

It is consequently possible to adjust the amplitude

and (or) frequency of EVA coil current, i.e. the
adjustment intensity and frequency of exciting force is
applied on a conveying device, i.e. the adjustment of
the AMPLITUDE and (or) the FREQUENCU of the
mechanical oscillations.
Regulated Vibratory Conveying Drive- RVCD
power converter-EVA-vibratory conveyor RVCD
Power Converters with Phase Angle Control (PAC)

SCR power converters; (a)-unidirectional, (b)- bidirectional

AMPLITUDE FREQUENCY
 PHASE CONTROLLED THYRISTOR CONVERTER for
DRIVING VIBRATORY HOPPERS

(a) unidirectional topology and (b) waveforms of the EVA current and voltage
 PHASE CONTROLLED TRIAC CONVERTER for
DRIVING VIBRATORY HOPPERS

(a) bidirectional topology and (b) waveforms of the EVA current and voltage
SCR POWER CONVERTER FOR ELECTROMAGNETIC
DRIVE OF VIBRATORY
vibratory
bunker

vibratory hopper

(a)electrical circuit, (b) waveforms

Resonant SCR Power Converters

mechanical
resonant circuit

fres (mech) << fres (el)

FREQUENCY

AMPLITUDE

electrical resonant circuit

SCR resonant topology
CIRCUIT FOR ANALYSIS
(a),(b)- regime I ; (c),(d)-regime II
Switching Power Converters in Vibratory
Conveying
Controlling of EVA current it is possible
adjustment electromagnetic exciting force applied
on vibratory trough of conveyor
From electrical standpoint, the EVA is mostly
inductive load by its nature, so that adjusting the
current of EVA is possible by:
-PWM voltage or current-mode control
-ZVS or ZCS resonant control
Triangle and sinusoidal half-wave of EVA current

In this way it is provided amplitude and (or)

frequency control of vibratory conveying
The Topologies of Power Converters in Vibratory
Conveying

The topologies of power converter with one switch and

freewheeling diode
(a)-without resistance, (b)-with resistance
 The topologies of power converters with one switch including Zener diode
(a)-with freewheeling diode ("back to back"), (b)-inverting control, (c)-without
freewheeling diode
TWO FREQUENCY CONTROL (TWO TOPOLOGIES OF POWER DRIVE)
-High frequency ELECTRICAL control of step-down power converter i.e.
Duty-Cycle ratio control D=0.5 (output voltage is of input DC voltage Vo)
-Low frequency control of EMVF (controlable MECHANICAL oscillator)
CURRENT CONTROL OF EELCTROMAGNETIC VIBRATORY ACTUATOR

(a)- block diagram of current control

(b)- waveforms
 The topology of half-bridge resonant converter
frequency control of the
voltage control in the mechanical oscillation
DC-link circuit
(step-down converter)

amplitude
and frequency
control
of mechanical
oscillation
 The topology of half-bridge switching converter
(a)-basic circuit, (b)-rising of EVA coil current, (c)-falling of EVA coil current
The topology of asymmetrical half-bridge switching converter
(a)-basic circuit, (b)- generating of positive half-wave EVA coil current,
(c)- generating of negative half-wave EVA coil current
 The topology of full-bridge switching converter
(a)-basic circuit, (b)- generating of positive half-wave EVA coil current,
(c)- generating of negative half-wave EVA coil current
 Current-Mode Control in Vibratory Conveying-generating
triangle wave shape of EVA current

Control circuit to provide adjusting triangle wave shape of EVA current;

(a)-principal scheme, (b)-characteristic waveforms
The influence of the referent value of the peak current on the output of the LCE
displacement
(a)-wave shape of output displacement and EVA current, (b)-detailed
presentation of interval I, (c)-detailed presentation of interval II
 Current-Mode Control in Vibratory
Conveying-generating sinusoidal wave shape of EVA
current
The two mostly used methods:

-average current mode control

-hysteresis control i.e. tolerance band control

Fundamental condition for tracking reference of

EVA current:

Vs
> res I Mref
L
Zero Average Current Error (ZACE) Control

ZACE control is based on

maintain zero average value
of EVA current ripple

~
AVG [ i ] = 0
 ZACE simulation

(a)-simulation waveforms, (b)- detailed description of marked

sections
Hysteresis Current Control (tolerance band control)

Vs
H =
2 L f sw
 Hysteresis current control
(a)-detail of control circuit, (b)-characteristic control signal
Simulation results
asymmetrical half bridge
 ANALYSIS OF DC LINK OF POWER CONVERTER
FOR DRIVING VRC
In addition to the output
current of asymmetrical
SMPC, DC link circuit
essentially determines the
input current waveform of the
entire regulated vibratory
conveying drive.
The influence of the sine and
triangular waveforms of the
output current which is fed,
through an asymmetric half-
bridge, to EVA coil has been
Simulation circuit of switching converter for analyzed.
driving of EVA with single phase full-wave diode
rectifiier (DC voltage source Vs).

