Problem and Solution Approach

Our Main Focus for Achieving Energy Savings:

🔹 Core Problem

In three-phase asynchronous motors, simultaneous magnetic field interactions between phases during operation cause the stator and rotor magnetic fields to deviate from their ideal geometry.

This situation is especially pronounced when two phases have similar polarities within the same alternation, leading to distortion of the main magnetic flux and causing unnecessary magnetic stress on the rotor.

Deviation from the ideal axis of the magnetic flux:

🔹 Increases iron and copper losses

🔹 Increases the risk of magnetic saturation

🔹 Increasing the slip ratio reduces the engine's efficiency

🔹 Causes the rotor and stator temperatures to rise

These effects cause the motor to incur significant energy losses, especially under partial load and no-load operating conditions.

🔹 VibroDrive Approach

VibroDrive has an innovative motor control approach that targets this structural inefficiency.

The system dynamically manages the phase angle control of the thyristors through a microprocessor.
This allows for partial voltage and phase angle optimization based on the load condition without changing the motor’s frequency.

With this approach:

🔹 The torque required by the motor is balanced with the torque produced

🔹 Active and reactive energy consumption is adjusted according to the load condition

🔹 The magnetic field is maintained along a more stable axis

As a result, the electric motor operates efficiently and in harmony with the load, with reduced losses.

Within the microprocessor software on the PIC16C620A, the software developed for power management in asynchronous motors includes the following definitions.

🔹 Deterministic Adaptive Control Algorithm
🔹 Self-Tuning Phase Angle Control
🔹 Load-Dependent Adaptive Voltage Modulation
🔹 State-Based Energy Optimization Control

The system uses a deterministic adaptive control algorithm that dynamically adjusts the TRIAC firing angle based on motor load and operating conditions, aiming to minimize energy losses.

In summary, its function can be described as “Load Torque and Energy Management” using “Deterministic Adaptive Control.”

🔹 Energy Savings Impact

VibroDrive technology provides significant energy savings, especially under operating conditions where the motor is running at partial load or no-load.

Typical Savings Ranges (Y-Connected Asynchronous Motors):

🔹 At 86–100% load: 3–9%

🔹 At 70–85% load: 10–15%

🔹 At no-load or very low load: 16–35%

In grid-started synchronous motors (LSPMSM) and in ∆-connected (Delta) motors, these rates are on average 10–15% higher.

🔹 Dynamic Start and Continuity

With the VibroDrive “Kick Start” function, the motor is brought online through a controlled start-up process.

🔹At the moment of initial start-up, the current drawn from the grid is reduced by 20–50%.

🔹 The motor reaches a steady speed within 1–2 seconds.

🔹 Thereafter, energy optimization remains continuously active.

Thanks to this dynamic structure, energy consumption is managed in a controlled and balanced manner during both start-up and continuous operation.

🔹 Harmonic Effect

🔹 It does not produce THD-V voltage harmonics in any class.

🔹 It produces THD-I current harmonics in the 3rd, 5th, 7th, 9th, 11th, and 13th orders.

However, the generated THD-I (3) harmonic component may reflect back to the grid within tolerance limits if the star point of Y-connected motors is neutralized or if the motor is powered through a line reactor.

In ∆-connected (Delta) motors, the THD-I (3) harmonic component circulates within the motor windings, dissipates, and does not reflect back to the grid.