e & i Elektrotechnik und Informationstechnik

The sensitivity of the hoist system in crane applications from speed control methods at
induction motor Die Empfindlichkeit des Hebesystems bei Krananwendungen von den
Geschwindigkeitsregelverfahren am Induktionsmotor
--Manuscript Draft--

Manuscript Number: EUIN-D-17-00052R1

Full Title: The sensitivity of the hoist system in crane applications from speed control methods at
induction motor Die Empfindlichkeit des Hebesystems bei Krananwendungen von den
Geschwindigkeitsregelverfahren am Induktionsmotor

Article Type: Original Paper

Keywords: induction motor; variable speed drive; crane hoist; V/f open loop control; V/f closed-
loop control; closed-loop vector control.

Induktionsmotor; drehzahlvariable Antriebe; Kranhub; U/f-Regelung; U/f-Regelung

mit offener Regelschleife; Regelung mit geschlossener Regelschleife.

Corresponding Author: Qamil Kabashi, Prof. Asoc.

University of Mitrovica-Faculty of Mechanical and Computer Engineering
Mitrovicë, Republic of Kosova ALBANIA

Corresponding Author Secondary

Information:

Corresponding Author's Institution: University of Mitrovica-Faculty of Mechanical and Computer Engineering

Corresponding Author's Secondary

Institution:

First Author: Sabrije Osmanaj, Prof. Asoc

First Author Secondary Information:

Order of Authors: Sabrije Osmanaj, Prof. Asoc

Myzafere Limani, Prof. Dr.

Kadrije Simnica Aliu, Assistant

Qamil Kabashi, Prof. Asoc.

Order of Authors Secondary Information:

Funding Information:

Abstract: Choosing the appropriate control technique in Variable Speed Drive (VSD) is very
important to avoid faults on the hoisting system of molten metal. This paper analyzes
the sensitivity of the hoist system in crane applications from the three various control
techniques of variable speed drives of induction motors: V/f open-loop control, V/f
closed-loop control and closed-loop vector control. It is noticed that stoppages of motor
run are usually caused by the wrong selection of control technique, by overload
(overcurrent and overvoltage) or by both. On the V/f control (open and closed-loop),
when the load is 45 t in low output speed (5- 6 Hz), the hook is moving without control
downward direction, even if the command was given for lifting (upward direction),
therefore we cannot use this control technique on the main hoist 50 t Crane. In the
closed-loop vector control, the feedback error information determines the exact voltage
vector position and norm to produce exactly what is needed to correct the error, as the
result of the number of fault/trip on hoist crane applications will be minimal. For
different loads, although the output currents change obviously, motor temperature
remains constant.

Die Wahl der geeigneten Regelungsstrategie bei drehzahlvariablen Antrieben ist sehr
wichtig um Schäden am Hebesystem an den geschweißten Verbindungen zu
vermeiden. Diese Arbeit analysiert die Empfindlichkeit des Hubsystems bei
Krananwendungen mit drei verschiedenen Regelungsverfahren von drehzahlvariablen

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 Asynchronmaschinen: U / f-Regelung, U / f-Regelung mit offener Regelschleife und
Regelung mit geschlossener Regelschleife. Man hat festgestellt, dass Stillstände des
Motorlaufs in der Regel durch die falsche Auswahl der Regelstrategie, durch
Überlastung (Überstrom und Überspannung) oder durch beides verursacht werden.
Bei der U / f-Regelung (offen und geschlossen), wenn die Last 45 t bei niedriger
Ausgangsdrehzahl (5-6 Hz) ist, bewegt sich der Haken ohne Regelung nach unten,
auch wenn der Befehl zum Heben gegeben wurde ( nach oben gerichtet), daher kann
diese Regelungsstrategie nicht am Haupthubwerk mit 50 t verwendet werden. Bei der
geschlossenen Vektorregelung bestimmt die Rückkopplungsfehlerinformation die
exakte Spannungsvektorposition, um genau das zu generieren, welcher zur Korrektur
des Fehlers erforderlich ist, damit die Anzahl der Fehler- / Auslösungen bei
Hubkrananwendungen minimal wird. Für unterschiedliche Lasten, obwohl sich die
Ausgangsströme offensichtlich ändern, bleibt die Motortemperatur konstant.

Response to Reviewers: Reviewers' comments:

Reviewer #1: The paper presents a comprehensive and thorough study of control
strategies for induction motors with a focus on practical application aspects. The text is
logically divided into sections focused on various aspects of the problem. The article
will be of interest to a broad readership of the journal because of its closed link to
practical application tasks.
English and german language needs minor improvement throughout the paper.

In conclusion, just few minor things:

In fig. 3 the font should be enlarged
In fig. 6 the shading of the blocks irritates because of its colour
It would be good to integrate fig. 10,11,12 in one single figure
In Fig. 13 there is nothing visible, may be a Zoom window would help ?
Chapter 5: ‚Experimental results …'
German Title: 'Geschwindigkeitsregelverfahren'
Keywords: 'drehzahlvariable Antriebe'

Thank you for your e-mail of 16th January, 2018 concerning our manuscript, EUIN-D-
17-00052, entitled “The sensitivity of the hoist system in crane applications from speed
control methods at induction motor / Die Empfindlichkeit des Hebesystems bei
Krananwendungen von den Geschwindigkeits kontrollverfahren am Induktionsmotor.

We also thank the reviewers for their valuable comments and suggestions, which we
have carefully analyzed and addressed accordingly in the revised version of our
manuscript.

