變頻器原理的基本知識(shí)

三相380V電網(wǎng)電壓從變頻器的L1， L2， L3輸入端輸入后，首先要經(jīng)過(guò)變頻器的整流橋整流，后經(jīng)過(guò)電容的濾波，輸出一大約530V左右的直流電壓(這也就是我們常用來(lái)判斷變頻器整流部分好壞的最常測(cè)試點(diǎn))。

 

當(dāng)然整流橋最初是要經(jīng)過(guò)斷電測(cè)試的)然后經(jīng)過(guò)逆變電路，通過(guò)控制逆變電路的通斷來(lái)輸出我們想要的合適頻率的電壓(變頻器能變頻最主要的就是控制逆變電路的關(guān)斷來(lái)控制輸出頻率)，變頻器故障有無(wú)數(shù)種，好在現(xiàn)在變頻器都趨于智能化，一般的故障它自己都能檢測(cè)，并在控制面版上顯示出其代碼，用戶只需查一下用戶手冊(cè)就能初步判斷其故障原因。

 

但有時(shí)，變頻器在運(yùn)行中或啟動(dòng)時(shí)或加負(fù)載時(shí)，突然指示燈不亮，風(fēng)扇不轉(zhuǎn)，無(wú)輸出。這時(shí)我們初學(xué)者就不知該怎辦了。其實(shí)很簡(jiǎn)單的，我們只要把變頻器的電源斷了。斷電測(cè)試一下它的整流部分與逆變部分，大多情況下就能知其故障所在了。

 

這里有一點(diǎn)千萬(wàn)要注意：

 

斷電后不能馬上測(cè)量，因變頻器里有大電容存有幾百伏的高壓，一定要等上十幾分鐘再測(cè)!

 

? 變頻器上電前整流橋及逆變電路的測(cè)試

 

具體測(cè)量方法如下：

 

找到變頻器直流輸出端的”+”與”-”，將萬(wàn)用表調(diào)到測(cè)量二極管檔，黑表筆接”+”表筆分別接變頻器的輸入端L1， L2， L3端，整流橋的上半橋若是完好，萬(wàn)用表應(yīng)顯示0.3…的壓降，若損壞則萬(wàn)用表顯示”1”過(guò)量程。

 

相反將紅表筆接”-”黑表筆分別接L1， L2， L3端應(yīng)得到上述相同結(jié)果，若出現(xiàn)”1”則證明整流橋損壞。然后測(cè)試其逆變電路，方法如下：將萬(wàn)用表調(diào)到電阻×10檔將黑表筆接”+”紅表筆接變頻器的輸出端U， V， W應(yīng)有幾十歐的阻值，反向應(yīng)該無(wú)窮大。反之將紅表筆接到”-”重復(fù)上述過(guò)程，應(yīng)得到同樣結(jié)果。

 

這樣經(jīng)過(guò)測(cè)量在判斷變頻器的整流部分與逆變部分完好時(shí)，上電測(cè)量其直流輸出端看是否有大約530V高壓，注意有時(shí)萬(wàn)用表顯示幾十伏大家以為整流電路工作了，其實(shí)它并沒(méi)工作，它正常工作會(huì)輸出530V左右的高壓，幾十伏的電壓是變頻器內(nèi)部感應(yīng)出來(lái)的。若沒(méi)530V左右高壓這時(shí)往往是電源版有問(wèn)題。

 

有的變頻器就是由于電源版的一小貼片電阻被燒毀，導(dǎo)致電源板不工作，以致使變頻器無(wú)顯示無(wú)輸出，風(fēng)扇不轉(zhuǎn)，指示燈不亮。　這樣就可以初步判斷出變頻器是哪部分出現(xiàn)了故障，然后拆機(jī)維修時(shí)就可以重點(diǎn)測(cè)試懷疑故障部分。

二、技術(shù)基礎(chǔ)

 

1、Electronic Line Shafting---ELS，許多工業(yè)生產(chǎn)線都由多臺(tái)機(jī)器組成，各軸之間具有運(yùn)動(dòng)關(guān)系。過(guò)去是使用機(jī)械機(jī)構(gòu)連接各軸，如果使用電子方式連接各軸，各州各有其驅(qū)動(dòng)馬達(dá)，則稱(chēng)為”Electronic Line Shafting”(ELS)。

 

2、 Auto Tuning(自動(dòng)調(diào)校)，常見(jiàn)于磁束向量型變頻器的一種技術(shù)，能自動(dòng)監(jiān)測(cè)(找出)馬達(dá)的參數(shù)，如轉(zhuǎn)差頻率/場(chǎng)電流/轉(zhuǎn)矩電流/定子阻抗/轉(zhuǎn)子阻抗/定子感抗/轉(zhuǎn)子感抗等.有了這些參數(shù)后才能作[專(zhuān)據(jù)估算]及[轉(zhuǎn)差(滑差)補(bǔ)償].也因?yàn)榇思夹g(shù)，在無(wú)編碼器的運(yùn)轉(zhuǎn)下仍能獲得良好的運(yùn)轉(zhuǎn)精度.

