Abstract
The article presents a method of generating key performance indicators related to electric motor energy efficiency on the basis of Big Data gathered and processed in a frequency converter. The authors proved that using the proposed solution, it is possible to specify the relation between the control mode of an electric drive and the control quality-energy consumption ratio in the start-up phase as well as in the steady operation with various mechanical loads. The tests were carried out on a stand equipped with two electric motors (one driving, the other used to apply the load by adjusting the parameters of the built-in brake). The measurements were made in two load cases, for motor control modes available in industrially applied frequency converters (scalar V/f, vector Voltage flux control without encoder, vector voltage flux control with encoder, vector current flux control, and vector current flux control with torque control). During the experiments, values of the current intensities (active and output), the actual frequency value, IxT utilization factor, relative torque, and the current rotational speed were measured and processed. Based on the data, the level of energy efficiency was determined for various control modes.
Highlights
The reduction of energy consumption states is a key criterion forcing the optimization of the operating parameters of electric drive systems [1,2,3,4]
Modern drive systems are most often extended by frequency converters, which constitute the superior system for setting operating parameters and monitoring the drive motor
The efficiency parameters of electric motors, which are identified by the IE code for energy efficiency classes, are measured with the new measuring procedures in accordance with IEC 60034-2-1:2014 (Rotating electrical machines— Part 2-1: Standard methods for determining losses and efficiency from tests—excluding machines for traction vehicles)
Summary
The reduction of energy consumption states is a key criterion forcing the optimization of the operating parameters of electric drive systems [1,2,3,4]. Industry 4.0 is related to gathering and processing Big Data related to operation of machines (a majority of them are driven by frequency-controlled electric motors). The researchers tried to find a way of computing on the edge (directly in the source) the big data produced in the frequency converter, providing factors useful in the drive management, which can be communicated in the IIoT directly from the drive controller. The experiment consisted of transforming a classical actuator (electric drive) into the Industry 4.0 component: an edge device analysing and processing the operational Big Data to output KPIs. The frequency converter was considered in an innovative way, as energy analyser and smart sensor, which could process and transfer data via the IIoT as it is commonly equipped with a programmable microcontroller and proper communication interface
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