{"id":27755,"date":"2023-01-04T15:00:55","date_gmt":"2023-01-04T15:00:55","guid":{"rendered":"https:\/\/tecnologiaparalaindustria.com\/?p=27755"},"modified":"2025-07-22T11:47:14","modified_gmt":"2025-07-22T11:47:14","slug":"ejemplos-de-aplicaciones-con-variadores-de-velocidad-en-plantas-industriales","status":"publish","type":"post","link":"https:\/\/tecnologiaparalaindustria.com\/en\/ejemplos-de-aplicaciones-con-variadores-de-velocidad-en-plantas-industriales\/","title":{"rendered":"Examples of applications with variable speed drives in industrial plants"},"content":{"rendered":"<div id=\"ez-toc-container\" class=\"ez-toc-v2_0_82_2 counter-hierarchy ez-toc-counter ez-toc-grey ez-toc-container-direction\">\n<div class=\"ez-toc-title-container\">\n<p class=\"ez-toc-title\" style=\"cursor:inherit\">Table of Contents<\/p>\n<span class=\"ez-toc-title-toggle\"><a href=\"#\" class=\"ez-toc-pull-right ez-toc-btn ez-toc-btn-xs ez-toc-btn-default ez-toc-toggle\" aria-label=\"Toggle Table of Contents\"><span class=\"ez-toc-js-icon-con\"><span class=\"\"><span class=\"eztoc-hide\" style=\"display:none;\">Toggle<\/span><span class=\"ez-toc-icon-toggle-span\"><svg style=\"fill: #999;color:#999\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" class=\"list-377408\" width=\"20px\" height=\"20px\" viewbox=\"0 0 24 24\" fill=\"none\"><path d=\"M6 6H4v2h2V6zm14 0H8v2h12V6zM4 11h2v2H4v-2zm16 0H8v2h12v-2zM4 16h2v2H4v-2zm16 0H8v2h12v-2z\" fill=\"currentColor\"><\/path><\/svg><svg style=\"fill: #999;color:#999\" class=\"arrow-unsorted-368013\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"10px\" height=\"10px\" viewbox=\"0 0 24 24\" version=\"1.2\" baseprofile=\"tiny\"><path d=\"M18.2 9.3l-6.2-6.3-6.2 6.3c-.2.2-.3.4-.3.7s.1.5.3.7c.2.2.4.3.7.3h11c.3 0 .5-.1.7-.3.2-.2.3-.5.3-.7s-.1-.5-.3-.7zM5.8 14.7l6.2 6.3 6.2-6.3c.2-.2.3-.5.3-.7s-.1-.5-.3-.7c-.2-.2-.4-.3-.7-.3h-11c-.3 0-.5.1-.7.3-.2.2-.3.5-.3.7s.1.5.3.7z\"\/><\/svg><\/span><\/span><\/span><\/a><\/span><\/div>\n<nav><ul class='ez-toc-list ez-toc-list-level-1' ><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-1\" href=\"https:\/\/tecnologiaparalaindustria.com\/en\/ejemplos-de-aplicaciones-con-variadores-de-velocidad-en-plantas-industriales\/#Factores_de_proceso_que_afecta_la_aplicacion_de_variadores_de_velocidad\" >Process factors affecting the application of variable speed drives<\/a><ul class='ez-toc-list-level-4' ><li class='ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-2\" href=\"https:\/\/tecnologiaparalaindustria.com\/en\/ejemplos-de-aplicaciones-con-variadores-de-velocidad-en-plantas-industriales\/#La_necesidad_de_velocidad_con_mayor_control\" >The need for speed with greater control<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-3\" href=\"https:\/\/tecnologiaparalaindustria.com\/en\/ejemplos-de-aplicaciones-con-variadores-de-velocidad-en-plantas-industriales\/#Par_de_carga_en_aplicaciones_con_variadores_de_velocidad\" >Load torque in applications with variable speed drives<\/a><\/li><\/ul><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-4\" href=\"https:\/\/tecnologiaparalaindustria.com\/en\/ejemplos-de-aplicaciones-con-variadores-de-velocidad-en-plantas-industriales\/#Consideraciones_del_lado_de_la_linea_de_suministro_electrico_en_aplicaciones_con_variadores_de_velocidad_en_procesos_industriales\" >Considerations on the power supply side in applications with variable speed drives in industrial processes<\/a><ul class='ez-toc-list-level-4' ><li class='ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-5\" href=\"https:\/\/tecnologiaparalaindustria.com\/en\/ejemplos-de-aplicaciones-con-variadores-de-velocidad-en-plantas-industriales\/#Consideraciones_del_lado_de_la_linea_de_suministro_electrico\" >Considerations on the power supply line side<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-6\" href=\"https:\/\/tecnologiaparalaindustria.com\/en\/ejemplos-de-aplicaciones-con-variadores-de-velocidad-en-plantas-industriales\/#Consideraciones_del_lado_de_la_carga_en_aplicaciones_con_variadores_de_velocidad\" >Load-side considerations in applications with variable speed drives<\/a><\/li><\/ul><\/li><\/ul><\/nav><\/div>\n<p dir=\"ltr\">Variable speed drives are considered state-of-the-art in industrial plant process control, but it is important to realise that they may not be the answer to all process control problems. End users must understand the requirements of different applications with variable speed drives and the mechanical and electrical limitations of the system to ensure that a frequency drive is the right solution, and above all, to specify it correctly. In this article, we summarise some of the main characteristics of the process and the load that must be taken into account before specifying a variable speed drive.