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Thread: Variable Frequency Drive for a larger factory fan

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    Supporting Member chy_farm's Avatar
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    chy_farm's Tools

    Variable Frequency Drive for a larger factory fan

    Last year we had a very hot Summer and Autumn so had a presumption that we should need a very big fan in our shed to get our job easier this year.
    This motivation gave me a way to build a single phase Variable Frequency Drive for a bigger fan motor!

    Fortunately or unfortunately we have cool Summer now, so not yet get a new big fan yet, nor have a chance to run this VFD...

    Variable Frequency Drive for a larger factory fan-img_4006.jpg

    Variable Frequency Drive for a larger factory fan-img_3995.jpg
    Last edited by chy_farm; 07-30-2020 at 07:23 AM.

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    Jon (07-31-2020), nova_robotics (07-30-2020)

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    Supporting Member chy_farm's Avatar
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    chy_farm's Tools
    Variable Frequency Drive for a larger factory fan-illuestration.jpg

    Inside: Triangle and rectangle generators are analogue unit.

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    nova_robotics (07-30-2020)

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    Supporting Member chy_farm's Avatar
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    chy_farm's Tools
    Started from these;

    Variable Frequency Drive for a larger factory fan-img_0058.jpg

    Variable Frequency Drive for a larger factory fan-img_0059.jpg


    Making shifts to the frequency is to be done with a couple of white dials, an obsolete analogue way.
    Variable Frequency Drive for a larger factory fan-img_0113.jpg

    Variable Frequency Drive for a larger factory fan-img_0114.jpg

    Chy

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    nova_robotics (07-30-2020)

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    Supporting Member chy_farm's Avatar
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    chy_farm's Tools
    But on the way of assembling I found this handmade case was a tad small, so added some more rooms ;
    Variable Frequency Drive for a larger factory fan-added_rooms_1.jpg


    Main power board with magnetic contactor and a transformer;
    Variable Frequency Drive for a larger factory fan-transformer.jpg

    Placed a noise filter right after the main contactor;
    Variable Frequency Drive for a larger factory fan-tdk_emc_filer_6ajpg.jpg

    Temperature sensors are placed onto five different part,
    1: Bridge diode (50A),
    2: Short cut unit,
    3: Isolated Gate Bipolar Transistor unit,
    4: High speed diodes for return current re-circulation unit,
    5: Double 2mH filter coils right before the output terminal;
    Variable Frequency Drive for a larger factory fan-tem_sensor_1.jpg

    Output frequency monitor;
    Variable Frequency Drive for a larger factory fan-frequency.jpg

    Output current monitor, and its detector (HAS-50);
    Variable Frequency Drive for a larger factory fan-current_sensor.jpg

    Variable Frequency Drive for a larger factory fan-has_50-s_current_transducerjpg.jpg

    Chy
    Last edited by chy_farm; 07-30-2020 at 05:35 PM.

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    Supporting Member chy_farm's Avatar
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    chy_farm's Tools
    Schematic for power units is;
    Variable Frequency Drive for a larger factory fan-rsz_power_unit_01-02.jpg

    Chy

    please note there may be a wrong design in above drawing.

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    Carnel (07-31-2020), nova_robotics (07-30-2020)

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    Supporting Member chy_farm's Avatar
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    chy_farm's Tools
    A couple of logic units of this type is known as noise-fragile to electro-magnetic noises. This part was one of the complexities to me.
    Variable Frequency Drive for a larger factory fan-noise_shield.jpg

    Units in the right half (marked yellow) are electrically shielded with copper plate around them, they are a triangle wave generator and a wave form comparator, and a sine wave generator.

    These in the left half are also shielded with so called shield wire (black wires), they make up a Pulse Width Modulation logic unit.

    Chy
    Last edited by chy_farm; 07-30-2020 at 07:29 PM.

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    nova_robotics (07-30-2020)

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    nova_robotics's Tools
    That's great. Well done.

    Why three Arduinos?

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    chy_farm (07-30-2020)

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    Supporting Member chy_farm's Avatar
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    chy_farm's Tools
    Good morning Nova, Why? ,,, only because I did not know other ways, lol. Do you make them in one Uno?
    Chy

    p.s. Glad to know you are a specialist of robotics, Nova!
    Last edited by chy_farm; 07-30-2020 at 07:37 PM.

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    Supporting Member chy_farm's Avatar
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    chy_farm's Tools
    The logic unit needs a delay-time-unit for one of the safety purposes;
    Variable Frequency Drive for a larger factory fan-delay_time.jpg
    This unit is not yet given the noise shield.

    The delays are confirmed with oscilloscope views;
    Variable Frequency Drive for a larger factory fan-delay_time_4.jpg
    Variable Frequency Drive for a larger factory fan-delay_time_5.jpg

    Chy

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    Does the breadboard not contribute to rf noise ?Once the design goes to PCB there should not be so much interference.

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