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A.C. Full MagneticCourse #806
Morris Material
Handling
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Safety
Objectives
At the Completion of thissection, the student should
know and understand the
standard safety precautions
as they apply to cranes andtheir operation.
References:
OSHA 1910.179 Shutdownconditions
ANSI/ASME B30
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Safety
Safety Precautions
Tags
Shutdown Conditions
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Safety
References:
OSHA 1910.179 Shutdownconditions
ANSI/ASME B30
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General Crane
Safety
Inform the operator or
person responsible forthe crane and all affected
employees that the crane
will be serviced.
Observe lock out and tag
out procedures. Always
verify the removal of
power.
Use platforms step and
ladders whenever
available.
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General Crane
Safety
Use a Safety harness not a
beltand remember tosecure it to a proper
location.
Always use P.P.E.
Insure that loose parts andtools dont fall.
Be aware of loose or torn
clothing that may get caught
in moving parts.
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General Crane
Safety
Select the appropriate tools
and test equipment for thejob.
Replace all guard and safety
devices being removed for
service before returning tonormal operation.
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General Crane
Safety
Upon completion of service,
inform the operator or theperson responsible for the
crane that service has been
completed .
Your plant may haveadditional requirements
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TAGS
Temporary means of
warning to all. Essential to safety and
health.
Not the only method of
warning to be employed.
Tags can only be removed
by the installing person.
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Shutdown
Conditions
Faulty or worn brakes
Structural problems
Worn or damaged wire
rope
Worn or damaged pawlsor ratchets
Worn or faulty hydraulics
Faulty switches
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Shutdown
Conditions
Faulty or missing fire
protection Malfunctioning operator
controls
Faulty, damaged or wornblocks and hooks
Faulty or missing
warning devices Faulty safety devices
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Basic Electronics
Review
Basic Circuit Review:
Definition of electrical terms
Ohms Law
Series and Parallel Circuits
Transformers Common Symbols
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Basic Electronics
Review
Diodes:
Operation
Half Wave Rectification
Full Wave Rectification
Diode Testing
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Basic Electronics
Review
Protective Devices:
Fuses
Thermal Overloads
Surge Suppressors
Circuit Breakers Pressure Switches
Timers
Limit Switches
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Basic Electronics
Review
Objective:
Upon Completion of thissection the participant
should have a basic
understanding of:
Ohms Law and how to apply itto circuits
Understand basic series and
parallel circuits
The operation and applicationof diodes
Understand the application of
protective devices
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Basic Electronics
Review
Protective Devices:
Fuses
Thermal Overloads
Surge Suppressors
Circuit Breakers Pressure Switches
Timers
Limit Switches
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Basic Electronics
Review
Voltage:
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Basic Electronics
Review
Current:
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Basic Electronics
Review
Power:
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Basic Electronics
Review
Ampere:
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Basic Electronics
Review
Watt:
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Basic Electronics
Review
Inductance:
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Basic Electronics
Review
Inductive Reactance:
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Basic Electronics
Review
Capacitance:
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Basic Electronics
Review
Capacitive Reactance:
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Basic Electronics
Review
The basic formula for Ohms
Law is as follows:
E = I x R
I =E/R
R =
E/I
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Basic Electronics
ReviewSeries Circuits:
The total Resistance of a
series circuit can bedetermined by using
following formula:
RT= R1 + R2+ R3 + R4+ etc.
The total voltage in a seriescircuit is equal to the sum of
the individual voltage drops.
ES= ER1 + ER2 + ER3 + ER4 +
etc.
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Basic Circuit Review
Parallel Circuits
The total resistance of a
parallel circuit can be
determined by using thefollowing formula:
_______________1_________
______
1/R1 + 1/R2 + 1/R3 +1/R4 +1/etc
The total voltage in a parallel
circuit is common in all
branches.
Es = E1 = E2 = E3 = E4 = etc.
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Diode
sOperati
on
Cathode -
Anode +
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Diod
es
Cathode is biased negative
with respect to the anode (andvice versa) in order for forward
bias to exist.
Electron flow (current) from
cathode to anode.
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Half-Wave
Rectification+
-
-
+
No current flow
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Bridge Rectifier with
Filter
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Diode Testing
These tests only determine if a
diode is open or shorted. Theydo not indicate or detect
leakage current or a weak
diode. Other testing devices
are available that do test alloperations of diodes.