<\/p>\n<p>&nbsp;<\/p>\n<h3 dir=\"ltr\"><span class=\"ez-toc-section\" id=\"Factores_de_proceso_que_afecta_la_aplicacion_de_variadores_de_velocidad\"><\/span>Process factors affecting the application of variable speed drives<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<h4 dir=\"ltr\"><span class=\"ez-toc-section\" id=\"La_necesidad_de_velocidad_con_mayor_control\"><\/span>The need for speed with greater control<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p dir=\"ltr\">Many industrial processes can benefit from the ability to reduce production periodically or continuously by reducing the speed of driven equipment. For example, piping systems are often \u00aboversized\u00bb to accommodate future expansion or simply to provide some operating margin. If we drive the motor at full speed, the result is an output that must be \u00abreduced\u00bb, for example, through control valves. There is the possibility of increasing the overall efficiency of the system and reducing energy consumption by using a variable speed drive. Considering that capital costs tend to be higher for the use of variable speed drives, it is important to determine the percentage of time and flow reduction required, and then use that information to estimate the reduction in motor power that could be tolerated. Considering an example of the application of variable speed drives with centrifugal pumps, the motor power varies according to the speed hub. As a result, a reduction in motor speed of only 15% can reduce the horsepower required (and therefore the kW consumed) by almost 40% (0.853 = 0.61).<\/p>\n<p dir=\"ltr\">On the other hand, some systems are designed in such a way that speed reduction does not provide any operational benefits. An example to explain this point is the case of hermetically designed piping systems with high static pressure available. In this case, the system flow tends to be controlled more efficiently with valves, especially when the costs of variable speed drives are taken into account.<\/p>\n<p dir=\"ltr\">Many processes could benefit from using reduced voltages during start-up, even if speed control is not required. In such cases, a reduced voltage (i.e., \u00absoft\u00bb) starter can be used. The soft starter will typically reduce the inrush current, which in turn reduces mechanical and electrical stresses on the driven equipment. While the application of a variable speed drive can also provide this \u00abramp up\/ramp down\u00bb function, it may well be excessive (adding unnecessary cost and complexity) if variable process speed is not required.<\/p>\n<h4 dir=\"ltr\"><span class=\"ez-toc-section\" id=\"Par_de_carga_en_aplicaciones_con_variadores_de_velocidad\"><\/span>Load torque in applications with variable speed drives<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p dir=\"ltr\">Variable speed drives are sized directly by continuous amperage output, not by horsepower. While horsepower can be used to approximate the size of the variable speed drive, it is the amount of current required in both steady state and overload conditions that determines the correct drive to specify. The torque required to operate the driven load affects the amperage required. Loads with a constant torque or constant power profile require a greater amount of torque during start-up, which places greater amperage demands on the drive at start-up. Therefore, it is important to understand the load torque profiles in order to know which drive amperage rating and overload capacity to select.<\/p>\n<ul>\n<li dir=\"ltr\"><strong>Variable pair:<\/strong> This profile is characteristic of centrifugal pumps and centrifugal fans. The torque increases as the load speed increases, which translates into lower demand on the frequency converter during start-up. The torque increases with the square of the speed increase.