electric machine drive technology for elevators - ifeec. sul.pdf · electric machine drive...

Electric Machine Drive Technology for Elevators

2th Nov, 2015, @Taipei, Taiwan

Seung-Ki SulIEEE Fellow

Professor, Seoul National University, Seoul, Korea.

Outline

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01 Introduction

02 Electrolytic Capacitor-less Elevator

04 Ultra High-Speed Elevator Drive System

05 Reduction of Vertical Vibration

03 Super Capacitor-aided Elevator

06 Summary

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Introduction

Brief History of ElevatorsPrimitive elevator(hoist)

Middle age: powered by animal, human, water-drive

Steam / Hydraulic plunger Value governing water flow were manipulated by

passenger using lopes(later, lever control) to control speed.

Elisha Graves Otis invented rope-break safety failure device in 1853.

The world’s first passenger service elevator was installed in a five-story hotel on Broadway in New York, in 1857. Manufactured by the Otis Elevator Company. Steam powered, 450kg Pay Load, 12m/min

01

http://spec.snu.ac.kr

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Introduction

Brief History of Elevators

01


<1963 Otis type F elevator safety governor>< Modern elevator safety governor - Hyundai elevator>

Speed governor

Fly ball type

<Elisha Otis demonstrating his safety system, Crystal Palace, 1853>

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Introduction

Brief History of ElevatorsIn 1887, Electric elevator was invented by

German inventor Werner von Siemens.In 1889, Norton Otis, son of the pioneering

Elisha, developed an electric elevator, the first direct-connected geared elevator in the world. Pay Load:675 kg, 30m/min

In 1900, the alternating current induction motor was introduced and used for Elevator.

In 1903, the traction type elevator models appeared in the United States. Car is connected to a counterweight by a rope and

a pulley.In 1922, Westinghouse installed a gearless

elevator in the Physical Education Building in Chicago, and in the Rockefeller Building in New York.

01


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Introduction

Conceptual diagram of elevator

01


Traction Machine

Main Rope

Counterweight

Car

Highest Floor

Lowest Floor

Brake

Buffer

Compen-sationSheave

Motor

Sheave

Car or Cage

Counter Weight

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Introduction01

Photo of main sheave and pulley

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Introduction01

Photo of traction motor and rope

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Introduction

Photo of up to date control DSP board for elevator .

01


Control board based on TMS28377D DSP and associated I/Ounder test

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Electrolytic Capacitor-less Elevator

Low and medium speed elevator

Up to 20kW 30~150m/min Within 20 floors No regenerative rectifier Simple diode rectifier and DB circuit

02


30 150 1080 m/min300 600

Ultra high speedLow-medium speed High speed

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Conventional low and medium speed elevator up to 20kW

Complex initial charging circuit Reliability issueBulky Electrolytic Capacitor Limited life time, Poor input THDBraking ResistorWaste of regenerating energy Poor

Efficiency

02


Source Diode Rectifier PWM Inverter

+

Motor

DC Reactor

Initial ChargingCircuit

ElectrolyticDC-linkCapacitor

BrakingResistor

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Electrolytic capacitor-less elevator

Diode rectifier + Resistive braking circuit→ Bidirectional rectifier using IGBTs Regeneration

Bulky electrolytic capacitor + Initial charging circuit→ Small polypropylene capacitor + input line filter

Smaller & Cost effective

02


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Experimental Waveform (Test Tower)

02


Ch. 1 : Vdc100V / div. (center : 500V)

Ch. 2 : Source Current10A / div.

Ch. 3 : Motor Speed25 rpm / div.

Ch. 4 : Motor Q axis Current25 A / div.

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Experimental Waveform (Test Tower)Generating

02



Ch. 2 : AC Grid Current4A / div.


Ch. 4 : Motor Q Axis Current25 A / div.

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Experimental Waveform (Test Tower)Motoring

02



Ch. 2 : AC Grid Current4A / div.


Ch. 4 : Motor Q axis Current25 A / div.

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Energy Consumption Data

02


0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

50% 60% 70% 80% 90% 100%

Ene

rgy

[kW

h]

Load

Conventional

Cap-less

Load Conventional Cap-less Saving

100% 0.8134 (kWh) 0.3132 (kWh) 61.5%

90% 0.6777 (kWh) 0.2714 (kWh) 59.9%

80% 0.5460 (kWh) 0.2374 (kWh) 56.4%

70% 0.4254 (kWh) 0.2078 (kWh) 50.4%

60% 0.3108 (kWh) 0.1881 (kWh) 38.3%

50% 0.2110 (kWh) 0.1728 (kWh) 14.3%

*World best energy efficiency

German TUV - VDI 4707 “A” Class

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About 40% energy saving; Max. 60% savingRegeneration effect