 

3、無(wú)編碼器運(yùn)轉(zhuǎn)，在速度控制上，與舊式variable frenquency變頻器的開(kāi)回路比較，磁束向量型變頻器內(nèi)部由速度觀測(cè)計(jì)算功能達(dá)成閉回路.馬達(dá)側(cè)不用裝編碼器也能達(dá)到良好的速度精度.無(wú)編碼器運(yùn)轉(zhuǎn)有如下好處:

 

1)，配線精省;

 

2)，不必?fù)?dān)心RF雜訊對(duì)編碼器低電壓信號(hào)的影響;

 

3)，在多震動(dòng)的場(chǎng)合不用擔(dān)心編碼器的高故障率。

 

4、變頻器的矢量控制，在AC馬達(dá)中，轉(zhuǎn)子由定子繞組感應(yīng)電流產(chǎn)生磁場(chǎng).定子電流含兩部分一部分影響磁場(chǎng)，另一部分影響馬達(dá)輸出轉(zhuǎn)矩.要使用AC馬達(dá)在需要速度與轉(zhuǎn)矩控制的場(chǎng)合，必須能夠把影響轉(zhuǎn)矩的電流分離控制，而磁束矢量控制就能夠分離這兩部分進(jìn)行獨(dú)立控制.(具有大小及方向的物理量稱(chēng)為矢量)。

 

5、Field WeakeningField Weakening線路可用以減弱馬達(dá)的場(chǎng)電流，改變與磁場(chǎng)的平衡關(guān)系，使馬達(dá)高于基本轉(zhuǎn)速運(yùn)轉(zhuǎn)。

 

6、定轉(zhuǎn)矩應(yīng)用，所需轉(zhuǎn)矩大小不因速度而變的場(chǎng)合，常用到[定轉(zhuǎn)矩應(yīng)用].如傳送帶等負(fù)載.[定轉(zhuǎn)矩應(yīng)用]通常需要較大的起動(dòng)轉(zhuǎn)矩.[定轉(zhuǎn)矩應(yīng)用]在低速運(yùn)轉(zhuǎn)時(shí)易有馬達(dá)發(fā)熱問(wèn)題，解決的方法:

 

(1)加大馬達(dá)功率;

 

(2)使用裝有定速冷卻的變頻器專(zhuān)用馬達(dá)(即馬達(dá)的冷卻方式為強(qiáng)制風(fēng)冷)。

 

7、變轉(zhuǎn)矩應(yīng)用多見(jiàn)于離心式負(fù)載，如泵/風(fēng)機(jī)/風(fēng)扇等，其使用變頻器的目的一般為節(jié)能

 

比如當(dāng)風(fēng)扇以50%轉(zhuǎn)速運(yùn)轉(zhuǎn)時(shí)，其所需轉(zhuǎn)矩小于全速運(yùn)轉(zhuǎn)所需。可變轉(zhuǎn)矩變頻器能夠僅給與馬達(dá)所需轉(zhuǎn)矩，達(dá)到節(jié)能效果。次應(yīng)用中短暫的巔峰負(fù)載通常無(wú)需給與馬達(dá)額外的能量。故變轉(zhuǎn)矩變頻器的過(guò)載能力可以適用于大部分用途。

 

定轉(zhuǎn)矩變頻器的過(guò)載(電流)能力須為額定值150%/1minute，而可變轉(zhuǎn)矩變頻器所需過(guò)載(電流)能力僅需額定值120%/1minute。因?yàn)殡x心式機(jī)械用途中很少會(huì)超出額定電流。另外，變轉(zhuǎn)矩用途所需起動(dòng)轉(zhuǎn)矩也較定轉(zhuǎn)矩用途小.。

 

8.變頻器專(zhuān)用馬達(dá),所謂[Inverter-duty Motor]

 

主要特征如下:

 

1)分離式它力通風(fēng)(它力風(fēng)冷);

 

2)10Hz-60Hz為定轉(zhuǎn)矩輸出

 

