Low Harmonic Drives: Driving Towards a Greener Future How Clean Power is Empowering the Automotive Industry
Over the past few decades, variable frequency drives (VFDs) have become widespread in industrial and commercial applications for their ability to control motor speed and torque. Traditionally, VFDs utilize pulse width modulation (PWM) techniques to vary motor voltage and frequency. However, PWM generates high harmonic currents that can damage motors, heat up transformers and power cables, and potentially cause voltage distortions on the utility grid. To address these challenges, a new generation of low harmonic drives has emerged based on advanced switching algorithms.
What are Harmonics?
In electrical systems, harmonics refer to sinusoidal voltages or currents having frequencies that are integer multiples of the fundamental power supply frequency, usually 50 or 60 Hz. Harmonics are produced by non-linear loads like adjustable speed drives that draw non-sinusoidal currents from the power source. The extra frequencies generated interact with the system impedance and generate losses, heating, vibrations, torque pulsations and can even cause misoperation of protective devices if sufficiently high in magnitude. Harmonics cause additional power losses in distribution transformers and overvoltages that reduce insulation lifetime. They can also interfere with communication lines.
Traditional PWM Drives and their Harmonic Impact
Traditional PWM VFDs employ insulated-gate bipolar transistors (IGBTs) or thyristors to rapidly switch the motor voltages on and off, generating quasi-square wave voltages to control motor speed. However, when these non-sinusoidal voltages are applied to the motor windings, they produce harmonic currents in the supply lines that are integer multiples of the fundamental supply frequency. Specifically, PWM drive techniques generate dominant 5th and 7th order harmonics that can propagate back into the utility system if not properly filtered.
The harmonic currents not only stress motor windings but also increase I2R losses in the supply feeders and distribution transformers. Low Harmonic Drives can cause overheating in older transformers not designed for harmonics. Harmonic distortions also increase circulating currents within delta-wye grounded transformers. To mitigate these issues, dedicated harmonic filters need to be installed, increasing overall system costs. Excessive harmonics if left unchecked can even cause protective relays to malfunction.
Advancements in Low Harmonic Drive Technology
To address harmonic pollution from VFDs, innovative drive manufacturers have developed new low harmonic drive technologies based on advanced switching algorithms that naturally minimize the generation of lower order harmonics.
Pulse-Density Modulation
One such technique is pulse density modulation (PDM) where the IGBTs are switched at high frequencies using narrower pulses compared to traditional square waves. By spacing the pulses closer together over time, PDM produces quasi-sinusoidal drive output voltages that inherently contain lower harmonics. PDM drives generate less than 5% total harmonic distortion (THD) without additional filters.
Active Front End Drives
Another option is active front end (AFE) drives with a front-end rectifier consisting of IGBTs or MOSFETs instead of diode bridges. The AFE rectifier actively shapes the supply current waveform to follow the voltage waveform and provide near unity power factor without harmonics. AFE drives come with integrated DC chokes to absorb any remaining higher order harmonics internally, keeping them well below 5% THD.
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