About 40% space savingFavorable for a machine room-less elevator

Reliability enhancementsNo electrolytic capacitorsNo initial charging circuit (No magnetic contactor, No charging

resistors)No braking resistor

Over 40,000 units have been installed in Korea, soon in China.Saving 75GWh annually in Korea 3 days operation of 1GW

nuclear power plant

02


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Super Capacitor-aided Elevator Medium-high speed elevator

Peak power shaving Reduction of distribution system cost Reduction of basic price of electricity

Higher efficiency due to energy storage

03


<Test Tower> < Experimental Setup at SNU lab.>

Super-Cap Super-Cap

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Super Capacitor-aided Elevator

Typical grid power consumption of 240m/min elevatorMaximum power : 92kWConstant power : 48kW

Input power requirement of conventional elevator: 100kW

03


92kW

100%

0%

0%

100%

48kW

<Elevator power consumption>

moving upward moving downward

Loading Loading

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Why Super Capacitor(ultracapacitor)?

High Power densityLow Energy density

03


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DC/DC ConverterHalf bridge DC/DC converter

033


scC

esrR

filmC

strayL fL

Supercapacitor1.58F648~450V

DC/DC convertor

Traction motor

380V Grid DC link700V

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Test tower ExperimentDC/DC Converter(Half-bridge)

IGBT : 1200V, 150A Lf : 0.3mH Cfilm : 30mF (ESR : 2mΩ)

Super capacitor Unit cell : 2.8V 400F(110A) – 240 unit series connection Total 648V, 1.58F(ESR : 0.72 Ω), max. energy : 331kJ, max power : 71kW

03

Super-CapDC/DC Conv

Super-Cap

Stack

inductor

IGBT

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Experimental results at test towerLoading : 100%

03

Grid power: 25kW/div

5s

100kW

Motor q-axis current: 50A/divMotor speed: 100r/min /div

Grid power: 50kW

Motor power:25kW/div

Grid power:-50kW

<UP> <DOWN>

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Experimental result at test towerLoading : 100%

03

5s

502V550V

648V

Super-Cap Terminal Voltage: 200V/div

Super-Cap Estimation Voltage : 200V/div

Super-Cap Current: 25A/div

DC-Link Voltage : 200V/div

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Ultra High-Speed Elevator Drive System

World tallest elevator test towerHyundai Asan Tower, South Korea : running distance,205meters

04


New test tower

Old test tower

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World tallest elevator test towerHyundai Asan Tower, South Korea : running distance,205meters

04


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Why ultra high speed elevator?More high-rise buildings; above 100 floors

Around 30s travel time from bottom to top floor.Higher speed

More than 1,000 m/min 400m travel ; around 30s

Higher powerPeak power ; more than 1MWSheave load ; more than 500kN

Higher reliability Fault tolerance

World fastest elevator commercially operating 1040m/min; 101 building at Taiwan by Toshiba Electric.

04


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Ultra High-Speed Elevator Drive SystemSimulation Profiles(Total Mass for Acc.=50ton)

Max speed: 1080m/min. Pay Load 1600kgDesigned for world record

04


Te (k

Nm

)

Spe

ed (m

/min

)P

ower

(MW

)

Vdq

sr (V

)

Maximum 1.25 MW

Distance=378m

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High power system with low input voltageAC Input voltage: 380V~440V line to line rms

from building distribution panelPeak power of 1.2MW with 700V DC-link

voltagePeak phase current of motor: More than 3,000A in the

case of 3 phase motorCurrent limitation of switching devices

Multi-level inverterParallel connection of devicesMulti-phase machine

04


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Designed System Configuration9-phase PM machine3 sets of Back-to-Back Converters

04


Photo of traction motor for 1080m/min elevator

Continuous 200kWPeak 1250kW

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Designed System Configuration9-phase PM machine3 sets of Back-to-Back Converters

Each converter: Peak 600kW

04


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9-phase PM machineSystem fault toleranceTorque ripple reductionReduction of current rating per phase

3 sets of Back-to-Back ConvertersConsist of inverter and Active-Front-End(AFE)3 sets of existing standard model (600m/min

elevator)Each set can be separated from the system when

fault occurs.

