摘要
矿用隔爆变频一体式电机与传统隔爆电机相比具有节能、转速转矩可调、机械负荷小等特点。传统的变频电机与变频器是分立的,在采煤工作面中,开关柜与电动机的距离在几百米以上,且井下工作环境复杂多变,为保证电机正常运行需要在线路中加装电抗器等设备,降低了电机运行线路的稳定性与可靠性,并增加了运行成本,限制了该种电机的应用。采用矿用隔爆型变频一体式调速三相感应电动机可以从根本上解决这个难题。本文针对一体式电机设计中存在的问题对关键技术进行了深入研究,在此基础上设计并制造了国内首台矿用隔爆变频一体式电机,形成了一整套隔爆变频一体式电机的设计方法。
本文的内容分成以下几部分：
第一部分：主要研究了变频电机损耗问题,以铁磁材料损耗产生机理为根据,采用场路耦合法对变频器参数对变频电机损耗的影响做了研究。提出了温度下降法分离转子损耗,对转子损耗进行了计算,为定量分析隔爆变频电机转子损耗提供了理论依据。
第二部分：基于传热学基本理论及有限元分析理论对隔爆电机内温度场分布进行了计算,对电机设计具有一定程度的指导意义。由于矿用隔爆电机的工作环境要求,电机的外壳具有高密封性的特点,这就导致了矿用隔爆电机的散热比普通电机困难,尤其是一体式变频电机发热量增加,因此对电机温升及损耗的研究就尤为重要。本文提出了一种适应于高水压的新型高强度水冷却结构,并通过有限元法和实验验证了设计的有效性。
第三部分,对隔爆变频一体式电机调速系统功率主电路的电磁干扰耦合路径进行了分析和研究。为抑制IGBT的电磁干扰强度,提出了一种破坏电磁耦合路径的方法,通过软件仿真验证了该法的有效性；针对PWM电机驱动产生的电磁干扰发现了传统的EMI滤波器的不足,在此基础上改进使其能够抑制共模电压、共模电流；在对变频器物理样机的研制过程中,从电磁兼容、低感母线角度,设计了一种层叠母线以减小电机驱动器空间电磁干扰。
第四部分：基于以上的研究与分析设计了一台刮板输送机用隔爆变频一体式调速感应电机,应用有限元法对电机的电磁性能进行了仿真分析,并搭建了实验平台,对样机进行了型式实验,完成了国内第一台隔爆变频一体式电机的研发,为今后开发新型矿用隔爆电机提供设计依据及理论基础。
Coal mine explosion-proof VFD (Variable Frequency Drive) induction motor has the advantages of saving energy, low mechanical load and adjustable speed and torque comparing with traditional explosion-proof induction motor. The motor and converter of traditional VFD motor are discrete components. In the coal mine the motor is hundreds meters away from the switch cubicle, additionally, the work environment of the motor is complex. In order to maintain the motor normally running, reactors must be installed in the circuit; consequently, stability and reliability of the motor are reduced. This dissertation presents an explosion-proof VFD integration induction motor used in scraper conveyor. A series of key technological and design method for the explosion-proof VFD integration induction motor was formed.
The contents of this dissertation can be divided into following parts.
In the first part, the problems of loss, thermal field and cooling structure of the explosion-proof induction motor were studied. The seal performance of the explosion-proof induction motor shell is good, so it is hard for the explosion-proof induction motor to dissipate heat. The problem is even more serious for the explosion-proof VFD integration induction motor. This dissertation presents a new high strength type of water-cooling structure to adapt the high hydraulic pressure. The effectiveness of the design was proved by EMF analyze and the hydraulic pressure experiment.
In the second part, an experiment to separate was presented, the temperature of rotor was measured and the loss of the rotor was calculated. A concept of quality for rotor loss and temperature was built. The3-D temperature of the explosion-proof VFD integration induction motor is calculated by using the finite element method. It is a powerful analytical tool in guiding the design of motor.
In the third part, the EMI coupling path of the main power topology of the explosion-proof VFD integration induction motor speed control system was researched. In order to cut down the electric influence of IGBT, the suppression method is presented by breaking EMC coupling path. Theory analysis adopts the simulation of surface current and electrical field of heat sink. The disadvantage of traditional EMI filter, electric influence caused by PWM motor drive, was discovered. The improved design was done to restrain common-mode voltage and common-mode current. From the perspective of the EMC and low stray inductance bus bar, the terrace generatrix was developed to weaken the EMI.
In the forth part, based on above achievements, an explosion-proof VFD integration induction motor used in scraper conveyor was developed. The experiment method of motors of this type was improved, and the experimental platform was constructed. Those all provided integrated design specification for the development of the explosion-proof VFD integration induction motor.
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