Low Harmonic Drives: Benefits of Low Harmonic in Industrial Applications In Market
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| Low Harmonic Drives |
Electric
drives play a crucial role in powering modern industrial machinery and
processes. However, standard drives can generate unwanted harmonic currents
that interfere with the proper functioning of equipment and electrical systems.
Harmonics are distortions in the sine wave of the alternating current power
supply. They are caused when nonlinear loads like variable frequency drives
draw nonsinusoidal current from the mains. The most common harmonics are
multiples of the fundamental supply frequency, such as the 3rd, 5th, 7th
harmonics and so on. Too many harmonics can overheat transformers and motors,
damage sensitive electronic equipment through malfunction, and even cause power
quality issues on the utility grid if not properly mitigated.
Types of Low Harmonic Drive Technologies
To address the harmonic distortion introduced by standard drives, engineers
have developed several low harmonic drive technologies:
Active Front End Drives: These feature an active front end rectifier that
converts AC mains power to DC using IGBTs or GTOs. It generates quasi-square
waveforms to draw near-sinusoidal current from the supply, reducing harmonics
to less than 5%. This front end isolates the drive from the mains and allows
for regeneration of power.
Multilevel Inverters: Multilevel inverters have multiple DC voltage levels to
produce staircase voltage waveforms that are closer to pure sine waves. Common
topologies include neutral point clamped, flying capacitor, and cascaded
H-bridge inverters. They can achieve total harmonic distortions well under 5%
without additional filtering.
Passive Filters: Passive L-C filters dampen specific harmonics through
resonance. Low
Harmonic Drives are inexpensive but bulky for higher power applications.
Advanced filters use active damping to prevent filter resonance issues.
Active Harmonic Filters: These detect and cancel out specific harmonics in real
time through high-speed switching of IGBTs. They are most effective for
variable load conditions but require complex control algorithms.
Benefits of Using Low Harmonic Drives
The primary benefits of adopting low harmonic drive technologies for industrial
applications include:
Increased Reliability - By decreasing harmonic heating effects, low harmonic
drives help extend the lifetime of motors, transformers, switchgear, and other
electrical equipment. This improves overall system reliability.
Lower Energy Costs - Less energy is wasted heating up conductors and core
losses due to harmonics. Energy usage and costs are reduced. Regenerated power
from active front end drives also cuts operational expenses.
Downsized Electrical Infrastructure - With lower harmonic distortion, the KVA
rating of transformers can be right-sized. Smaller and less expensive
distribution equipment can be specified.
Enhanced Power Quality - VFDs with low harmonics draw cleaner current that is
closer to a pure sine wave. This ensures stable operations of sensitive loads
and complies with utility grid standards.
Extended Motor Life - Motors last longer when operated with low harmonic
currents that avoid additional heating and degraded performance over time.
Reduced Maintenance Needs - As equipment endures less thermal and electrical
stress, maintenance requirements and downtime are minimized. This improves
plant productivity and availability.
Compatibility with Sensitive Loads - Process instruments, variable speed
motors, computers/PLCs are protected from harmonic interference that can cause
malfunctions or digital errors.
Applications for Low Harmonic Drives
Given these advantages, harmonic drives have become increasingly popular for
applications with stringent power quality needs, including:
- Pumping systems - For water, wastewater, oil & gas pipelines. Harmonics
can damage pumps and piping infrastructure.
- Fan and blower systems - Particularly in large HVAC installations like data
centers which require clean power.
- Material handling - For lifting magnets, conveyors and other equipment in
warehousing, logistics centers.
- Metal processing - Tools in machining factories are vulnerable to spikes.
Clean drives boost uptime.
- Mining industry - Pumps, grinders and ventilation equipment operate 24/7 in
harsh conditions.
- Oil & gas - Downhole pumps, compressors and industrial processes demand
reliable, low maintenance solutions.
- Renewable energy - Variable speed generators and power electronic converters
in wind and solar farms.
- Marine industry - Propulsion, cargo handling and mission critical systems in
ships benefit from power quality.
low harmonic drive technologies help maximize the lifetime, efficiency and
reliability of industrial machinery across many vital sectors of the economy.
As power electronic switches continue advancing, these drives will only become
more powerful, flexible and affordable in the years ahead - cementing their
importance for mission critical applications with stringent power quality
requirements. Their benefits justify any small premium over standard drive
solutions.
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Market Insights, leveraging extensive expertise gained from her previous role
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