Single-Phase Phase-Controlled DC Drives

Introduction to Single-Phase Drives

Basic Concept

Single-Phase Phase-Controlled DC Drive

A DC motor drive where the armature circuit is connected to the output of a single-phase controlled rectifier using thyristors (SCRs).

Key Operating Principles:

  • Armature voltage controlled by varying the delay angle \(\alpha_a\) of the converter
  • Field current also controlled using a converter with delay angle \(\alpha_f\)
  • Phase-controlled converters use line-commutated thyristors
  • For improved power factor and reduced harmonics, forced-commutated converters (choppers) can be used

Basic Circuit Arrangement

Basic circuit arrangement of a single-phase DC drive
Figure 1: Basic circuit arrangement of a single-phase DC drive

Important Components:

  • Smoothing inductor \(L_m\) reduces ripple current to acceptable magnitude
  • Separate converters for armature and field circuits
  • Essential at low delay angles and high speeds to prevent discontinuous current
  • Free-wheeling diode (in semiconverter) improves performance

Motor Speed-Torque Relationship

DC Motor Fundamental Equations:

\[V_a = E_b + I_a R_a\]

where \(E_b = K_b \phi \omega_m\) is the back EMF.

Speed Equation:

\[\omega_m = \frac{V_a - I_a R_a}{K_b \phi}\]

Torque Equation:

\[T_e = K_t \phi I_a\]

Speed control is achieved by controlling \(V_a\) (armature voltage) and \(\phi\) (field flux).

Reversal Techniques

Field and Armature Reversal Methods

Field and armature reversals using contactors
Figure 2: Field and armature reversals using contactors

Reversal Techniques:

  • Armature reversal: Using contactors SW1 and SW2 in armature circuit
  • Field reversal: Using contactors SW1 and SW2 in field circuit

Safety Considerations

  • Reversal performed at zero armature current to avoid voltage surges
  • Dead time of 2–10 ms provided to ensure zero current
  • Field reversal takes longer due to large time constant (\(L_f/R_f\))
  • Only one direction should be reversed at a time

Types of Single-Phase Drives

Classification of Single-Phase Drives

Single-phase drives can be subdivided into four types:

  1. Single-Phase Half-Wave Converter Drives

    • Armature current normally discontinuous
    • High ripple content
    • Not commonly used in practice
  2. Single-Phase Semiconverter Drives

    • One-quadrant operation
    • Applications up to 15 kW
    • Lower cost, simpler control
  3. Single-Phase Full-Converter Drives

    • Two-quadrant operation
    • Most commonly used
    • Regenerative braking capability
  4. Single-Phase Dual-Converter Drives

    • Four-quadrant operation
    • Maximum flexibility
    • Higher cost and complexity

Single-Phase Semiconverter Drives

Semiconverter Drive Configuration

Single-phase semiconverter drive circuit and quadrant
Figure 3: Single-phase semiconverter drive circuit and quadrant

Characteristics:

  • One-quadrant drive (forward motoring only)
  • Limited to applications up to 15 kW
  • Two thyristors and two diodes
  • Free-wheeling diode improves performance and reduces ripple
  • Current waveforms for highly inductive load

Semiconverter – Voltage Equations

Average Armature Voltage:

\[V_a = \frac{V_m}{\pi}(1 + \cos \alpha_a) \quad \text{for } 0 \leq \alpha_a \leq \pi\]

where \(V_m\) is the peak value of the AC supply voltage.

Average Field Voltage (if semiconverter used):

\[V_f = \frac{V_m}{\pi}(1 + \cos \alpha_f) \quad \text{for } 0 \leq \alpha_f \leq \pi\]

Control Range

  • Delay angle \(\alpha_a\) varies from 0 to \(\pi\) radians
  • Voltage can be controlled from \(\frac{2V_m}{\pi}\) (at \(\alpha_a = 0\)) to 0 (at \(\alpha_a = \pi\))
  • Output voltage is always positive (unidirectional)

Semiconverter – Current Analysis

RMS Armature Current:

For continuous conduction mode:

\[I_{a,rms} = \sqrt{\frac{1}{2\pi}\int_{\alpha_a}^{\pi + \alpha_a} i_a^2 \, d\omega t}\]

Current Ripple:

  • Peak-to-peak ripple depends on \(L_m\), load, and \(\alpha_a\)
  • Critical inductance to maintain continuous conduction
  • Free-wheeling diode reduces negative voltage period

Important Note

For discontinuous conduction, analysis becomes more complex and average voltage decreases.

