Regeneration in Variable Frequency Drives and Energy Saving Methods

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 1246
Regeneration in Variable Frequency Drives and Energy saving Methods
Rasin K R1, Arunkumar G2
1MTech in Power Electronics and Drives, VIT University, Vellore, Tamilnadu,India
2Professor, SELECT school, VIT university,Vellore,Tamilnadu, India
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Abstract - When an induction motor is driven by a variable
frequency drive, electric power delivered from the supply is
regenerated back while the motor decelerates by applying
negative torque to the motor shaft. Energy storage capacity
inside the variable frequency drives is usually high limited so
energy regenerated should be return back to the grid instead
of dissipating as heat .This paper reviews different supply line
regeneration options for effective utilization of regenerated
power of variable frequency induction motor Drives and a
comparison of this methods.
Key Words: Variable frequency Drives, Regeneration,
Matrix converter, SPWM, Utility cost saving,
Regeneration power unit selection.
1. INTRODUCTION
Some applications demands operation in a quadrant region
where applied torque is in the opposite direction of rotation of
Induction motor. The variable frequency Drive must be drive
release stored energy from the mechanicalloadsystemthrough
the motor terminals to the inverter. This situation faces when
the variable frequency drive is trying to break the rotating
induction motor, such asthemotorinertiastartsdeceleratingor
a situation of whenever using loading as in a dynamometer, or
when an overhauling holding back . As the Load fed back stored
energy to the front end, the main DC bus capacitors of the drive
starts charging. The lack of a proper method of utilizing that
energy, will leads to continue rise of DC bus voltage to
dangerous Level and the drive will get tripped on a fault of Bus
over voltage. A method called line Regenerationdischargesthat
energy from the DC bus capacitors and feed it back on the AC
utility. The Regenerative power can be dissipated using an
arrangement of Brake chopper and Braking Resistor there by
the drive will be protected from overvoltage tripping. Also an
overvoltage control enabling is available in variable frequency
Drives. A significant energy cost saving can be achieved by a
regenerative power unit especially in frequent on and off
applications, deceleration along with large inertia load, and
torque is in overhauling condition. Such applications include
decanter centrifuges, hoists, spindle drives, cranes, elevators
etc., because of this electricity cost per kilowatt hour is more
expensive. So it will be beneficialtounderstandaboutthebasics
of regenerative units and to review estimated energy cost
saving. Three types of regenerativepowerunitsareavailable
depends on the applications. Basic features and power
topologies are explained and compared. Dynamic brake
chopper and resistor arrangement is used to convert
regenerated power in to heat loss becauseoflowinstallation
cost and simplicity.
1.1 Regenerative converter
In most of the Drives applications Braking choppers and
resistors are used to simply dissipate the power in the form
of heat loss. An efficient low budget alternative solution
called line regeneration using Regenerative converters that
can replace the use of the dynamic braking chopping circuit
and external brake resistor network. During regeneration
excess regenerative energy available in the inverter front
end of variable frequency Drive bypass it to the ac power
source through a converter circuit. Figure 1 illustrates how
the excessive regenerative energy will feedback from an
induction motor to the supply side by utilizing a
regenerative converter circuit parallel to the drive inverter
circuit , . During motoring mode, the Variable frequency
Drives transfer power to the motor terminals without
coming the regenerative converter in the picture of main
power flow. So during motoring there is no loss in the
regenerative converter .When the regenerationtaking place,
the dc link capacitors starts charging. Regenerative
converter will get activated because of regenerative energy