We would like thank the Subject Editor Prof. Dr. Harald Neudorfer for the useful
comments to improve the paper. We made all corrections and tried to improve all the
addressed points on this revision manuscript as follow:
1.The font has been enlarged in Figure 3.
2.This point (about shading of the blocks) is corrected very carefully. Thanks a lot for
your suggestion!
3.Figure 10, 11 and 12 are integrated in in one single figure (now numbered Figure
10), whereas Figure 13 is presented more clearly and numbered as Figure 11.
4.In this revision manuscript, has been proofreading.

Best regards,
Qamil Kabashi

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revision manuscript Click here to download Manuscript
revised_SO_ML_KS_QK_e&i.DOCX

The sensitivity of the hoist system in crane applications from speed control
methods at induction motor
1 Sabrije Osmanaj1, Kadrije Simnica Aliu1, Myzafere Limani1, Qamil Kabashi2*
2
3
4 1
Faculty of Electrical and Computer Engineering, University of Prishtina, Prishtina 10000, Kosovo
5 2
Faculty of Mechanical and Computer Engineering, University of Mitrovica, Mitrovica 40000, Kosovo
6
7
8 Correspondence: qamil.kabashi@uni-pr.edu; Tel. +383-44-244-630
9
10 Abstract: Choosing the appropriate control technique in Variable Speed Drive (VSD) is very important to avoid faults on
11 the hoisting system of molten metal. This paper analyzes the sensitivity of the hoist system in crane applications from the
12 three various control techniques of variable speed drives of induction motors: V/f open-loop control, V/f closed-loop control
13 and closed-loop vector control. It is noticed that stoppages of motor run are usually caused by the wrong selection of control
14 technique, by overload (overcurrent and overvoltage) or by both. On the V/f control (open and closed-loop), when the load
15 is 45 t in low output speed (5- 6 Hz), the hook is moving without control downward direction, even if the command was
16 given for lifting (upward direction), therefore we cannot use this control technique on the main hoist 50T Crane. In the
17 closed-loop vector control, the feedback error information determines the exact voltage vector position and norm to produce
18 exactly what is needed to correct the error, as the result of the number of fault/trip on hoist crane applications will be minimal.
19 For different loads, although the output currents change obviously, motor temperature remains constant.
20
21 Keywords: induction motor; variable speed drive; crane hoist; V/f open loop control; V/f closed-loop control; closed-loop
22 vector control.
23
24
25
26 Die Empfindlichkeit des Hebesystems bei Krananwendungen von den
27 Geschwindigkeitsregelverfahren am Induktionsmotor
28
29
30 Zusammenfassung: Die Wahl der geeigneten Regelungsstrategie bei drehzahlvariablen Antrieben ist sehr wichtig um
31 Schäden am Hebesystem an den geschweißten Verbindungen zu vermeiden. Diese Arbeit analysiert die Empfindlichkeit des
32 Hubsystems bei Krananwendungen mit drei verschiedenen Regelungsverfahren von drehzahlvariablen
33 Asynchronmaschinen: U / f-Regelung, U / f-Regelung mit offener Regelschleife und Regelung mit geschlossener
34 Regelschleife. Man hat festgestellt, dass Stillstände des Motorlaufs in der Regel durch die falsche Auswahl der
35 Regelstrategie, durch Überlastung (Überstrom und Überspannung) oder durch beides verursacht werden. Bei der U / f-
36 Regelung (offen und geschlossen), wenn die Last 45 t bei niedriger Ausgangsdrehzahl (5-6 Hz) ist, bewegt sich der Haken
37 ohne Regelung nach unten, auch wenn der Befehl zum Heben gegeben wurde ( nach oben gerichtet), daher kann diese
38 Regelungsstrategie nicht am Haupthubwerk mit 50T verwendet werden. Bei der geschlossenen Vektorregelung bestimmt
39 die Rückkopplungsfehlerinformation die exakte Spannungsvektorposition, um genau das zu generieren, welcher zur
40 Korrektur des Fehlers erforderlich ist, damit die Anzahl der Fehler- / Auslösungen bei Hubkrananwendungen minimal wird.
41 Für unterschiedliche Lasten, obwohl sich die Ausgangsströme offensichtlich ändern, bleibt die Motortemperatur konstant.
42
43 Schlüsselwörter Induktionsmotor; drehzahlvariable Antriebe; Kranhub; U/f-Regelung; U/f-Regelung mit offener
44 Regelschleife; Regelung mit geschlossener Regelschleife.
45
46 1. Introduction maximal speed is restricted, due to mechanical
47 Nowadays variable speed devices are used in industrial restrictions (problems with commutators and brushes).
48 applications enormously. For many years, DC motors DC motors are distinguished with higher cost and higher
49 were preferred for variable speed drives in industrial rotor inertia. On the other hand, they cannot operate in
50 applications because their flux and torque could be polluted and explosive environments.
51 controlled easily by the field and armature current. The These problems can be overcome through the
52 permanent magnet motors (brushless DC motors or application of induction motors (IM), because they have
53 BLCDs) are in most cases used at Variable Speed Drive a simple structure, no brushes, nor commutators and they
54 (VSD). The stator windings create a rotating field which do not require maintenance as DC motors.
55 creates a rotating torque by pulling the permanent magnet IMs are distinguished with low cost, high reliability,
56 rotor, where stator windings currents are electronically fairly high efficiency and ease of manufacturing.
57 commutated by digital signals from simple rotor position Therefore, in the last three decades, DC motors are
58
sensors [1]. progressively replaced by IMs for industrial applications
59
The drive with DC motors has its advantages, as an with variable speed, but they require more complex
60
adjustment of required speed is easily accomplished with multivariable and nonlinear control techniques, such as
61
drive, but it is followed with some disadvantages because the speed and torque control.
62
of complicated construction and periodic maintenance The adjustment speed of induction motors is achieved
63
problems (precise processing of commutators), and the by changing the number of pole pairs, changing level of
64
65
1
 the applied voltage or frequency, or both [2-4]. It cannot 2.1 V/F open-loop control
be accomplished directly from 3-phase/multi-phase AC V/f control technique is based on varying two parameters
electrical network, nor with transformers. It can be simultaneously, the voltage and frequency with ratio V/f
accomplished with PWM inverters. Figure 1 represents = constant, which is usually called as scalar control of
1 the core circuit of a typical model of a Voltage Source induction motor drive. Figure 2 shows a block diagram of
2 Inverter, configured using IGBT modules, generating a the V/f open-loop control of an IM. Input commands is
3 three-phase system from the DC link voltage to feeding reference speed and calculated commands for reference
4 the motor for VSD applications [5]. The rectifier circuit, frequency (f*) and reference voltage (V*) also such as V/f
5 filter, and driver circuit for switching semiconductor ratio to be constant.
6 devices are not presented here.
7 For larger cranes in industry, the drives use a common
8 DC-link. All the inverter bridges supplying the induction
9 motors are connected to the same DC-link, which is
10 supplied by one or more active front-end converters [6].
11
12
13
14
15
16
17
18
19 Fig. 2. Block diagram of an induction motor-drive
20 system, V/f open-loop control
21
22 With the voltage to frequency maintained at the same
23 ratio, flux and torque can be kept constant throughout the
24 speed range [7].
