VFX

In 1977, Emotron was the first company to introduce an AC Drive based on Pulse Width Modulation (PWM). Further developments led to one of the first market launches of AC Drives with Direct Torque Control in 1998. The Emotron technology has an extremely fast response time since actual and required torque is compared 40,000 times per second.

Emotron drives can provide the highest possible torque per Ampere from a normal industrial motor, offering the option of controlling a motor without a rotor sensor while still maintaining control of torque and speed.

First and foremost, the Direct Torque Control method, invented by Depenbrock and Takahashi, offers highly efficient control of dynamic and demanding applications. The Emotron technique reacts quickly to peak loads, abrupt load changes, or inaccurately set ramp times. The response time is compared 40,000 times per second. This is invaluable in crane control for example, where frequent and critical starts and stops demand instant high torque - or in crusher applications where speed quickly needs to be adjusted to the type or size of material.

With Direct Torque Control, the torque/current ratio is linear above nominal torque, i.e., 200% current results in 200% torque, compared to approximately 150% torque at 200% current without Direct Torque Control. Therefore, the overload capacity required for the Emotron AC Drive to stay in full control of the motor can be considerably lower than when using control methods without Direct Torque Control.

The Direct Torque Control works with the AC Drive’s integrated vector brake to ensure rapid and protective braking. The available braking torque is doubled compared to conventional braking methods. The braking energy is dissipated through the motor itself, which helps avoid interruptions due to excessive brake voltage. In most cases, no mechanical brakes are required. Brake choppers and brake resistors are needed only to achieve an extremely short braking time.

AC Drives with Direct Torque Control all operate with direct control of the motor’s torque and flux. This effectively eliminates false trips caused by shock loads, mains supply disturbances or inaccurately set ramp times. This is realized with a quick response and very accurate control of the motor flux based on the motor model used in the software. Each and every switching in the AC Drive is directly related to the electromagnetic state of the motor, resulting in smooth and accurate control at all times.

The essential part of the Direct Torque Control is the motor model which provides accurate estimates of the actual flux and torque of the motor.

By comparing the calculated actual values with reference values at an extremely high calculation frequency, a closed loop of flux and torque control can be achieved. All relevant motor parameters are measured automatically, the load inertia is checked and internal parameters are automatically set accordingly.

Together with superior braking capacity and precise control of acceleration and deceleration, this results in a torque response time that can be less than 1 ms and a speed accuracy as good as ±0.1% of rated rpm, even without a separate sensor on the motor. Typical values with conventional sensorless vector control are 50-100 ms torque response and ±1.2% speed accuracy.