charges dc link capacitors of the variable frequency drives.
The regenerative converter converts the Dc voltage in to AC
and returns stored energy in the dc capacitors to the grid.
Size of Variable Frequency Drives will vary according to the
power ratings thereby the size of regenerative converters
will vary according to drive size, Regenerative Power and
Duty Ratio. The 6-step PWM method is used for switching
thereby can reduce the switching losses in very low value.
Some applications demands very high duty cycle braking, in
such situations the regenerative converter can reduce the
cost of electricity usage by significantly improving the
system efficiency.
1.2 Sinusoidal PWM converter
In both motoring andregenerativepowerconditions a highly
efficient solution developed to regulate dc bus voltagecalled
sinusoidal PWM converter. The converter is designed to
generate sinusoidal current waveform at supply mains side
grid side with very low rate of harmonic distortion,
approximately saying total harmonic distortion (THD) will
be 5%.The converter is designed to obey the standard of
IEEE-519 .To make possible the synchronization with input
grid voltage control of input current also taking place,which
will help to obtain a unity input power factor. Thesinusoidal
PWM converter is connected in series between the Variable
frequency Drive and incoming power line. To reduce the
harmonic from the grid side an AC filter is accompanied in
front end of the grid side, usually a LCL filter is used as an
external harmonic filter component to reduce input ac
current harmonics. For controlling the inverter mostly
sinusoidal PWM techniques is used because of it is possible
to control the output voltage and frequency accordingly
with sine functions Sinusoidal pulse width modulation is
widely used in control applications. Because of circuit is less
complex and simple control scheme. SPWM techniques are
characterized by same amplitude pulses with different duty
cycles for each period. The width of these pulses are
controlled to obtain inverter output voltage modulationand
to minimize its harmonic content there by reducing THD.
1.3 Matrix Converter
A matrix converter is a single stage conversion converter
with direct ac to ac conversion having motoring and
regeneration capability. With the helps of bidirectional
controlled switches direct conversion of power from AC to
AC.The converter is characterized bysinusoidal waveforms
that decides the output and input switchingfrequencies.By
using bidirectional switches it is possible to control power
factor input. In addition, the main advantage is lack of DC
voltage link will provide compact design. The matrix
converter using to control induction motors has more
advantages over traditional rectifier-invertertypeVariable
Speed converters. The Input and output waveforms of
Matrix converter issinusoidal,withminimizedhigherorder
harmonics components, there is no subharmonics will
present. Matrix converters has energy flow capability in
both directions. Input power factor can be fullycontrolled. .
It has minimal energy storage Requirements, Which will
improve the lifespan of energy storing capacitors.
The disadvantages of Matrix converters are transfer ratio of
its maximum input output voltage limited to nearly 85 % for
sinusoidal output and input waveforms. Comparing to
conventional frequency converters matrix converters
requires more number of semiconductor devices which will
increase the switching stresses. Discrete unidirectional
devices are variously arranged to be used for each bi-
directional switch because no monolithic bi directional
switches exist .It is sensitive to the fluctuations of the input
voltage systemIn matrix converters using nine bidirectional
switches alternating input is directly transformed into
variable frequency ac output. So sinusoidal regeneration
converter and Variable frequency Drives functions are
combined. This combination enables the induction motors’
to operate in regenerating and motoring modes without
using an additionalDrive.Traditional rectifier-invertercircuit
requires more maintenance because there is diode rectifier
and dc electrolytic capacitor in the main power flow as a
filter circuit. Normally, an electrolytic capacitor is bulky in
size also has a shorter lifetime thanotherparts.Butinmatrix
converters there is electrolytic capacitor present so needs
less maintenance. It is possible to control Input current in
matrix converters this capability reduce harmonics of input
current significantly. Under full load condition inputcurrent
harmonic THD is in the range of 5% - 10%.Unliketraditional
frequency converters external line reactor circuit is not
required to minimize current harmonics, which are usually
bulky in size.
2. ENERGY SAVING USING REGENRATION
CONVERTERS
For an application requires to feedback excess regenerative
energy to the supply grid, line regeneration is an option.
Regeneration happens when the load tries to rotate the
motor shaft faster thantheoutputfrequencyinverteroutput.
This is usually called to as “overhauling”, and may occur
when trying to reduce speed a load, or applying mechanical
power to the motor system by something on the loading. In