25 Fig. 1. A 3-phase voltage source inverter (VSI) driving V
26 an induction motor  4.44  N   S    const.
f
27 (1)
T V2 V
28 Advancements in semiconductor technology, mainly  const .
29 through Power MOSFTs improvements and IGBT  2  f 2 f
30 developments, as well as technology of digital signal where
31 processing (DSP), have brought significant improvements V - the inducted voltage in stator
32 in power electronics systems and VSDs. f - the frequency of supplied voltage from VSI
33 Modulation techniques of switching elements of the N - the number of turns
34 Voltage Source Inverter represent the control technique of ФS – magnetic flux-linkage in the stator
35 induction motors. ζ - constant of coil
36 The speed control of an IM is made with various T – the torque of the motor in air-gap
37 control techniques: pole changing, variable supply Figure 3 shows the typical V/f diagram with three
38 voltage control, variable supply frequency control, frequency ranges [3, 8, 9]:
39 variable rotor resistance control, slip recovery, V/f  0-fc, the voltage drop across the stator resistance
40 control, vector control, etc. that cannot be neglected and must be
41 In the metallurgy and other industrial applications compensated for by increasing the V on stator.
42 related with them, VSDs are often used in electric hoists The torque on this frequency range is very high
43 system as well as in overhead cranes. (especially at zero speed).
44 In general applications of the heavy machinery  fc-fbase, it follows the constant V/f relationship.
45 industry, the control of variable voltage and frequency is The slope actually represents the air gap flux
46 realized with two methods: V/f control as scalar control quantity.
47 and space vector control as vectorial control.
48 This paper is focused on the experimental analysis of
49 the hoist system in crane applications from speed control
50 technique of an induction motor, realized in New Co
51 “Ferronikeli” in Drenas, central Kosovo.
52
53
54 2. The Principle of Constant V/Hz for Induction
55
Motor
56
The speed of IM can be adjusted by varying only supply
57
frequency, but this results in a change of impedances. If
58
the impedance is high value the current on it is small and
59
the torque of the motor decrease. The voltage increases
60
can lead to the overheating of stator, burning it or causing
61
saturation to occur in the iron of the coil. To avoid these Fig. 3. Stator voltage versus frequency at V/f control
62
problems, a popular method in the industry is control with
63
a constant voltage/frequency.
64
65
2
  > fbase, the stator voltages would be limited at the When the stator windings of IM are supplied with
rated value in order to avoid insulation three phase balanced currents as rotating resultant of
breakdown at stator windings and the air gap synchronous speed magnetic field vectors will be
flux would be reduced, and cause the decreasing produced. Three phase sinusoidal currents isu, isv and isw at
1 developed torque correspondingly. a neutral point of the 3-phase AC motor, satisfy equation
2 V/f scalar control technique is simple to implement, (2) and these currents can be combined to a vector is(t)
3 and has the following advantages [10]: circulating with the stator frequency fs, as shown in Figure
4  Lower starting currents. 4. Three unit vectors u, v, w are displaced from each
5
 Torque is constant in all operation range fc-fbase other by 120° [14].
6
 Allows two or more IMs to be run of a single 2 4
7 2 j j 
8
VSD, because all motors follow the same speed i s  isu (t )  isv (t ) e 3  isw (t ) e 3  (2)
9 reference. Therefore, all IMs will start and stop 3 
10 at the same time.
11  The acceleration and deceleration of the motor
12 speed can be controlled by adjusting supply
13 voltage variation over time.
14 Since the motor torque is proportional to the square of
15 the voltage, then by changing the supply voltage for the
16 same torque we can change the number of rotations,
17 therefore V/f control technique does not provide high
18 performance.
19 The disadvantage of this control method is a sluggish
20 control response because of the inherent coupling effect
Fig. 4. Formation of the stator current vector from the
21 (that both torque and flux are functions of the stator
phase currents
22 voltage or current and frequency) and the system is prone
23 to instability because of a high order system effect [6, 11,
Clarke transformation (α-β) is a very useful tool to
24 12].
simplify the analysis and modeling of a 3-phase electrical
25 The torque is influenced by an incremental slip and
systems by reducing the order of the mathematical model
26 flux that tends to decrease. This sluggish nature lengthens
from three to two dimensions.
27 the response time and an induction motor can never give
Via the α-β transformation, the three-phase voltages
28 a fast transient response [7, 8].
and currents of two quantitative phases are independent
29 This control method has no sensing that the motor
(two voltages and two currents), while the third phase is
30 shaft actually is rotating. Additionally, starting torque of
dependent on the two of them. Establishing such an
31 the motor is limited to 150%, speed response is rated 3 Hz
algorithm can lead to better results that implies the
32 and speed regulation is typically ± 2% to ± 3% of
simplest modeling of the 3-phase inverter bridge
33 maximum frequency [13].
switches, which is the core of the VSDs.
34
Matrix equations below represent the Clarke
35 2.2 Closed Loop V/F Control
transformation, that converts balanced three phase
36 V/f control closed-loop is used when requiring a more
quantities abc, into balanced two phase, where quantities
37 precise speed regulation of induction motor’s [11]. Figure
38 from three phase system are presented in the two-phase
3 can add encoder and other feedback hardware to
orthogonal α-β quantities.
39 measure the induction motor’s actual speed (not shown).
40 Based on the difference between the actual speed of IM  1 1 
1   ia 
i   2  2   
41 and commanded speed, an error signal is generated, and
2
42 to compensate this error the controller generates a new      ib
43 frequency command. i  3  0 3 3  
  ic 
44 The encoder feedback tightens speed regulation down 2 2 
45 to 0.03% of the maximum frequency [12]. During the (3)
 1 1 
46 1   ua 
u   2  2   
experimental analysis we have noticed that this control
2
47 method is not common because it entails the costs of an       ub
48 encoder and feedback hardware, and its advantages in u   3  0 3 3  
  uc 
49 comparison of V/f open-loop control are minimal. 2 2 
50 Starting torque, speed response, and speed control range
51 are almost identical to the V/f open-loop control. For a three-phase balanced system (xo = 0) a three-
52 Recently, the precise speed response and position phase vector is transformed into dq (zero-axis
53 control of the motor shaft can be achieved using VSD component) vectors, through the transformation matrix T,
54 with vector control. defined as:
55
56  2 2 
3. The principle of Vector control of induction motors cos(t ) cos(t   ) cos(t   ) 
57 Vector control is based on a mathematical abstraction 2 3 3
58 T   (4)
3
 sin(t   ) 
with rotating vectors in a complex coordinate system. The 2 2
59  sin(t )  sin(t   )
60
basic principle of the vector control consists of controlling  3 3 
the stator currents represented by a vector. The objective
61 of this control technique is to give independent control of
62 torque and flux in an induction machine, which gives the
63
induction motor control in a similar way as DC motor.
64
65
3
 X a  On raising and lowering loads with precision on crane