3)高起動(dòng)轉(zhuǎn)矩

 

4)低噪音

 

5)馬達(dá)裝有編碼器.*但并非所有稱(chēng)之為變頻器專(zhuān)用馬達(dá)的馬達(dá)都具有上列特征。

 

9.關(guān)于調(diào)速

 

1)調(diào)速：根據(jù)工況需要調(diào)整設(shè)備運(yùn)行速度，以達(dá)到節(jié)能降耗、減少磨損、按需生產(chǎn)等目的。

 

2)直流調(diào)速(DC Controler/motor)：由直流控制器調(diào)節(jié)直流電機(jī)以達(dá)到調(diào)整速度的目的。

 

3)交流變頻調(diào)速(AC inverter/motor)：由變頻器輸出頻率變化的三相交流電流從而控制交流電機(jī)的轉(zhuǎn)速。

 

4)矢量變頻調(diào)速(AC vector inverter)：通過(guò)復(fù)雜的計(jì)算變換，使交流變頻器按照直流電機(jī)的控制方式去控制交流電機(jī)，從而達(dá)到精確速度控制、轉(zhuǎn)矩控制、提高輸出扭矩等特性。

 

5)伺服控制系統(tǒng)(Servo control system)：在運(yùn)動(dòng)系統(tǒng)中引入速度反饋或位置反饋元件，通過(guò)負(fù)反饋?zhàn)饔眠_(dá)到極其精密的速度控制、定位控制及高動(dòng)態(tài)響應(yīng)。

 

10.幾個(gè)常見(jiàn)工業(yè)元件

 

1)測(cè)速發(fā)電機(jī)(Tacho-generator)：一種轉(zhuǎn)速測(cè)量元件，有交流、直流之分。

 

2)旋轉(zhuǎn)變壓器(Resolver)：一種經(jīng)濟(jì)、準(zhǔn)確地轉(zhuǎn)速和角位移測(cè)量元件。

 

3)光電編碼器(Encoder)：一種精密的角位移、轉(zhuǎn)速測(cè)量元件，適合在位置控制系統(tǒng)中作為反饋元件。

 

4)PLC：工業(yè)用計(jì)算、控制裝置，實(shí)現(xiàn)邏輯、時(shí)序、計(jì)算等控制功能，一般作為整個(gè)自動(dòng)化控制系統(tǒng)的上位主機(jī)。

 

5)HMI(Human-Machine Interface)：人機(jī)界面。

 

6)現(xiàn)場(chǎng)總線(Field-Bus System)：應(yīng)用于工業(yè)控制現(xiàn)場(chǎng)的串行通訊總線系統(tǒng)，大幅度降低接線成本，提高控制的抗干擾能力。

 

7)分布式控制(Distributed control)：區(qū)別于傳統(tǒng)的集中式控制，強(qiáng)調(diào)各個(gè)節(jié)點(diǎn)設(shè)備的智能化，一般由現(xiàn)場(chǎng)總線系統(tǒng)將各子設(shè)備連接起來(lái)。極大地提高系統(tǒng)應(yīng)用的靈活性、可靠性，降低上位機(jī)的運(yùn)算負(fù)擔(dān)。

 

11.關(guān)于電機(jī)的術(shù)語(yǔ)

 

1)防護(hù)等級(jí)(Protection Code)：(IP**)考察一個(gè)設(shè)備防止異物進(jìn)入和防水的能力，使IEC標(biāo)準(zhǔn)之一。其兩個(gè)數(shù)字分別代表防異物和防水的能力，數(shù)值越高表明可以防止更細(xì)小的物體進(jìn)入以及經(jīng)受更強(qiáng)烈的水流沖擊。一般為IP54(防塵，防潑灑水滴)以上防護(hù)等級(jí)的設(shè)備可以直接應(yīng)用于露天。

 

2)絕緣等級(jí)(Insulation Grade)：考察一個(gè)電氣設(shè)備(一般針對(duì)電機(jī))在保證良好絕緣特性的前提下所能承受的極限溫升能力，是IEC標(biāo)準(zhǔn)之一。一般有B級(jí)(85度)、F級(jí)(105度)、H級(jí)(125度)。

Of course, the rectifier bridge will go through the power-off test at first) and then go through the inverter circuit to control the on-off of the inverter circuit to output the voltage of the appropriate frequency we want (the main thing that the inverter can convert frequency is to control the off of the inverter circuit to control the output frequency). There are numerous kinds of inverter faults, but now the inverter tends to be intelligent, and general faults can be detected by itself Test, and display its code on the control panel, the user only needs to check the user manual to preliminarily determine the cause of its failure.