these conditions, the inverter is behaves to restrain the
motion of the load by inertia and this leads to regeneration.
Here a converter is used to sends excess regenerativepower
back to the grid by line regeneration technique. To
accomplish this, the drive system must utilizea regenerative
converter. This converterconnectedintothecommondc link
just like the existing drives. This converter receives excess
feedback energy caused dc voltage from the DC bus and
produce a six-step waveform back to the grid.By using
matrix converter power factor is always kept nearly at 0.95.
Because the power factor is constant or regardless of
operation frequency, energy wastage is minimized.
Regeneration results in to rise of DC bus voltage, will cause
to tripping of variable frequency Drive because of DC bus
overvoltage .The traditional method of resolvingthisissueis
by using Brake chopper circuit and external resistors the
regenerative power is dissipated as heat loss. A dc bus
voltage sensing circuit is accompanied with chopper
transistor which will sense the increase in dc voltage and
which will enable the transistor and will conduct and
dissipate the power in external resistorconnected.Instead of
simply wasting the energy as heat loss we can convert to
efficient form and utilize in grid side. The Regeneration
Converters replacestraditional dynamic brakingsystem, and
transform this regenerated powerback intosupplysidegrid.
It converts that regenerated energy back into the grid as
three-phase AC supply instead of wasting it as heat loss. By
doing so the regenerated power can be feedback to input,
and minimizes the energy consumption and therefore the
utility bill. In other words regenerative converter unit is like
another generator placed on the utility grid, supplying
power into it by synchronizing to it.
2.1 Estimation of Energy Savings
The Regeneration converter unit converts the excess
regenerated power in grid under the same condition of
power is dissipated as heat. So that calculating total energy
saving using a regenerationconverterissametocalculating
the heat loss taking place in braking resistor. For the above
required braking duty cycle and braking torque must be
determined. From the obtained data, we can calculate total
amount of regenerated energy for a given period. The
Regenerative converter converts almost 95% of
regenerated energy in to grid. This gives all the variables
needed to calculate the kW-hr reclaimed for give time
period. By knowing the utility demand rate, this reading
values can be converted into money and hence a payback
period.
2.2 Comparison of Regeneration Converters.
In variable frequencydrives underregenerativeconditionall
three above said converters has good energy saving
capability. Instead of wasting the regenerated power simply
as heat loss in external resistor circuit. The converter circuit
said in first section multiple VFD connection is but lowinput
current harmonics is present and medium level installation
space is required. The best low-cost solution is sinusoidal
PWM converter which has utility good utility cost saving
using Regenerative braking and multiple VFD connection is
possible similar to first converter. The best solution may
differ if extra benefits such as low current harmonics and
unity power factor are alsoimportant,Thematrixconverters
is another fair solution which require less space comparing
to other two regeneration converter units and multiple VFD
connection is not possible and matrix converter is a product
that has both regeneration converter and VFD capabilities
inherently. The table compares regeneration power units.
Table -1:
Item Regenerati
ve
converter
SPWM
converter
Matrix
convert
er
Utility cost saving
by regenerative
braking
Good Good Good
Low input current
harmonics
None Good Good
Multiple VFD
connection
Yes Yes No
Initial cost
including VFD
Good Fair Good
Input power factor
improvement
None Good Good
Installation space
including VFD
Medium Large Small
3. CONCLUSIONS
There is huge amount of energy is wasting in variable
frequency drives when a regeneration take place, By using
brake chopper and external resistor arrangement the
excessive regenerative power is simply wasted as
heatloss.Itcan be found that from energy saving calculation
almost 50% of energy is wasted as simply heatloss.By using
Regenerative converters this excessive regenerative power
can be feedback to the grid. For multiple VFD connections
the converters explained in first and second section is good
choice but in overall performance matrix converter is more
efficient choice.

REFERENCES
[1] D. H. Braun;T. P. Gilmore;W. A.Maslowski“Regenerative
converter for PWM AC drives”, IEEE Transactions on
Industry Applications, Volume: 30, Year: 1994, , Issue: 5
,Pages: 1176 - 1184, DOI: 10.1109/28.315227
[2] Patrick. W. Wheeler, J. Rodriguez, Jon. C. Clare, L.
Empringham, "Matrix converter-A TechnologyReview",
IEEE Trans. Ind. Electron, vol. 49, no. 2, pp. 276-288,Apr.
2002.
[3] Norm Lindner, “Line regenerating with variable speed
AC drives”.

Regeneration in Variable Frequency Drives and Energy Saving Methods

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