  X b  (fixed three phase

applications, it is necessary to work at very low speeds
Transformation from X abc without using the mechanical brakes.
The torque and power that have to be delivered by the
1  X c  drive may be obtained from the torque versus speed
2
X d  characteristic from the load (so-called mechanical
3 coordinates) on X dq    (rotating coordinates dq) characteristics) and the differential equation of motion
4  X q  describing the behavior of the drive is [17]:
5 represent Park transformation (5).
6 d
7 X dq  T  X abc (5) J  Te  Tl (6)
8 dt
9 where
Figure 5(a) represents the three phase current on abc
10 Te is the electromagnetic torque of the motor,
axes and at the same coordinate system is also the α-β
11 Tl is the torque of the load, J is the inertia of the drive.
fixed coordinate system, while Figure 5(b) represents the
12 If Te  Tl , the system accelerates (d / dt  0) , while if
Park transformation that transforms the stationary
13 coordinate system α-β to the rotary coordinate system d- (Tl / Te )  0 it decelerates (d / dt  0) .
14 q [14]. The steady state operation is reached if Te  Tl and ω
15
16 = const.
17 Figure 6 presents a simplified block diagram of
18 closed-loop vector control [18].
19 Motor drive vector control torque and continued speed
20 starts from zero. The driving characteristic of IM on
21 vertical motion is that on low output frequency it should
22 have a high torque. Thus, the parameter for motor torque
23 in a closed-loop vector control is solved because the time
24 between the reference and feedback signal is ≤ 20 ms and
25 in this case, there is no rotor flux calculation block, while
26 in V/f control with linear characteristic, this time is about
27 45 ms because the flux calculation block is used [19].
(a) The speed sensor paired with the vector control in
28
29 Figure 6, means 200% of the motor’s rated torque is
30 available at 0 rpm, speed response is rated 0.3 Hz and
31 speed regulation is typically ± 0.02% of maximum
32 frequency [13].
33
34 4. Speed control by Simovert Master Drive VC on 50T
35 crane–hoist application
36 A crane is mainly used for lifting heavy things and
37 transporting them to other places, generally equipped with
38 (b) hoist rope, wire ropes or chains, and sheaves.
39 Nowadays VSDs are designed around a
40 Fig. 5. Principe of (a) Clark and (b) Park microprocessor, which allows for the creation of
41 transformation programmable functions for specific applications and
42 provides programming via the removable standard
43 The vector control method does not control only keypad, or through the advanced PC-based software.
44 effective value of voltage and frequency, but the actual Drive in crane - hoist application is fully four-
45 position of voltage vectors, current and flux, as well. This quadrant applications where the direction of speed and
46 provides an improved dynamic behavior of the supplied torque can freely change [11].
47 unit, in general. The three-phase voltages, currents and Using the VSDs to control the crane hoists have three
48 fluxes of induction motors can be analyzed in terms of main benefits listed below:
49 complex space vectors. This control is based on  Efficiency (VSDs are more efficient than
50 projections which transform a three phase time and speed contactors and soft-starters because they
51 into two coordinate (d and q frame) time invariant consume only the amount of power needed)
52 systems. Vector controlled machines need two constants  Load control is improved (In the production lines
53 as input references: the torque component (aligned with it is required that the number of trips (errors) be
54 the q coordinate) and the flux component (aligned with d as small as possible, so the VSD allows a gradual
55 coordinate) [8, 13, 15, 16]. lifting/slowing of a load, a smooth acceleration
56 When a two-axis coordinate reference frame is and deceleration to prevent load swings in the
57 employed, it has to be fixed to different variables of the vertical and horizontal motions).
58 machine. The main configurations are the synchronously  Crane Life is increased (Some VSDs provide
59 reference frame fixed to: stator flux, air-gap flux and rotor thermal overload and overcurrent protection for
60 flux. Calculation of the rotor flux spatial vector and the hoist induction motors, safe circuit for torque
61 transformation into the coordinate system d-q done that prolongs its life). The brakes are only used
62 through digital signal processing [3, 9]. for parking and emergency situations.
63
64
65
4
 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18 Fig. 6. Block diagram of an induction motor-drive system, closed-loop vector control
19
20 In the New Co Ferronikeli Complex that operates the refined metal with the ladle from the converter area to
21 nickel plant in Drenas, Kosovo we are using 50T crane Granulation and then the temperature of the refined metal
22 that serves for load handling in heavy metal industry can be up to 16500C. To control the speed of the Main
23 (Figure 7), in our case Ferro Nickel (FeNi). hoist is used inverter/motor drive (Simovert Master Drive
24 The main task in adjustable speed drives design is a 90 kW) as shown in Figure 8.
25 safe movement of molten metal of Ferro-Nickel handling
26 (holding and transporting) throughout the work area.
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42 Fig. 8. Inverter (Simovert Master Drive 90 kW)
43
44 Fig. 7. Picture of Crane 50T
Simovert Master Drive Vector Control (VC) which is
45
Below are listed briefly some technical data of the used for drive hoist in Crane 50T enables to select five
46
used crane. control techniques listed below:
47
 Main hoist load capacity: 50 t and height up to  V/f control with superposed speed control
48
49 24 m (refereed as hoisting).  V/f open-loop control, without speed sensor
50  First Auxiliary hoist load capacity: 12.5 t and  V/f control, textile application
51 height up to 24 m (helps to unload the molten  Closed-loop vector control, with speed sensor
52 metal from ladle).  Torque control
53  Second Auxiliary hoist load capacity: 12.5 t and Most induction motors can be overloaded for short
54 height up to 24m (helps to unload the molten periods of time without damage when the motor has been
55 metal from ladle). running with a reduced load (i.e. the current) for some
56  Travel (horizontal) movement, two directions time. In this case it is permissible for the voltage, current
57 (helps crane to move horizontal). (and hence the torque) to be much greater than normal for
58  Trolley (horizontal) movement, two directions a short period of time [16, 17].
59 (helps hoists system to move horizontal). The overload of the engine will be followed by the
60 The 50T crane transports and holds molten metal overload of the three-phase rectifier bridge (AC/DC),
61 Ferro-Nickel with ladle from the Electric Furnace Area to inverter circuit (DC/AC) and thus there is the permissible
62 Converter Area for Refination. The temperature of the overheating of stator windings, power semiconductor
63 molten metal reaches up to 12000C, also the crane sends devices of AC/DC and DC/AC converters. Rising of
64
65
5
 allowed temperatures in the motor is the main cause for 5. Experimental results and discussion
the converter damage. The measurements are made for the three control
The maximum permissible overload current is 1.36 techniques under the same work and load conditions: V/f
times greater than the rated current for a period of 60s, if open-loop control, V/f closed-loop control with speed
1 the driver has just been switched on and has not reached sensor, closed-loop vector control with speed sensor, and
2 its maximum permissible temperature, Figure 9 (a). If the analysis is focused on the sensitivity of the hoist system
3 whole overload capability has been utilized, this is in crane applications from speed control technique of IM.
4 detected by the I2t monitoring function and an alarm is The first control technique in drive of the main hoist
5 output for 30 s. The VSD overload units can be of 50T Crane is set to V/f open-loop control, where the
6 overloaded by 160 % for 30 seconds with a cycle time of output voltage is increasing linearly from 0 to the max
7 300 seconds, Figure 9 (b) [19]. allowed value of V/f characteristic and are made
8 Overload capability of an induction motor on crane measurement for three different loads at base frequency:
9 applications can be utilized using only the observing  Load 5 ton only the hook
10 following conditions:  Load 25 ton empty ladle (the ladle + hook is
11  In vector control, but not in V/f scalar control weight 25ton)
12
13
technique.  Load 45 ton full ladle (the metal weight is 20ton)
 The overload duration is limited to 30 s. The reference speed signal is continual from 0 Hz to
14
15  The permissible length of the motor supply 50 Hz and is given from the main hoist drive joystick
16 cables with or without reactors must be reduced command, whereas the measured parameters are output
17 to half of the maximum values which are voltage, current, DC bus link voltage, motor torque*,
18 otherwise possible. motor temperature and output speed for maximum
19  Cannot be used in conjunction with sinusoidal reference (output frequency).
20 filters and dv/dt filters. The second and third control technique in drive of
21  In regenerative mode and with a braking unit at main hoist is set to V/f control (close loop with speed
22 the upper threshold, the current limit is sensor), respectively vector control (closed-loop, with
23 automatically lowered to 1.36 times the rated speed sensor).
24 current (no current reduction with AFE and All measurements on three control techniques are
25 rectifier/regenerative unit) [19]. shown in Table 1.
26 The results shown in Table 1 (reading from simovert
27 Short time current master drive by drive monitor) are summarized in Figure
136% 10 that shows a comparison of main parameters in three
28
29 100% used control techniques at maximal speed of IM.
30 91% The motor rated torque is 581 Nm, so in speed vector
Base load current (with
control technique the motor torque in Table 1. When,
Current rating