But sometimes, when the frequency converter is running or starting or loading, suddenly the indicator light is not on, the fan does not turn, and there is no output. At this time, we beginners don't know what to do. In fact, it's very simple. We just need to turn off the power supply of the inverter. Power off test its rectifier part and inverter part. In most cases, you can know the fault.

Here's one thing to note:

After power failure, it can't be measured immediately, because there is a large capacitance in the frequency converter with hundreds of volts of high voltage, it must wait for more than ten minutes to measure!

? test of rectifier bridge and inverter circuit before power on of frequency converter

The specific measurement method is as follows:

Find "+" and "-" of the DC output terminal of the converter, adjust the multimeter to the measurement diode, connect the black probe with "+" probe to the input terminals L1, L2 and L3 of the converter respectively, if the upper half of the rectifier bridge is intact, the multimeter shall display 0.3 If it is damaged, the multimeter will display "1" over range.

On the contrary, connect the red lead and the black lead to L1, L2 and L3 respectively. The same result above shall be obtained. If "1" appears, it indicates that the rectifier bridge is damaged. Then test the inverter circuit, the method is as follows: adjust the multimeter to the resistance × 10, connect the black probe with "+" red probe to the output terminal u, V, w of the converter, which should have a resistance value of tens of ohms, and the reverse should be infinite. On the contrary, if you repeat the above process, you should get the same result.

In this way, when judging whether the rectifier part and inverter part of the converter are in good condition through measurement, power on and measure the DC output terminal to see if there is about 530v high voltage. Note that sometimes the multimeter shows dozens of volts. We think the rectifier circuit is working, but it is not working. It will output about 530v high voltage when it is working normally, and dozens of volts are induced from the inside of the converter. If there is no high voltage around 530v, it is often a problem with the power version.

Some frequency converters are due to the burning of a small chip resistance of the power version, which causes the power board to not work, so that the frequency converter has no display and output, the fan does not turn, and the indicator light does not light up. In this way, we can initially determine which part of the frequency converter has a fault, and then we can focus on testing the suspected part of the fault when disassembling the machine for maintenance.

2、 Technical basis

1. Electronic line shafting --- els, many industrial production lines are composed of multiple machines, and each axis has motion relationship. In the past, mechanical mechanisms were used to connect the shafts. If the shafts were connected electronically, each state had its own driving motor, it was called "electronic line shifting" (ELS).

2. Auto tuning is a technology commonly used in magnetic beam vector converter. It can automatically monitor (find) motor parameters, such as slip frequency / field current / torque current / stator impedance / rotor impedance / stator reactance / rotor reactance, etc. only with these parameters can we make [Special estimation] and [slip (slip) compensation]. Because of this technology, it can still be obtained without encoder Good running accuracy

3. In the speed control, compared with the open-loop of the old variable frequency converter, the closed-loop is achieved by the speed observation and calculation function in the magnetic beam vector converter. The motor side can achieve good speed accuracy without encoder. The operation without encoder has the following advantages:

1) , fine wiring;

2) , do not worry about the influence of RF noise on the low voltage signal of the encoder;

 

3) In the case of multi vibration, there is no need to worry about the high failure rate of the encoder.

 

 

 

4. In vector control of frequency converter, in AC motor, the rotor generates magnetic field by induced current of stator winding. Stator current includes two parts: one part influences magnetic field, the other part influences motor output torque. In order to use AC motor in the situation of speed and torque control, it is necessary to be able to separate the current that affects torque, and the magnetic beam vector control can separate the two parts independently Control. (the physical quantities with size and direction are called vectors).

 

 

 

5. The field peaking field peaking circuit can be used to weaken the field current of the motor, change the balance relationship with the magnetic field, and make the motor run at a speed higher than the basic speed.

 

 

 

6. Constant torque application, where the required torque does not change due to speed, is often used to [constant torque application]. For example, load such as conveyor belt. [constant torque application] usually requires a large starting torque. [constant torque application] is easy to have motor heating problem when running at low speed. Solution:

 

 

 

(1) Increase motor power;

 

 

 

(2) Use the inverter special motor equipped with constant speed cooling (that is, the cooling mode of the motor is forced air cooling).

 

 

 

7. Variable torque applications are commonly found in centrifugal loads, such as pumps / fans / fans, etc., whose purpose is generally to save energy

 

 

 

For example, when the fan is running at 50% speed, the required torque is less than that required for full speed operation. The variable torque converter can only give the required torque to the motor, achieving energy saving effect. Secondary application