For generation of voltage in the intermediate DC circuit the use is made

of the input diode rectifier (diodes D3-D6), bank of electrolytic capacitors
of equivalent capacitance , and input inductor which is set on the
network side.
 Typical waveforms of the characteristic voltages and currents in a
DC link circuit in relation to EVA current, in the cases of the sine
and triangle half-wave output current.

f sw = 5kHz

Characteristic waveforms of voltages and currents in DC link for hard and soft switching operations;
(a)-sinusoidal half-wave of EVA current , (b)-triangular half-wave of EVA current
 The simulated waveforms of a converter having sinusoidal output current half-
wave of variable driving frequency of EVA coil: (a) 30Hz, (b) 70Hz, (c)50Hz
 The simulated waveforms of a converter having triangular output current half-
wave of variable driving frequency of EVA coil: (a) 45Hz, (b) 55Hz, (c) 50Hz
 The characteristic waveforms
for the case of sinusoidal
half-wave current drive of
EVA

driving frequency of EVA coil

30Hz:
(a) CH1: supply network
voltage and CH2: input
current,
(b) CH1: EVA current, CH2:
input current and CH3: DC-
link voltage.
 The characteristic waveforms
for the case of sinusoidal half-
wave current drive of EVA

driving frequency of EVA coil

70Hz:
(a) CH1: supply network voltage
and CH2: input current,
(b) CH1: EVA current, CH2: DC-
link voltage and CH3: input
current
 The characteristic waveforms for
the case of sinusoidal half-wave
current drive of EVA;
driving frequency of EVA coil
50Hz:
(a) CH1: supply network voltage
and CH2: input current,
(b) CH1: input current and CH2:
DC- link voltage
From these results it can clearly be
concluded that the input current is a
string of unipolar current pulses.

It should be mentioned that this is the

worst case in practice.

This shape of input current is a

consequence of synchronization of the
output current with the network voltage.
 FFT

The characteristic waveforms for

the case of triangular half-wave
current drive of EVA;
driving frequency of EVA coil
55Hz (SUPER-RESONANT
OPERATING):
(a) CH1: input current and CH2:
DC-link voltage,
(b) CH1: input current, CH2:
supply network voltage, CH3:
DC-link voltage and CH4: EVA
current
 FFT

The characteristic waveforms for

the case of triangular half-wave
current drive of EVA;
driving frequency of EVA coil 45Hz
(SUBRESONANT OPERATING)
(a) CH1: input current and CH2:
DC-link voltage,
(b) CH1: input current, CH2: DC-
link voltage, CH3: EVA current and
CH4: supply network voltage.
 FFT

The characteristic waveforms for

the case of triangular half-wave
current drive of EVA;
driving frequency of EVA coil 50Hz
(RESONANT OPERATING):
(a) CH1: input current and CH2:
DC-link voltage,
(b) CH1: input current, CH2: DC-
link voltage, CH3: EVA current,
and CH4: supply network voltage.
 AC/DC POWER CONVERTER FOR VIBRATORY ACTUATOR
DRIVING

AC/DC/DC
 EXPERIMENTAL RESULTS
Output DC/DC power converter

Influence the output DC/DC power converter on

the mains power

Input AC/DC power converter with PFC

Transfer characteristics of regulated vibratory

conveying drive
The Block Scheme of Resonant Electromagnetic Vibratory Conveyor
AMPLITUDE
CONTROL

-sinusoidal
driving EVA

(a)- VW=6mm
(b)-VW=0.5mm

-triangle
driving EVA

(a)- VW=6mm
(b)-VW=0.5mm
 Oscilloscopic Records of Characteristic Waveforms
for VCD with Transistor Control

EVA voltage and EVA current; (a)- triangle drive (b)-sinusoidal drive
Oscilloscopic
Records of Resonant
Frequency Seeking
Process
Detailed scope
(a) - interval I
(b) - interval II
(c) - interval III
Comparison of Vibratory Conveying Drives with and without PFC

sinusoidal excitation
(a)-with PFC
(b)-without PFC

triangle excitation
(a)-with PFC
(b)-without PFC
Influence The Vibratory
Conveying Drive with PFC on The
Power Consumption