31 overload capability)
32  Load = 5 ton is 12.4% (72.044 Nm),
33  Load = 25 ton is 34% (197.54 Nm) and
34  Load = 45 ton is 62.8 (364.868 Nm).
35 60s t On three of the control techniques the high breakaway
36 300s torque is required and if the load torque is constant it
37 (a) means that the load torque is not a function of speed.
38 Due to the calculation of function block of rotor flux
39 Short time current at V/f control open-loop with the linear characteristic, the
40 160%
time between feedback and reference signal is
41 approximately 45 ms (higher than in closed-loop). In the
42 50T crane the main hoist application time delay is very
100%
43 91% large. Sometime is needed to run at below 5-6 Hz (Table
44 Base load current (with 2) and the motor on a V/f control technique cannot
Power rating

45 overload capability) generate sufficient torque because at those low speeds, the
46 V/f ratio to achieve maximum torque is different than at
47 higher speeds.
48 t When we tried to lift load up to 45 t in low output
49 30s 300s
speed and due to lower motor torque, the hook moves
50 (b) without control in downward direction, even if the
51 command was given for lifting in upward direction,
52 Fig. 9. (a) VSD with overload capability, (b) VSD with according to Fig 3, the region on the left side of the fc
53 increasing overload capability frequency. So this is the reason that we do not prefer to
54 use this control technique on main hoist 50T crane.
55 High voltage during the braking process of motor also Reading parameters from Simovert master drive by
56 causes overloading. Many VSD have selective features drive monitor which are presented in Table 1 (output
57 that the controller does not take into account like the time frequency, current and voltage are zero) when Load = 45
58 of deceleration and prevents stopping by overvoltage. t, because there was a fault trip and was stopped the work
59 Protections from under voltage and overvoltage are of IM.
60 monitored by the DC link because the DC link is a source
61 of DC voltage to the inverter and the control circuits.
62
63
64
65
6
 Table 1. The parameters comparison of the crane main hoist on three control techniques for different loads

Crane–main hoist-lifting with different load

1 Volt/frequency open-loop Volt/frequency closed- Vector control closed-loop
2 VSD- Motor
control loop control
3
4 5 ton 25 ton 45 ton 5 ton 25 ton 45 ton 5 ton 25 ton 45 ton
5
6 Output frequency (Hz) 48.431 48.432 0 48.837 49.29 48.22 49.437 49.430 49.424
7
8 Output voltage (V) 387.5 387.5 0 390.5 395 386.8 381.4 386.4 393.7
9
10 Output Current (A) 60.7 66.9 0 57.9 70 109 53.7 73.4 111.0
11
12 DC bus voltage (V) 539 533 706 540 531 523 550 541 537
13
14 Motor Torque (%) 0* 0* 0* 0* 0* 0* 12.4 34 62.8
15
16 Motor Temperature (°C) 40 42 40 42 43 44 50 48 50
17
18 Motor Speed (1/min) 1453.1 1453.2 464.4 1460.6 1497.8 1446.9 1483.1 1482.8 1483.1
19
20 *Simovert Master Drive VC calculates the motor torque only in vector control technique, therefore on Table 1 the motor
21 torque of V/f (open and closed-loop) control is not calculated.
22
23
24
25 T he chart of parameters comparison at crane main hoist on three control
26 techniques for different loads
27
28