<\/li>\n<li dir=\"ltr\"><strong>Constant pair:<\/strong> Typical in conveyor equipment, positive displacement pumps\/compressors, and screw feeders, this profile is characteristic of a load that effectively requires the same torque at any speed within the operating range.<\/li>\n<li dir=\"ltr\"><strong>Constant horsepower:<\/strong> In this profile, typical of machine tool applications, winders, and some load-driven conveyors, the required torque varies inversely with speed (decreasing as speed increases).<\/li>\n<\/ul>\n<p dir=\"ltr\">Variable speed drives rated for variable torque applications have higher continuous amperage ratings because they are not being applied as much at start-up or when they need to respond to changing loads. For example, a variable speed drive sized for a 20 HP variable torque application, capable of supplying 31 continuous amps at 480 volts, would only be rated for a 15 HP constant torque application, supplying 23 continuous amps. This is done to prevent the variable speed drive's electronic components from becoming overloaded when faced with the need to maintain torque in heavy-duty industrial applications.<\/p>\n<h3 dir=\"ltr\"><span class=\"ez-toc-section\" id=\"Consideraciones_del_lado_de_la_linea_de_suministro_electrico_en_aplicaciones_con_variadores_de_velocidad_en_procesos_industriales\"><\/span>Considerations on the power supply side in applications with variable speed drives in industrial processes<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<p dir=\"ltr\">We have seen that defining the variable speed drive application and specific characteristics is essential to ensure a cost-effective and successful installation using a variable speed drive. In addition to the mechanical considerations discussed so far in this article, there are several power line and load side issues that must be taken into account when deciding on the correct variable speed drive (or no drive) application for the specific industrial process to be controlled.<\/p>\n<h4 dir=\"ltr\"><span class=\"ez-toc-section\" id=\"Consideraciones_del_lado_de_la_linea_de_suministro_electrico\"><\/span>Considerations on the power supply line side<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<ul>\n<li dir=\"ltr\"><strong>Voltage:<\/strong> Frequency converters (for AC motor applications) are rated to accept a nominal voltage with a standard tolerance of +10\/-10%. Outside this range, the units generally disconnect to protect themselves. In the event of an overvoltage condition, the risk is to the DC bus, which typically operates at approximately 1.2 times the input voltage level. Once that level exceeds approximately 1.4x the upper end of the input voltage range, the unit will disconnect (Note that, unlike AC drives, due to the nature of their output electronics, DC drives up to 500V can operate at lower input voltages; however, their output voltage is reduced accordingly).<\/li>\n<li dir=\"ltr\"><strong>Phase:<\/strong> Almost all variable speed drives provide a three-phase output, most often powered by a three-phase supply. But drives are also specified for their ability to convert single-phase voltage to three-phase, often in place of rotary or electronic phase converters. However, they do so at a higher cost since their DC electronics must be reinforced to handle the single-phase input. Essentially, this is because the DC link capacitors are charged only 1\/3 of the time they would be if fed from 3 phases, so to smooth the DC bus ripple and supply the inverter with the correct voltage level, they must be higher capacity. In addition, single-phase results in higher line currents, so more drive capacity is needed.<\/li>\n<\/ul>\n<p dir=\"ltr\">Generally, a single-phase AC drive will need to be reduced by approximately 50% of its three-phase rated value, effectively doubling the size of the drive required. You will find lower-power variable speed drives rated as \u00abready to use\u00bb for single-phase input; these are simply units manufactured to handle the higher capacity. Such units are difficult to find in ratings above 3 kW.