elevator drives
DESCRIPTION
Elevator drives examplesTRANSCRIPT
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Elevator DrivesPast, Present and Future
As Presented
at
NAVTP Annual Forum
Atlanta, Georgia
May 3, 2007
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Elevator Drives - Discussion
History
Requirements
Motor and Control Types
Industry Trends
Future Drives
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History236 BC – First Passenger Lift,
Archimedes
1853 – Safe Elevator Demo, Elisha Otis
1857 – First Safe Elevator Installation, Cooper Union, NYC
1861 – Otis Elevator Patent
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Otis Patent 1861
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History
1873 – First Modern DC Motor
1874 – J. W. Meaker Door Opener Patent
1880 – First Electric Motor Controlled Elevator Siemens / Sprague
1882-1889 – Tesla AC Induction Motor 3-Phase Squirrel Cage Design
1889 – Otis Elevator Uses DC Motor
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Otis DC
Elevator Motor
Circa 1889
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History1891 – Ward Leonard Variable
Speed Control– AC Induction Motor Turning DC Dynamo
– Rheostat to Control Generated Voltage
– DC Voltage Controls DC Motor Speed
1900-1970’s – Ward-Leonard M-G Sets and DC Motors Used for Variable Speed Elevators
AC Motors Used 1 and 2 Speed Starters
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Otis No. 1 Geared DC Machine with DC Motor
Circa 1915
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Otis Gearless DC Machine
Circa 1919
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M-G Set Controls (Otis Elevator, 1920’s)
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Otis Type 84 26 Broadway,NYC
Circa 1930’s
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History
1975-Present
– Thyristor (SCR) DC Drives Control Elevators
– All Analog Components in the 70’s
– Replaces Aging M-G Sets
1980’s – Microprocessors Improve
– Car Dispatch and Motor Drive Controllers
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Otis type 84,NYC with Encoder
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Westinghouse #205 with Encoder
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History Late 1980’s –
– Variable Frequency Inverters AC Induction Motors, Geared Applications Only
Early 1990’s – – More AC Inverters and Motors Begin to Displace
Small DC, 3-15 HP
Mid-1990’s – – Vector Control AC Inverters 10-40 HP Almost as
Good as SCR-DC.
– KONE Introduces PM EcoDisc AC Machine
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History
– Custom Gearless AC Induction Machines
– First Fully Regenerative AC Elevator Drives
– Much Discussion on PM-AC and MRL
– SCR-DC Still Used for Medium and Large Building Mods
Late 1990’s –
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History
– More PM-AC Motor Manufacturers. PM Gearless Begins to Replace AC Geared
– EU Focus on Efficiency and Harmonics/EMC
– Lower Cost IGBT Inverter Components
– North America Begins to Focus on Energy Reduction
– New Construction Leaning toward AC
– SCR-DC Still Used on Medium-Large Building Mods
2000-Present –
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Elevator Drive Requirements
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Elevator Duty Cycle
1.0
0
-1.0
-2.5
2.5POWER
KILOWATTS
FULL CAR
EMPTY CAR
EMPTY CAR
FULL CAR
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Four Quadrant Operation
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What Customers Want Repeatable Elevator Performance
Smooth Operation
Reliable Operating Life
Effortless Installation
Custom Control Interface
High Efficiency
Conformance to All Codes
Low Installed Cost
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Elevators vs. Industrial Applications
Infinitely Variable Speed Range
Infinitely Variable Torque Range with Smooth Bump Less Operation
Millions of Repeated Operating Cycles with High Peak Torque
High Inertia Resonant Load
Accurate Stopping Position
Unattended Operation 24/7/365
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Elevators vs. Industrial Applications
Quiet Operation
Long Operating Life
Long-Term Product Support
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Types of Motors DC Shunt Field
– High Speed Geared
– Low Speed Gearless
– Full HP Range 5 – 600 HP
– 89–94% Efficient
– High Torque Capacity Accel/Decel
– In Elevator Service for 70+ Years
– Requires DC Generator, SCR or Other AC-DC Power Conversion from AC Utility Power
– DC Motor Can Act Like a Generator
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Types of Motors AC Induction
– High Speed Geared, 2–75 HP– Few Low Speed Designs for Gearless– 85–94% Efficient
– Many with Single or 2 Speed Starters
– Can be Variable Speed by Inverter Control of Frequency
– Torque Strength Derived from Out of Phase Excitation Current
– Requires Flux Vector Control for Wide Operating Speed Range
– Can Act Like a Generator
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Types of Motors
AC Permanent Magnet (PM)– New Designs for Compact Gearless Machines
– Torque Strength from Permanent Magnets
– 90–95% Efficient
– Compatible with Inverters to Control Speed
– Requires Synchronous Flux Vector / Angle Control to Regulate / Modulate Torque
– Supply Limited to Specialty Machine Builders
– Not Suitable for High rpm Speed Geared Designs
– Can Act Like a Generator
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Modernization
Why keep a DC machine?– Many large DC machines cannot be
easily replaced with AC.