1497.8
1483.1

1483.1
1482.8
1460.6

1453.2
1453.1

1446.9
29
30
31
32
33
34
706

35
550

541
540
539

464.4
537
533
531

523
393.7
390.5
387.5

387.5

386.8
386.4
381.4

36
395

37
49.437

49.424
48.837
48.431

48.432

48.22

38
49.43
49.29

111
109
73.4
66.9
60.7
57.9
53.7

70

50

50
48

44
43
42

42
40

40

39
0

40
41 Output Output Output current DC bus voltage Motor temperat. Motor
frequency (Hz) voltage (V) (A) (V) (°C) speed (1/min)
42
43 5 ton V/f - open loop 5 ton V/f - closed loop 5 ton VC - closed loop
44 25 ton V/f - open loop 25 ton V/f - closed loop 25 ton VC - closed loop
45 45 ton V/f - open loop 45 ton V/f - closed loop 45 ton VC - closed loop
46
47
Fig. 10. Comparison of V/f open-loop control, V/f closed-loop control and vector control closed-loop for three loads:
48
Load 1 = 5 ton, Load 2 = 25 ton and Load 3 = 45 ton.
49
50
The uncontrolled rotation of the motor shaft can cause In speed vector control technique with speed sensor
51
big problems in transporting molten metals. During (Table 1) the calculation of time between the reference
52
testing at high speeds of V/f open-loop control occurred signal and feedback is approximation 20 ms (not using the
53
overcurrent fault (Figure 11). So this control technique is function block for calculating the rotor flux) and can
54
not preferable to be used for crane hoist movement due to generate more starting torque and can provide full torque
55
56 the instability and because the fault/trip of VSD. In heavy down to 1 Hz or less, in contrast the V/f control speed
57 machinery industries the number of fault/ trips should be technique below 5-6 Hz cannot provide much torque.
58 minimal. The motor temperature increase is usually the result of
59 The overcurrent in VSD is caused by short circuit, a high flow of current, but from experimental results in
60 ground fails or mechanical overload, motor temperature, vector control speed, output current for Load = 45 t is
61 drive temperature, etc. According to Figure 10, approximately twice of the output current for Load = 5 t,
62 protections from undervoltage and overvoltage are motor temperature remains the same (see Figure 10).
63 monitored by the DC link between 537V to 550 V. The
64 shutdown threshold has been exceeded.
65
7
 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30 Fig. 11. Over current fault (F11 = Over current) has been occurred
31
32
33 Table 2. Crane-main hoist-lifting on the V/f control 6. Conclusions
34 open-loop (low speed) The main challenge for speed motor control drive on
35 crane hoist applications in industry is the number of
36 Crane–main hoist-lifting with process fault/trip (stoppages) to be minimal.
37 different load The main advantage of vectorial control closed-loop
38 technique in hoist crane applications is that the speed
VSD- Motor Volt/frequency open-loop control of IM could be achieved not only for the speed
39 control
40 ranges lower than 6 Hz, but also for frequencies lower
41 5 ton 25 ton 45 ton than 1 Hz, where the number of fault/trips will be
42 minimal. For different loads, the output currents change
Output frequency obviously, but the motor temperature remains almost
43 5.657 5.080 -
(Hz)
44 constant.
45 Output voltage (V) 47.5 42.9 - In V/f control (open and closed-loop) speed control
46 under 1Hz is already impossible, whereas in range 1-6 Hz,
47 Output Current (A) 57.6 71.8 - the motor cannot produce sufficient torque and as a
48 consequence the ladle with molten metal moves in a
DC bus voltage
49 551 557 560 downward direction, even if the command was given for
(V)
50 an upward direction.
51 Motor Torque (%) 0 0 - Therefore, from theoretical and experimental analysis,
52 we prefer vector control closed-loop on crane hoist
Motor
53 47 48 50 applications.
Temperature (°C)
54 Motor Speed
55 169.8 154.8 - References
(1/min)
56
57 1. Niapour, S. M., Garjan G. S., Shafiei, M., Feyzi, M. R.,
Protection from over current is realized through an Danyali, S., Kouhshahi, M. B. (2014): Review of
58 over current protection unit. The maximum permissible
59 Permanent-Magnet Brushless DC Motor Basic Drives
overload current value (P128 set to 252.8A) is 1.36 times Based on Analysis and Simulation Study. Int. Rev. Elec.
60
greater than the rated current values (P072 set to 186A) Eng., 9(5), 930-957. doi: 10.15866/iree.v9i5.827.
61
for a period of 60s if the machine has just been switched 2. Holopainen, T. P., Niiranen, J., Jörg, P., Andreo, D.
62
on and has not reached its maximum permissible (2013): Electric motors and drives in torsional vibration
63
temperature.
64
65
8
 analysis and design. In Proceedings of the Forty-Second Authors
Turbomachinery Symposium, Houston, Texas.
3. Boldea, I. (2008): Control issues in adjustable speed Sabrije Osmanaj received the
drives. IEEE Ind. Elec. Mag., 2(3), 32-50. doi: Dipl.Ing. degree in Electrical