-sinusoidal drive of EVA

-triangle drive of EVA

 PRACTICAL REALIZED VIBRATION CONTROL OF EMVF

Output signal of displacement

inductive contact less sensor
INPUT RECTIFIER
high quality power
power factor PF 1
MEASURING OF OUTPUT DISPLACEMENT p(t) - contactless inductive sensor

(a)-disposition of sensor, (b) block scheme of electronic transmitter,

(c) output characteristics, (d) principle of operation
Experimental results- parameters
AMLITUDE CONTROL Experimental results
Resonant frequency: fres=44.5Hz, T=22.5ms, EVA voltage +/- 200V

reference values: reference values:

output LCE displacement output LCE displacement

(amplitude) : Pm= +/- 0.7mm (amplitude) : Pm= +/- 1.5mm
FREQUENCY CONTROL (mass change compensation)
Experimental results-increasing of load mass
Detailed scope of time interval t1

The change mass compensation of LCE

FREQUENCY CONTROL (mass change compensation)
Experimental results-increasing of load mass
Detailed scope of time interval t3

The change mass compensation of LCE

CONTROL SYSTEM
x1 0 1 x1 0 2
x = = 0 + K
p1 0 i

x 2 1 0 x2 1
x1 = z z 0
K p L( z )
K p1 =
2 z z = z0

Luenberger
observer
T1 = T2 = /(100 )
 k1 1  0 2 k1
x = 0 + + ( )
0
0 k

x K p1 i z z
1
a = K C (a R a ) + (a R a )dt 1 k 2 1
2
TI
k1 = 6.3694 k 2 = 9.1424
 PI control
1 TI = 10 / 0
a = K C (a R a ) + (a R a )dt
TI
a = K C (a R a ) K C 0.8

Anti-windup structure of the PI controller

To illustrate dynamic characteristics of the EVA load in both cases
(empty and full trough), the trough of our experimental conveyor is filled with sugar
and the feeder is excited by short current pulse as before.
Time responses for the empty and full trough are compared

Experimental time responses of the EVA armature displacement:

CH1-empty trough, =0.01, CH2- fill of sugar, =0.1.
Reference change tests are made for empty and for full trough.
Reference is changed in steps from 0.1mm to 1mm and back to
0.1mm.
Both responses are well damped and with small overshoots.

Experimental reference change responses:

CH1- empty trough, CH2- full trough.
DISTURBANCE RESPONSE

A 250g particulate material

bag dropped onto LCE trough
is used to demonstrate
disturbance response of the
electromagnetic vibratory
drive.
After about 1 - 1.5s, the bag
is removed from the trough.
The results are presented
for amplitude reference
a R = 0.5mm

and for empty trough, when

the effect of disturbance is the
highest.

Experimental disturbance change responses for empty trough

IMPLEMENTED PROTOTYPE of RESONANT EMVF
THE PROTOTYPE OF POWER CONVERTER UNIT
 Mounting of acceleration sensor Mounting of displacement sensor

Electromagnetic Vibratory Actuator-EVA Vibratory trough - top view

PC 104 - CONTROL UNIT

LINUX- OPERATING SYSTEM

Time 5 ms/c DISPLACEMENT 0,5mm/c CURRENT 1A/c

AMPLITUDE CONTROL
AMPLITUDSKA KONTROLA
http://www.youtube.com/watch?v=cc26Ds54sxg
http://www.youtube.com/watch?v=4TvfS4kth7w
AMPLITUDE-FREQUENCY CONTROL
http://www.youtube.com/watch?v=4TvfS4kth7w
 CONCLUSIONS
The most significant contribution of this research is a
development of an optimal control for the
electromagnetic resonant vibratory feeder and an
increase of theirs energy efficiency

There has been achieved a compensation of required

resonant regime and change resonant frequency

Dominating influences are:

-changing of conveying material mass
-changing stiffness of flexible element
-variation of mains voltage supply
freedom to operate a EMVF with any natural (resonant) frequency
from 5 Hz to 150 Hz frequency control
the proposed vibratory controller will continually search for the
natural frequency of the EMVF(resonance) and excite it at that
frequency (active tuning); in the located natural (resonant)
frequency, it is possible to tune amplitude and time duration of
the EVA coil current i.e. amplitude oscillations of the LCE
amplitude control
flexible automation with minimum change-over time because
electronics replace the comprehensive and the complicated
calibrations and mechanical settings
VCD can operate nondependent on mains frequency (50Hz-
Europe or 60Hz-North America) without changing the conveyor
springs or balancing masses
energy efficiency:
minimum EVA coil current
minimum EVA coil heating
minimum supply current
minimum power consumption
power factor correction
 At the END

THANK YOU IN
ATTENTION!!!!