<\/p>\n<p dir=\"ltr\">Impedance: In cases where the upstream line impedance is too low, such as with a drive system connected very close to a main distribution board, it may be necessary to increase the impedance to reduce stresses on the drive electronics caused by high current rate of change. This is often achieved by inserting<a href=\"https:\/\/tecnologiaparalaindustria.com\/en\/reactores-de-linea-para-proteger-variadores-y-motores-usos-y-aplicaciones\/\" target=\"_blank\" rel=\"noopener\" data-saferedirecturl=\"https:\/\/www.google.com\/url?q=https:\/\/tecnologiaparalaindustria.com\/reactores-de-linea-para-proteger-variadores-y-motores-usos-y-aplicaciones\/&amp;source=gmail&amp;ust=1670663468660000&amp;usg=AOvVaw20j4k9MtLscYfg_LHb9f5h\"> line reactors to protect drives and motors on the AC line<\/a> or chokes on the DC bus.<\/p>\n<p class=\"alert alert-warning\" dir=\"ltr\">Many variable speed drives come equipped with line reactors, which typically provide an impedance of 3:1; if more is required, optional reactors are available. The <a href=\"https:\/\/tecnologiaparalaindustria.com\/en\/aplicaciones-de-reactores-de-linea-para-variadores-y-motores\/\" target=\"_blank\" rel=\"noopener\" data-saferedirecturl=\"https:\/\/www.google.com\/url?q=https:\/\/tecnologiaparalaindustria.com\/aplicaciones-de-reactores-de-linea-para-variadores-y-motores\/&amp;source=gmail&amp;ust=1670663468660000&amp;usg=AOvVaw0LV2WiD4m44uXajIOqNxXQ\">line reactor applications for inverters<\/a> They have the added benefit of reducing harmonics in the supply line, which are inherent in most drive designs and can cause operational problems for sensitive upstream equipment.<\/p>\n<p dir=\"ltr\">Overcurrent protection: Variable speed drives provide extensive user-programmable motor protection. However, they have limited built-in protection for their electronic components, and proper installation requires the use of high-speed, low \u00abI-squared\u00bb overcurrent protection. Class J\/gG fuses are typically specified to limit the current and remove it very quickly, before sensitive electronic components are damaged. In some cases, variable speed drive manufacturers have tested and approved circuit breakers for this purpose. However, they tend to offer a slower response, more challenging coordination with other protection devices, and, if set too tightly, trade annoying trips for the convenience of not having to replace the unit once it trips. In any case, it is always recommended to use the devices and ratings recommended by the manufacturer.<\/p>\n<h4 dir=\"ltr\"><span class=\"ez-toc-section\" id=\"Consideraciones_del_lado_de_la_carga_en_aplicaciones_con_variadores_de_velocidad\"><\/span>Load-side considerations in applications with variable speed drives<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<ul>\n<li dir=\"ltr\"><strong>Motor amperage:<\/strong> Units are sized by amperage, not horsepower. To ensure adequate output capacity, the full-load amperage must be known from the nameplate of the driven motor. It is important to note that sizing the unit based on full-load amperage is not simply conservative. Assuming that the motor is correctly sized for the required load torque, sizing a variable speed drive solely for what the motor consumes under \u00abnormal\u00bb (i.e., non-peak) load conditions may not provide sufficient torque to drive the process under heavy load conditions. Furthermore, sizing a unit solely by power ignores the amount of overload that the unit can provide.\n<p class=\"alert alert-warning\" dir=\"ltr\">An example of the application of variable speed drives to explain this point is the case of a 460-volt unit suitable for a 75 hp motor that, under variable torque conditions, can generate 96 amps continuously; under constant torque conditions (also known as heavy duty), that same unit would only be suitable for 60 hp and 77 amps. This is because, under heavy load conditions, the output electronic components (usually IGBTs or \u00abinsulated gate bipolar transistors\u00bb) must fire for longer periods and are more prone to overheating, so the ratings are reduced to protect them.<\/p>\n<\/li>\n<li><strong>Voltage frequency and magnitude:<\/strong> These same IGBTs are controlled by the drive circuit to trigger (turn on and off) at high frequency, typically from 2 kHz to 16 kHz, creating high-frequency voltage transients at the drive output. And unlike a pure, well-balanced three-phase sine wave, the transients do not cancel each other out. As a result, they can generate voltages at the motor terminals that are 2 to 3 times or more the input supply voltage. This effect is greatly exacerbated by long motor cable lengths. Premium efficiency motors, particularly those that meet NEMA MG-1 standards, are built to withstand these transients to a certain extent. Once motor cable lengths become excessive (depending on the manufacturer and testing agency, from perhaps 30 metres or more), output filters are recommended.