1 10.1109/mie.2008.928605. Engineering and the Mr.sc.degree in
2 4. Saidur, R., Mekhilef, S., Ali, M. B., Safari, A., Electronics from University of
3 Mohammed, H. A. (2012): Applications of variable speed Prishtina, Faculty of Electrical and
4 drive (VSD) in electrical motors energy savings. Renew. Computer Engineering (FECE),
5 Sustain. Energy Rev., 16(1), 543–550. Kosova, in 1996 and 2003,
doi.org/10.1016/j.rser.2011.08.020. respectively. She received her Ph.D.
6
5. Kabashi, Q., Limani, M., Caka, N., Zabeli, M. (2017): The degree in Electronics from the
7 Polytechnic University of Tirana, Faculty of Electrical
impact of sampling frequency and amplitude modulation
8 Engineering in 2009. She currently holds the position of
index on low order harmonics in a 3-phase SV-PVM
9 Associate Professor at FECE, University of Prishtina. Her
voltage source inverter. Turk. J. Elec. Eng. & Comp. Sci.,
10 research interests include power electronics and biomedical
25(1), 184-199. doi:10.3906/elk-1408-34.
11 6. Kivelä, T., Golder, M. (2016): Simulation and analysis of informatics.
12 an emergency lowering system for crane applications.
13 Log. J. doi: 10.2195/lj_proc_kivelae_en_201605_01. Myzafere Limani received her
14 7. Gaeid, K. S., Ping, H. W., Khalid, M., Masaoud, A. Dipl.Ing. degree in Electrical
15 (2012): Sensor and Sensorless Fault Tolerant Control for Engineering from University of
16 induction Motors Using a Wavelet Index.Sensors, 12, Prishtina, Kosova, in 1978 and her
17 4031-4050. doi:10.3390/s120404031. Mr.sc. degree in Electrical
18 8. Yu, Z., Figoli, D. (1998): AC Induction Motor Control Engineering from University of
19 Using Constant V/Hz Principle and Space Vector PWM Belgrade, Serbia in 1988. She
20 Technique with TMS320C240. Application report: received her Ph.D. degree in
SPRA284A. Electrical and Computer
21
9. Akin, B., Garg, N. (2013): Scalar (V/f) Control of 3-Phase Engineering from the University of Prishtina in 2000. She is
22
Induction Motors, Texas Instruments Application Report, currently a Full Professor in the department of Electronics at
23 the University of Prishtina, Faculty of Electrical and Computer
24 SPRABQ8.
Engineering and a Correspondent Member of the Academy of
25 10. Soni, S. K., Gupta, A. (2013): Analysis of SVPWM Based
Arts and Sciences of Kosovo. Her current research interests
26 Speed Control of Induction Motor Drive with using V/F
include electronics and audio signal processing.
27 Control Based 3 Level Inverter. Int. J. Sci. Eng. & Tech.,
28 2(9), 932-938.
Kadrije Simnica received her BSc.
29 11. Peña, J. M., Díaz, E.V. (2016): Implementation of V/f
And MSc. degrees in Electronics
scalar control for speed regulation of a three-phase
30 from the University of Prishtina,
induction motor. In IEEE Conference proceedings
31 Faculty of Electrical and Computer
Andescon, Arequipa, Peru. doi:
32 Engineering, in 2011 and 2015
10.1109/andescon.2016.7836196. respectively. Since 2015 she is
33 12. Behera, P. K., Behera, M. K., Sahoo, A. K. (2014): Speed
34 employed as part-time teaching
control of induction motor using scalar control technique. assistant at the University of
35 Int. J. Comp. Appl., 1, 37-39.
36 Prishtina, Faculty of Electrical and Computer Engineering in
13. Peterson, S. (2014): Choosing the right control method for Prishtina, Kosovo. Her main interests are control methods for
37 VFDs. Machine Designe. 86, 38. power electronics devices.
38 14. Kiran, N. (2014): Indirect vector control of three phase
39 induction motor using PSIM. Bull. Elec. Eng. & Inf., 3, Qamil Kabashi received the
40 15-24.doi: 10.11591/eei.v3i1.181. Dipl.Ing. (1996), Mr.sc. (2007) and
41 15. Quang, N. P., Dittrich, J. –A. (2015): Vector Control of Ph.D (2012) degrees in Electrical
42 Three-Phase AC Machines. System Development in the Engineering from the University of
43 Practice, 2nd edn. Springer. Prishtina, Faculty of Electrical and
44 16. Trzynadlowski, A. M. (2001): Control of Induction Computer Engineering. He currently
45 motors, Academic Press. holds the position of Associate
46 17. Mitrovic, N., Petronijevic, M., Kostic, V., Jeftenic, B. Professor at the Faculty of
47 (2012): Electrical Drives for Crane Application. Mechanical and Computer Engineering, University of
48 Mechanical Engineering IntechOpen Ed. M. Gokcek. doi: Mitrovica. His research interests are in the Power Electronics,
49 10.5772/35560. focused on harmonic effects by PWM Inverters.
50 18. Lepka, L., Stekl, P. (2005): 3-Phase AC Induction Motor
Vector Control Using a 56F80x, 6F8100 or 56F8300
51
Device. Application Note, Freescale Semiconductor.
52
19. Siemens. (2012): Simovert Master Drive Vector Control,
53
User manual.
54
55
56
57
58
59
60
61
62
63
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9
Vitae Click here to download Vitae CVs.docx