Single-Phase Full-Converter Drives

Full-Converter Drive Configuration

Single-phase full-converter drive circuit and quadrant
Figure 4: Single-phase full-converter drive circuit and quadrant

Characteristics:

  • Two-quadrant operation (motoring and regenerative braking)
  • Most commonly used configuration
  • Four thyristors in bridge configuration
  • Output voltage can be positive or negative
  • Regenerative braking capability

Full-Converter – Voltage Equations

Average Armature Voltage:

\[V_a = \frac{2V_m}{\pi}\cos\alpha_a \quad \text{for } 0 \leq \alpha_a \leq \pi\]

Average Field Voltage:

\[V_f = \frac{2V_m}{\pi}\cos\alpha_f \quad \text{for } 0 \leq \alpha_f \leq \pi\]

Operating Modes

  • Motoring mode: \(0 \leq \alpha_a < 90°\), \(V_a > 0\)
  • Regenerative braking: \(90° < \alpha_a \leq 180°\), \(V_a < 0\)
  • Transition: \(\alpha_a = 90°\), \(V_a = 0\)

Full-Converter – Current Waveforms

Full-converter current waveforms
Figure 5: Full-converter current waveforms for continuous conduction

Waveform Analysis:

  • Armature current has fundamental frequency of \(2f\)
  • Ripple frequency is twice the supply frequency
  • Continuous conduction maintained with adequate \(L_m\)
  • Source current is bidirectional

Single-Phase Dual-Converter Drives

Dual-Converter Drive Configuration

Single-phase dual-converter drive circuit
Figure 6: Single-phase dual-converter drive circuit and four-quadrant operation

Characteristics:

  • Four-quadrant operation
  • Two full-converters connected in anti-parallel
  • Converter 1: Positive voltage and current
  • Converter 2: Negative voltage and current
  • Maximum operational flexibility
  • Higher cost and complexity

Dual-Converter – Operating Principles

Voltage Equations:

\[V_{a1} = \frac{2V_m}{\pi}\cos\alpha_{a1}\]
\[V_{a2} = -\frac{2V_m}{\pi}\cos\alpha_{a2}\]

Control Strategies

  • Non-circulating current mode: Only one converter operates at a time
  • Circulating current mode: Both converters operate simultaneously with reactor
  • Dead time between converter switching to prevent shoot-through
  • Control constraint: \(\alpha_{a1} + \alpha_{a2} = 180°\)

Four-Quadrant Operation

Operating Quadrants:

  1. First Quadrant: Forward motoring (\(\omega_m > 0\), \(T_e > 0\))
  2. Second Quadrant: Forward regenerative braking (\(\omega_m > 0\), \(T_e < 0\))
  3. Third Quadrant: Reverse motoring (\(\omega_m < 0\), \(T_e < 0\))
  4. Fourth Quadrant: Reverse regenerative braking (\(\omega_m < 0\), \(T_e > 0\))

Applications

Dual-converter drives are essential for applications requiring:

  • Rapid reversal of direction (rolling mills)
  • Precise position control (hoists, elevators)
  • Regenerative braking in both directions

Comparison of Drive Types

Comparative Analysis

Feature Semiconverter Full-Converter Dual-Converter
Quadrant Operation One (1Q) Two (2Q) Four (4Q)
Thyristors Required 2 4 8
Output Voltage Unidirectional (+) Bidirectional (±) Bidirectional (±)
Regenerative Braking No Yes Yes (both directions)
Free-wheeling Diode Yes No No
Power Rating Up to 15 kW 15 kW – 2 MW Above 100 kW
Cost Low Medium High
Complexity Simple Moderate Complex
Applications Fans, pumps, blowers Machine tools, printing Rolling mills, hoists

Key Design Considerations

Field Circuit Control

Semiconverter vs. Full-Converter for Field

Semiconverter Field Control

  • Lower cost, simpler implementation
  • Unidirectional field current only
  • Cannot reverse field voltage
  • Slower field weakening response

Full-Converter Field Control

  • Bidirectional voltage capability
  • Faster field current reduction
  • Better for field-weakening operation
  • Can reverse field voltage

Recommendation

Full converter is preferable for field circuit due to its ability to reverse voltage polarity and reduce field current much faster than a semiconverter, enabling rapid field weakening for field-weakened operation.

