Processing spindles, turbo blowers or compressors, gas turbines, expanders or vacuum pumps: For these and many other applications in which output frequencies of over 200 Hz are required, KEB Automation now offers the ideal solution with the newly developed “High Speed Drives”. In combination with the COMBILINE Z2 sine filters, motors are particularly protected at high speeds and the system efficiency is increased effectively. Innovative simulation methods are available for the fast and resource-saving commissioning of the High Speed Drives.
In high-speed applications, motors have to achieve 100,000 rpm or more - this can be efficiently realised with the new High Speed Drives from KEB. With an output of up to 450 kW and switching frequencies of 2 kHz to 16 kHz, the robust and particularly compact inverters are optimised for demanding applications. “The High Speed Drives enable high output frequencies of up to 2,000 Hz. Thanks to an optionally available special 3C3 coating on the circuit board, the devices are designed for use in harsh environmental conditions, such as in sewage treatment plants,” says Fabian Fischer, team leader application sales at KEB Automation. “In addition, liquid-cooled and air-cooled versions of the inverter are available. This allows us to flexibly adapt to the individual needs of our customers.” The liquid-cooled version of the drive is also characterised by a high inlet temperature of 55 degrees Celsius and a very space-saving design. Just like the air-cooled variant, it also offers the option of supplying magnetic bearing controllers via the DC link voltage. This effectively protects the sensitive magnetic bearings even in the event of a voltage drop. The encoderless speed control is available for all current high-speed motor types – from IPM and PM to asynchronous or synchronous reluctance motors.
In combination with the COMBILINE Z2 sine filters, users benefit from a powerful system solution with coordinated components. The output filters consist of a motor choke and a capacitor and can be flexibly adapted to different applications thanks to the modular concept. “For motors that are less sensitive, the motor choke is available separately. Machine and plant manufacturers also have a high degree of freedom when it comes to mounting the filters in the cabinet,” says Fischer. The high-speed filters of the Z2 series have a high efficiency of more than 99.9 percent and reduce the harmonic losses in the motor to a considerable extent. Last but not least, the EMC behaviour of the overall drive is improved by the filters and cable lengths of more than 100 metres are made possible. “Compared to multilevel inverters, our customers achieve a higher system efficiency with the KEB system consisting of a 2-level drive controller and sine filter at comparable or even lower costs and an increased performance in the field weakening range,” Fischer summarises the advantages of the solution.
KEB relies on Matlab/Simulink for the optimal interaction of all high-speed components. The software is an established standard for modelling and simulating complex, dynamic systems. Based on the available motor data, reliable predictions can be made regarding the static and temporal course of the speed or the voltage, among other things. Costly practical tests are no longer necessary due to the extensive simulation options. KEB also uses virtual drive design by means of Hardware in the Loop (HIL). Based on the motor, sine filter and inverter data, commissioning is simulated in advance without the need for real components. Variations of the system-related parameters are thus possible at any time without risk, and the finished parameterisation is already available for the subsequent real commissioning. Noticeable time and cost savings during the entire project phase are the result.
The new High Speed Drives (water-cooled, up to 450 kW) in housing size 9 are available immediately. Other variants will follow soon. The drives will be presented live for the first time at this year's SPS in Nuremberg. You can get an impression from 14 to 16 November 2023 at the KEB trade fair stand: Hall 7, Stand 320.
The High Speed Drives in brief
- Power up to 450 kW
- Output frequencies up to 2,000 Hz
- Switching frequencies up to 16 kHz
- 3C3 coating
- Matching sine filters
- Air- or liquid-cooled
- Encoderless control of all motor types