<\/li>\n<li><strong style=\"color: var(--body-color,var(--color-body)); font-family: var(--body-font-family,unset); font-size: var(--body-font-size,var(--font-size-md)); font-style: var(--body-font-style,normal);\">Age\/condition of engine:<\/strong><span style=\"color: var(--body-color,var(--color-body)); font-family: var(--body-font-family,unset); font-size: var(--body-font-size,var(--font-size-md)); font-style: var(--body-font-style,normal); font-weight: var(--body-font-weight,unset);\"> Largely due to the factors mentioned above, care must be taken when attempting to control an older motor or one with a marginal insulation system with a frequency converter. High-frequency voltage transients can generate a lot of stress on the motor winding insulation, eventually causing dielectric breakdown and short-circuiting the windings. In addition, common mode noise (i.e., line-to-ground) generated by the drive electronics can cause currents to flow in the motor frame, shaft, and bearings; these currents will seek a path to ground, often resulting in bearing and track pitting. This is not usually a major factor for smaller frame motors (say, less than 500 NEMA\/315 IEC), but larger motors often require insulated bearings and shaft grounding to prevent premature wear of the bearing components.<\/span><\/li>\n<li><strong style=\"color: var(--body-color,var(--color-body)); font-family: var(--body-font-family,unset); font-size: var(--body-font-size,var(--font-size-md)); font-style: var(--body-font-style,normal);\">Wiring:<\/strong><span style=\"color: var(--body-color,var(--color-body)); font-family: var(--body-font-family,unset); font-size: var(--body-font-size,var(--font-size-md)); font-style: var(--body-font-style,normal); font-weight: var(--body-font-weight,unset);\"> For the drive to operate cleanly and with minimal problems, good wiring practices should be followed: separating power connections (line and load) from each other and from control wiring is good practice; use shielded cables, properly grounded, where susceptible to common mode noise; provide metal conduit where possible; and ensure that conductors are sized appropriately for the drive output current, with a properly sized grounding conductor being essential. We recommend consulting local\/regional electrical codes for additional information.<\/span><\/li>\n<\/ul>\n<p dir=\"ltr\">If you would like to know more about the <a href=\"https:\/\/tecnologiaparalaindustria.com\/en\/configuracion-y-puesta-en-marcha-de-variadores-de-frecuencia\/\" target=\"_blank\" rel=\"noopener\" data-saferedirecturl=\"https:\/\/www.google.com\/url?q=https:\/\/tecnologiaparalaindustria.com\/configuracion-y-puesta-en-marcha-de-variadores-de-frecuencia\/&amp;source=gmail&amp;ust=1670663468660000&amp;usg=AOvVaw0LkxT51noSGK51FRMibeC1\">configuration and commissioning of frequency inverters<\/a> in industrial applications, we invite you to subscribe to the <a href=\"https:\/\/recursos.tecnologiaparalaindustria.com\/newsletter?utm_source=Newsletter&amp;utm_medium=Cta_web&amp;utm_campaign=Newsletter_cta_web\" target=\"_blank\" rel=\"noopener\" 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&hellip;<\/p>","protected":false},"author":2,"featured_media":27756,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_genesis_hide_title":false,"_genesis_hide_breadcrumbs":false,"_genesis_hide_singular_image":false,"_genesis_hide_footer_widgets":false,"_genesis_custom_body_class":"","_genesis_custom_post_class":"","_genesis_layout":"","footnotes":""},"categories":[472],"tags":[],"class_list":["type-post","category-automatizacion-y-control","CTA-ebook-experto-en-variadores-de-frecuencia-alimentaria","CTA-tpi","entry"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Ejemplos de aplicaciones con variadores de velocidad<\/title>\n<meta name=\"description\" content=\"Aplicaciones con variadores de velocidad en plantas industriales:Par variable, Par constante, Caballos de fuerza constantes, Voltaje, Fase, Impedancia y 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