Continuous vs. Discontinuous Conduction

Continuous Conduction Mode (CCM):

  • Armature current never reaches zero
  • Occurs when \(L_m\) is large or load is heavy
  • Voltage equations derived earlier are valid
  • Better performance, lower ripple

Discontinuous Conduction Mode (DCM):

  • Armature current becomes zero for part of cycle
  • Occurs when \(L_m\) is small or load is light
  • Average voltage is higher than CCM for same \(\alpha_a\)
  • Analysis is more complex
  • Higher current and voltage ripple

Design Guideline

Design \(L_m\) to ensure continuous conduction at minimum expected load.

Power Quality and Harmonics

Harmonics in Single-Phase Drives

Output Voltage Harmonics:

  • Fundamental frequency: \(2f\) (for full-wave converters)
  • Dominant harmonics: \(2f\), \(4f\), \(6f\), etc.
  • Amplitude decreases with harmonic order
  • Smoothing inductor filters high-frequency harmonics

Supply Current Harmonics:

  • Odd harmonics predominate: 3rd, 5th, 7th, 11th, 13th, etc.
  • \(n\)-th harmonic current: \(I_n \approx \frac{I_1}{n}\)
  • Total Harmonic Distortion: \(\text{THD} = \frac{\sqrt{\sum_{n=2}^{\infty} I_n^2}}{I_1}\)
  • Typical THD: 40–80% depending on operating point

Mitigation Techniques

  • AC line filters
  • Multi-pulse converters (for higher power ratings)
  • Active power filters

Power Factor in Phase-Controlled Drives

Displacement Power Factor:

\[\text{DPF} = \cos\phi_1 \approx \cos\alpha_a\]

Distortion Factor:

\[\text{DF} = \frac{I_1}{I_{s,rms}} = \frac{1}{\sqrt{1 + \text{THD}^2}}\]

Total Power Factor:

\[\text{PF} = \text{DPF} \times \text{DF}\]

Power Factor Issues

  • Power factor decreases with increasing \(\alpha_a\)
  • At \(\alpha_a = 90°\), DPF = 0, no real power transfer
  • Poor power factor leads to reactive power penalties
  • Capacitor banks may be required for PF correction

Summary

Key Takeaways

  1. Single-phase phase-controlled drives use thyristor-based controlled rectifiers to vary DC motor armature voltage
  2. Four main types: half-wave (rarely used), semiconverter (1-quadrant), full-converter (2-quadrant), and dual-converter (4-quadrant)
  3. Smoothing inductor \(L_m\) is essential to reduce current ripple and maintain continuous conduction
  4. Field or armature reversal required for opposite direction operation
  5. Safety measures include zero current detection and dead time before reversal
  6. Full-converter preferred for field circuit due to faster current reduction capability
  7. Selection depends on quadrant requirements, power level, and application needs
  8. Power quality concerns: harmonics and poor power factor at high delay angles

Voltage Equation Summary

Drive Type Armature Voltage Field Voltage
Semiconverter \(V_a = \frac{V_m}{\pi}(1+\cos\alpha_a)\) \(V_f = \frac{V_m}{\pi}(1+\cos\alpha_f)\)
Full-converter \(V_a = \frac{2V_m}{\pi}\cos\alpha_a\) \(V_f = \frac{2V_m}{\pi}\cos\alpha_f\)
Dual-converter \(V_a = \pm\frac{2V_m}{\pi}\cos\alpha_{a1,2}\) \(V_f = \frac{2V_m}{\pi}\cos\alpha_f\)

All delay angles: \(0 \leq \alpha \leq \pi\) radians

Continuous conduction mode assumed

Practical Applications

Typical Applications by Type:

  • Semiconverter Drives:

    • Fans, blowers, pumps
    • Conveyors (unidirectional)
    • Simple machine tools
  • Full-Converter Drives:

    • Machine tools with regenerative braking
    • Printing presses
    • Paper and textile mills
  • Dual-Converter Drives:

    • Reversing rolling mills
    • Mine hoists and elevators
    • Cranes with frequent direction changes