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3-phase AC Motors
Section Outline
Construction
Overall Motor
Rotors
Duty & Temperature Rating
Speed & Torque Curves
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3-phase AC Motors
Motor Operation
Rotating Stator Fields Rotor Currents & Torque
Motor Problems &
Symptoms Stator Single Phased
Rotor Single Phased
Improper Connections
Unbalanced Resistance
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3-phase AC Motors
Motor Testing
Current Tests Voltage Tests
Grounding Tests
Periodic Maintenance Brushes & Slip Rings
Lubrication
Cleaning
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Motor Construction
1. Stator Housing 4. Bearing
2. Stator Coil 5. End Cap
3. Rotor
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Motor Construction
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Motor Duty and
Temperature Ratings
X
X
X
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Motor Operation
T1 T2 T3
S
NSN
s
n
s
n
s
n
s
n
-10
+5
+5
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Motor Operation
T1 T2 T3
n
sn s
N
S
N
S
s
n
s
n
+5
-10
+5
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Motor Operation
S
N S
N
N
S
S
N
S
N
S
N
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Rotor Currents and
Torque
Rotating stator fields induce
currents in rotor bars. Rotor Currents produce
magnetic poles that chase the
stators magnetic poles.
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Problems &
Symptoms
Symptom: Motor growls,cantachieve full speed, poor torque,
sluggish operation, heat may trip
overloads, sounds like a noisy
gearbox.
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Problems &
Symptoms
Symptom: Cant pick up a full
load, primary amps too high,
voltages and currents unbalanced,
trips overloads or smokes themotor.
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Motor Testing:Current Test
Remove brake fuses or gently
run the crane against the endstop.
Place the controller in first
point.
Using a clamp-on ammeter,read the current on the three
input Tleads, they must be
within 2% of each other.
Using a clamp-on ammeter,
read the current on the three
rotor Mleads, they must be
within 2% of each other.
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Motor Testing:Voltage Test
Open the rotor circuit.
Read the input phase to phaseand the rotor lead to lead. The
reading must be balanced and
agree with the nameplate
voltage.
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Motor Testing:Resistance Test
Open the input leads to the
stator. Open the rotor leads.
Using a multi-meter set to the
appropriate scale read the
primary stator winding
phase to phase. The resistance
should be low, but not zero.
Then read the secondaryrotor winding phase to phase.
The resistance should be low,
but not zero.
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Motor Testing:Resistance Test
Next read each winding to
ground using a meggar. Theresistance should at least 1
megohm to ground.
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er o cMaintenance: TypicalBrush Assemblies
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Speed Control
Introduction
Objectives
Upon completion of this section,the participant should be familiar
with and:
Be able to recognize festoon and
collector bar type power transfer
systems.
Understand basic power distribution
schematics.
Develop a basic understanding of
various motor controls and how they
work together as a system
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Power Distribution
Festoon System
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Speed Control
Techniques
Change Synchronous Speed
Change the number of statorpoles.
Change the frequency of the
applied power.
Change Motor Slip Vary the primary voltage
Vary the secondary resistance
Vary the secondary reactance
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Speed Control
Single Speed
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Speed Control
Reduced Torque Starting
100%
100%
75%
75%
Voltage builds slowly through anautotransformer
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Speed Control
Reduced Torque Starting
Gate Pulse
Start
Gate Pulse
Advance
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Speed Control
Two Speed
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Speed Control
Multi-speed Magnetic
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Speed Control
Multi-speed Magnetic
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Speed Control
Saturable Reactor
Induction
Master
More DC Current Less
impedence less slip
more speed
Master
Bias
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Speed Control
Adjustable Frequency
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Speed & Load
Curves
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Speed & Load
Curves
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Protection Circuits
Over Current Protection:
Thermal and Magnetic overloadsand fuses
Power and Control Circuits
Over Heating Protection:
Thermal switches and pluggingcircuits
Motor and solid state electrical
components
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Protection Circuits
Travel Limits:
Hoist Motions - geared andweight operated limits for power
and control sections
Traverse Motions - lever and
magnetic operated circuits Operational Safety Circuits:
Schematic Representations:
Device Maintenance &
Adjustment:
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Protection Circuits
Objectives
Upon completion of this sectionthe participant should:
Understand the basic concept
behind protection circuits.
Be familiar with the different types of
limit switches. Understand that a limit switches is a
SAFETY device and is not to be used
as a control device.
Become familiar with the operation
of bi - metallic, dashpot and meltingalloy overloads.
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Protection Circuits
Klixon
Thermal OL
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Protection Circuits
Magnetic OL
Neutral Safety SW.
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Limit Switches
Weight Operated
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Limit Switches
Weight Operated
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Limit Switches
Weight Operated
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Limit Switches
Gear Operated
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Overloads
Oil Filled Dashpots
Change Oil Annually
2/3 full, must be
ranslucent
Hand tighten only
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Overloads
Oil Filled Dashpots
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Overloads
Melting Alloy Type
Lead = 450 F
Tin = 680 F
60/40 Mix = 370
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Overloads
Melting Alloy Type
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Overloads
Bi - Metallic
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Brakes
Holding Brakes:
Release Time Comparison AC Brakes
DC Brakes
Typical Brake Rectifier Circuits
Electric Load Brakes: Capacitive Dynamic Braking
Eddy Current Brakes
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Brakes
Objectives:
This section promotes anunderstanding of the operation
and maintenance of brakes and
their control circuits.