04


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Control Block Diagram

04


FPGA

DC-linkVoltageControl


CurrentContol

x 3

CurrentContol

x 3

CurrentContol

x 3

CurrentContol

x 3 Inverter

DC-link

AFEConverter

Inverter

DC-link

AFEConverter

Position/Speed

Command CurrentReference

CurrentReference

Line-to-Line Voltage

Current Feedback

Current Feedback

Rotor Angle

CurrentContol

x 3

CurrentContol

x 3

Position/Speed

Control

MasterController

Inverterx 3

DC-linkx 3

AFEConverter

x 3

3-phaseGrid

Utility

9-phasePM

MOTOR

Position/Speed

ObserverEncoder

VoltageSensor

DC-link Voltage


x 3

GridAngle

Estimator

PWM

PWM

LoadPower

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DSP controllerLess frequent control loops

Position/Speed control loopActive front end voltage control loops

Communication with a host controllers such as group controller and MMI controller

FPGA controllerTime critical control loops

9-phase PM machine current control loopsActive front end current control loops

• Current Controller execution time : 347ns

04


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Experimental Waveform (Dynamo Test)

04


Motor Speed(75rpm/Div) Motor Phase Voltage(100V/Div)

Converter q-axis Current(300A/Div) Inverter q-axis Current(300A/Div)

10s

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Experimental Waveform (Test Tower)

04


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Reduction of Vertical Vibration

Why vertical vibration ?

05


cd

wv

cmwm

mv

mJ

mr

wd

cv

eT

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Reduction of Vertical Vibration Modeling of the Three-Mass System

Frequency Response ( )

05


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Acceleration Feedback Control Strategy

PI Control Using acceleration sensor

05


Young-Min Lee et al., “Acceleration Feedback Control Strategy for Improving Riding Quality of Elevator System”, IAS99, 34th IAS Annual Meeting

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05


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05


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Modeling of the Eccentric LoadingVibration proportional to rotational speed of sheave due to

eccentricity of sheave

05


rm

rmg

cosec rmT mg r

Rotor Position

cos

cos cosec rm

ec rm ec rm

T mg r

T T t

rme m rm L ec

dT J B T Tdt

sinrm avg ripple rmt

42/50


Phase Lock Loop for detection of phase of the speed ripple

Speed model

Signal processing

05


cos rmt

clpf

clpfs

1s ipK rm

rm*rm


cos1 1cos sin 2 sin2 2

rm rm

avg rm ripple rm ripple

t

t t

1cos sin sin2rm rm rippleLPF t

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Detection of magnitude of Speed ripple

Speed model

Signal processing

05



sin rmt

clpf

clpfs

rm

rm*rm

12 ripple

sin1 1sin cos 2 cos2 2

rm rm

avg rm ripple rm ripple

t

t t

1 1sin cos2 2rm rm ripple rippleLPF t

44/50


Current compensator

Speed control system

05


SMPMSM

CurrentCompensator

INVERTER

icpc

KKs

*r

qsffV

*rdsffV

+

+

*rqsV

*rdsV

+

icpc

KKs

*rdsfbV

*rqsfbV

++-

++

PulseCounter

rrje

rdsi

rdsi

-

rqsi

isps

KKs

* 0rdsi

*rqsi+

-

*rm

rmrm

rm +*r

qsffi

rm

Current Controller

Speed Controller

rqsi

ddt

cos rmt

clpf

clpfs

1s ipK

rm

sin rmt

clpf

clpfs

1s imK

magIrm

*rqsffI

rm

sin( )mag rmI t

*rqsffIrm

*rm

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Compensation of speed ripple in the case of 600m/min elevatorExperiment results at test towerCompensation based on the motor speed

05


Car acceleration : 0.01m/s2 /divMotor speed: 0.02r/min /div

2s 2s

Car acceleration : 0.01m/s2 /divMotor speed: 0.02r/min /div

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Current compensatorBased on measured cage acceleration

05


cos rmt

clpf

clpfs

1s ipK

rm

sin rmt

clpf

clpfs

1s imK

magIrm

*rqsffI

rm

sin( )mag rmI t

*rqsffIacc

*acc

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Test tower experiment result600m/min elevator

05


No Current Compensation

Current Compensation

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0

0.5

1

1.5

2

2.5

300 360 420 480 540 600가

속도[m

G]

회전속도[m/min]

전류 보상 전후 진동 크기 비교(DN 운전)

보상전 DN

보상후 DN

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

300 360 420 480 540 600

가속

도[m

G]

회전속도[m/min]

전류 보상 전후 진동 크기 비교(UP 운전)

보상전 UP

보상후 UP

Vibration magnitude comparison (moving upward) Vibration magnitude comparison ( moving downward)

Acc

eler

atio

n[m

G]

Acc

eler

atio

n[m

G]

Speed[m/min] Speed[m/min]

After compensation After compensation


Test tower experiment result600m/min elevator

05


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Summary

Electrolytic Capacitor-less ElevatorAbout 40% space saving About 50% energy saving

Super capacitor added elevatorPeak power shaving Reduced electric distribution equipment cost

Ultra High Speed Elevator SystemMaximum speed : 1080m/minWorld fastest elevator

Developed June of 2013Running 24hours, 7 days for last 2 years

Still waiting the first customer Vertical Vibration reduction

About 50% reduction of vertical vibration by feedforward control

06


Thank you SPEC

electric machine drive technology for elevators - ifeec. sul.pdf · electric machine drive...

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