– Large Installed Base of DC Machines Worldwide
– DC Motors and Machines are in Good Working Order and Provide Excellent Ride Quality
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Large DC Machines
Otis 72 and 269
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Types of Motor Drives
For DC Motors
M-G Set
SCR-DC
PWM-DC
For AC Motors
Variable Voltage
V V V F Inv. (V/Hz) Open/Closed Loop
Vector Control Inv. Open/Closed Loop
Synchronous PM Inv. Closed Loop
Regen or Non-Regen
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Elevator Power Consumption…the need for Regeneration
Horsepower = Torque x Speed
Gearless Friction Losses are 10-20% of Elevator HP Rating
Moving inertia absorbs energy during acceleration that must be removed during deceleration.
Mechanical, electric and electronic losses are proportional to torque or current flow.
Energy Wasted / Dissipated During Deceleration = Heat
Excessive heat in control rooms must be removed.
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– Drive type makes little difference in overall energy consumption.
– If DC, Good Candidate for Conversion to AC by
Replacing Motor– Low Installed Cost is Usual Critical Issue
Practical Energy Considerations Low Speed Elevators 50–150 fpm
– Almost Always Geared… or PM Gearless– Low Speed Usually Means Low Power
2-35 HP / 2-25 kW– Most power is consumed by frictional losses.– True regeneration is not critical.– High Gearbox Losses During Regeneration
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Practical Energy Considerations
Medium Speed Elevators 150–450 fpm
– Geared and Some Gearless… Including PM
– 15-60 HP / 12-45 kW
– Lower Frictional Losses in Gearbox
– Recovery of inertia energy becomes important, particularly with gearless.
– Resistive Braking Still Possible but Need to Perform Heat Load Calculations for Equipment Room
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Practical Energy Considerations
High Speed Elevators 500-1,600+ fpm
– Low Friction Gearless
– 45-600 HP / 34-450 kW or Larger
– True Regeneration is Mandatory
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Industry Trends
Energy Consumption Reduction– kW-hrs / Month
– Harmonics, Power Factor
Performance– Reduced Floor–Floor Time
– Reduced Vibration
Low Maintenance– Cleanliness
Larger PM Machines– More Gearless Applications
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Energy Consumption
Elevator Speed and Payload
Frequency of Use
Hoist Way Efficiency
Motor Efficiency
Power Conversion Efficiency
Idle Losses
Regeneration
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Desired Feature SCR-DC
Diode –PWM Inv
PWM - PWM
Installed Cost
Smallest vol. Wt.
External XFMR
Pwr conv efficiency
90% w/ XFMR 93-96% 92-94%
Drive Type Comparison
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Desired Feature SCR-DC
Diode –PWM Inv
PWM - PWM
Regen- eration No
Low Harmonics No No
Unity Pwr
Factor
No No
Drive Type Comparison
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Drive Type Comparison
Desired Feature SCR-DC
Diode –PWM Inv
PWM - PWM
Flexible Motor V
With XFMR
Below Vac input
Stand-by Friendly No
AC / DC Motor No No
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Future Expectations
More PM Gearless
– Low and High Power
More Interest in Energy Conservation– Overall Efficiency
– Regeneration
More Restrictions on Harmonics and EMC– Sinusoidal High pf Utility Line Current
– All Inclusive Drive Units with Filters
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Future Elevator Drives PWM-PWM Double Converter-Inverter
– Regulated Harmonics
– Unity pf
– Fully Regenerative
– Compatible with DC Stand-by Power
PM Operation without Resolver– Electronic Alignment Sensing
Compact All Inclusive Packaging
Works with AC Ind. or PM or DC Motors
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World’s Tallest Buildings
Magnetek has Elevator Drives in 17 of
the 30 tallest buildings in the world.