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Brake Release Time
X
X
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AC Motor Brakes
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AC Solenoid Brake
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DC Disc Brake
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DC Shoe Brake (CD)
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DC Shoe Brake
(SBE)
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DC Disc Brake
Rectifier
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DC Shoe Brake
Rectifier
Economizer
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DC Shoe Brake
Rectifier
Economizer
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DC Shoe Brake
Rectifier
Economizer
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Capacitive Dynamic
Braking
Rotor induces back into
capacitor if brake fails.As rotor voltage drops,
capacitor sees drop
and discharges into
stator.
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Capacitive Dynamic
Braking
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Capacitive Dynamic
Braking
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Magnetorque
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Magnetorque
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Multi-Speed
Magnetic Control
Basic Principles:
Secondary Resistors: Construction & Maintenance
Classification
Timed Acceleration Control:
Voltage Acceleration Control:
Typical Accelerating Relays:
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Motor Secondary
Circuit
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Motor Secondary
Circuit
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Secondary Resistors
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Power On
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Power O
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Typical Accelerating
Relays
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Saturable Reactor
Control
Basic Principles:
Block Diagrams: Basic Magnetics:
Saturable Reactors:
Construction & Maintenance
Operation
Magnetic Amplifiers:
Construction
Operation DC Power Supplies:
Silicon Controlled Rectifiers
Typical DC Power Supply
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Motor Secondary
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Control Block
Diagram
w/o Magnetorque
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V
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Magnetic Fields
Basic Magnetics
3A
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Magnetic Fields
Basic Magnetics
1.5A2A
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Magnetic Amplifier
2A 3A 2A
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Saturable Reactors
+ -
+
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Saturable Reactors
+ -
-
+
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Saturable Reactors
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Magnetic Amplifier
Control Windings
Master
Bias
Frequency
When core saturates, current flows
in output xfmr to generate gatepulses
AC IN Gate Pulse
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Magnetic Amplifier
Module - MFA
The Magnetic Amplifier is a
self - saturating device. Thereare up to six control signals in
the control windings that
influence the saturation of
cores.
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Frequency
Bias
Master
Anti-Hunt
Plugging
OPB
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Magnetic Firing Amp
Module Schematic
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Freq.
BIAS
Master
Anti-Hunt
Plugging
OPB
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Silicon Controlled
Rectifiers
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Silicon Controlled
Rectifiers
+ Anode - Cathode
+ Gate
Anode
Cathode
Gate
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Silicon Controlled
Rectifiers
Rules of Conduction
The SCR must be forward biased.The anode is positive with
respect to the cathode.
The SCR must receive a positive
gate pulse while forward biased.
The SCR must reach a minimum
holding current to break down
the junction.
Once conduction begins, the
SCR will not turn off until thejunction is reversed biased or the
current drops below the
minimum holding value.
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Typical DC Power
Supply
A. Fuse
B. Bridge Rectifier
C. Amp Meter
D. Current Limiting Resistance
E. Reactors
F. Magnetorque
G. Anode Transformer
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Typical DC Power
Supply
Allows fiield built bycoils to dissipate
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Typical DC Power
Supply
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Control Block
Diagram
w/ Magnetorque
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Adjustable
Frequency Control
Control Fundamentals:
Motor Speed Reactance & Stator Current
Inductance & Torque
V/F Patterns
Pulse Width Modulation 3-Phase PWM Waveforms
Block Diagram:
3-Phase AC-DC Converter:
3-Phase DC-AC Inverter:
Regeneration & Dynamic
Braking:
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AF Control
Fundamentals
Motor Speed
Ns=120 x Frequency
# of Poles
Reactance & Stator Current
XL= 2FL
IS =_V_ = _V__
XL 2FL
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AF Control
Fundamentals
Induction & Torque
e = B l v
T = B l i
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AF Control
Fundamentals
V/F Patterns
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AF Control
Fundamentals
V/F Patterns
9
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AF Control
Fundamentals
Pulse Width Modulation
D
C
B
U
S
Time Cycle
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3-Phase PWM
Waveform
120 phase to phase electronically produced
electronically reversed
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AF Block Diagram
Spine
Brain
Customize con
Parameters
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3-Phase AC-DC
Converter
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3-Phase AC-DC
Converter
Single Phase to charge
slowly
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3-Phase DC-AC
Inverter
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3-Phase DC-AC
Inverter Freewheeling diodes
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Regeneration
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Dynamic Braking
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Dynamic Braking