Sabrije Osmanaj received the Dipl.Ing. degree in Electrical Engineering and the Mr.sc.degree in Electronics from University of Prishtina,
Faculty of Electrical and Computer Engineering (FECE), Kosova, in 1996 and 2003, respectively. She received her Ph.D. degree in
Electronics from the Polytechnic University of Tirana, Faculty of Electrical Engineering in 2009. She currently holds the position of
Associate Professor at FECE, University of Prishtina. Her research interests include power electronics and biomedical informatics.

Myzafere Limani received her Dipl.Ing. degree in Electrical Engineering from University of Prishtina, Kosova, in 1978 and her Mr.sc.
degree in Electrical Engineering from University of Belgrade, Serbia in 1988. She received her Ph.D. degree in Electrical and Computer
Engineering from the University of Prishtina in 2000. She is currently a Full Professor in the department of Electronics at the University
of Prishtina, Faculty of Electrical and Computer Engineering and a Correspondent Member of the Academy of Arts and Sciences of
Kosovo. Her current research interests include electronics and audio signal processing.

Kadrije Simnica received her BSc. And MSc. degrees in Electronics from the University of Prishtina, Faculty of Electrical and Computer
Engineering, in 2011 and 2015 respectively. Since 2015 she is employed as part-time teaching assistant at the University of Prishtina,
Faculty of Electrical and Computer Engineering in Prishtina, Kosovo. Her main interests are control methods for power electronics devices.

Qamil Kabashi received the Dipl.Ing. (1996), Mr.sc. (2007) and Ph.D (2012) degrees in Electrical Engineering from the University of
Prishtina, Faculty of Electrical and Computer Engineering. He currently holds the position of Associate Professor at the Faculty of
Mechanical and Computer Engineering, University of Mitrovica. His research interests are in the Power Electronics, focused on harmonic
effects by PWM Invereters.