Regeneration Vs Dynamic

Braking in DC Drives
Application Solution

Introduction

Both regeneration and dynamic braking (DB) slow down a rotating Figure 1. Relative Stopping Times
DC motor and its load, but when should one method be chosen
over another, or when possibly should both be used? There are Top Speed
significant differences in stopping time, controllability during A = Regenerative Stop at X current
B = DB Stop at X initial current
stopping, and safety issues depending how one defines what
should happen under emergency conditions. Many application
requirements may dictate that a regenerative drive be selected for
an application. This comparison however deals only with
regeneration with respect to stopping performance. First let's
37% Top Speed
review exactly what regeneration and DB are in a DC phase B
controlled drive.
A
Discussion
REGENERATION in a phase controlled DC drive involves a second
(antiparellel connected) rectifier bridge. During regeneration, t Time
mechanical energy from the rotating load and armature (now act-
ing as a generator), is inverted from DC directly back onto the AC
power line. The reversal of current in the DC motor causes a brak- The following is a list of characteristics to consider:
ing action to slow the rotating load. It is a controlled process. The
1) STOP TIME
drive is operating and in control of the load during regeneration.
Regen: The deceleration torque is constant down to zero speed in
Regeneration does not occur when the drive is in a coast/DB stop
fixed field applications. It is a function of the decel rate setting of
mode or when a drive fault shutdown occurs.
the drive, or current limit setting if the decel rate causes limit to
be reached. Minimum stop time occurs in a current limit stop with
DYNAMIC BRAKING on a phase controlled DC drive is an “uncon-
limit set as high as possible. Neglecting frictional losses, the
trolled” process. During DB, the motor armature is disconnected
stopping time is easily calculated with the following equation:
from the drive. A resistor is placed across the motor's rotating
armature (now acting as a generator) and the resulting current t = RPM * inertia / 308 * T
causes braking torque in the motor that decays exponentially t = time in seconds
(assuming no overhauling load and fixed motor field) with the RPM = motor speed when stopping begins in revolutions/minute
motor's Counter Electro Magnetic Force (CEMF). The motor will
decelerate, even with a drive failure, as long as motor field excita-
tion is maintained.
Inertia = total motor and reflected load inertia in lb-ft2 into a stop mode.
T = motor torque during regeneration in foot pounds
DB: The drive must have the DC contactor open for DB stopping to
DB: In fixed field applications, the deceleration torque decreases occur. This typically occurs with a Coast/DB Stop command or a
exponentially with speed (armature volts) and is a function of the drive fault where the drive is in a standby mode.
total armature and DB grid resistance. The grid is often sized to
3) FAULT CONDITIONS
allow 150% of rated armature current to flow at top speed
Regen: Under drive fault conditions the drive is put into standby
(voltage). As the motor slows down, the armature voltage
and the contactor is opened. There is no regeneration. The load
decreases and hence the current and decelerating torque
coasts unless DB or a mechanical brake is applied.
continually decrease. In the time a regenerative 150% current
limit stop would occur, this DB stop would reduce the speed to DB: Under drive fault conditions, the DC contactor opens applying
37% of top speed (this again assumes negligible friction losses). the DB grid across the motor for a DB stop.
In twice that time, the speed would be down to .37 x .37 = 14%
General: What happens under drive fault conditions is a major
of the original speed etc. Eventually the motor will reach zero
consideration because this could happen at any time during any
speed. Of course observed stopping time will be somewhat
operating conditions (eg. tach loss of field loss). The application
quicker than calculated given the actual frictional losses.
and or user preference will dictate if is OK to coast or if DB is
General: In both cases the decel time is proportional to the speed required. The drive will not regenerate since a fault immediately
and total rotating inertia. Those two entities define the amount of puts the drive into standby and opens the contactor. Some
kinetic energy that needs to be “disposed of” in either case. applications that require regeneration for other reasons may
Consider the example where a 150% current limit stop from top require DB as well for braking under fault conditions.
speed is compared to a DB stop from top speed (where the DB
4) "EMERGENCY" CONDITIONS
grid was selected to allow 150% initial DB current). At the first
General: "Emergency" conditions are not for us to define.
instant of stopping both methods allow the same current and
Different applications and different user preferences dictate what
hence the same decel torque. The regenerative drive maintains
the drive should do under conditions that the user defines as an
that current and torque through the stopping cycle. The decel
emergency. The fastest and surest way to disconnect the motor
current in the DB case immediately begins to reduce because the
from the power source is with a Coast/DB stop. The contactor is
motor speed and voltage are decreasing. See figure 1.
opened, by a “hard-wired” mechanism immediately. The drive will
2) DRIVE STATUS DB if the proper contactor and grids are present, otherwise it will
Regen: The drive must be energized and running for regeneration coast. Regeneration will not occur.
to occur. Regenerative stopping occurs when a “Normal” stop
Typically, the fastest way to bring the load to a stop is with a
command is given. This is also known as a “Ramp” stop where
current limit regenerative stop with current limits set to the
the drive regenerates and decelerates as necessary to follow the
maximum. Constant regenerative torque is provided for the entire
decel ramp. If there is not enough torque to follow the ramp at
stopping process provided the drive remains energized and that
current limit then the drive decelerates in current limit. Some
no drive faults occur. Some applications that require the fastest
drives also have a "Current Limit Stop" mode. This is a
stopping time may employ a current limit stop with a time
regenerative stop where the decel ramp is bypassed causing a
delayed Coast/DB stop as a backup. All stopping sequences
current limit deceleration. During a regenerative stop the
should have the ability to employ the Coast/DB stop at some
contactor is not opened until zero speed is detected. One other
point since it will open the contactor even in the event of
consideration is that a regenerative drive can be decelerated by
regulator malfunction.
lowering the speed reference without the need to put the drive
5) REPETITION DC contactor it must have the normally closed pole to connect the
Regen: In regeneration, the energy from the rotating load is grid across the motor. If the drive does not have a DC contactor
converted and returned to the AC power lines for consumption then one must be added. These factors must all be considered in
elsewhere. The energy is not dissipated and no heating occurs evaluating the price difference between adding DB or going to a
other than the normal thyristor losses in the power unit. regenerative drive.
Regeneration can occur for as long as necessary and as
NOTE: Assumes Fixed Field and Negligible Friction Losses.
repetitively as necessary within the thermal limitations of the
drive and motor itself. This typically would be 150% regenerative Conclusion
current for one minute or equivalent. In a cyclical application, the Some applications require regenerative stopping, some require
RMS of the total current waveform (motor and regen) must not dynamic braking, while still others require both. Making the
exceed the 100% rating of the drive. proper selection involves four main considerations:

DB: During DB, the energy from the rotating load is lost as heat in 1. What is the required stop time under normal stopping
the DB grid. Because dynamic braking is not a continuous conditions for the application? Regen can be the fastest and
occurrence, the grids are usually sized for intermittent operation. deceleration doesn't necessarily require the drive be put in a
Several successive DB cycles without sufficient time for cooling stop mode.
can damage or destroy the grids. Typically grids may be sized for 2. What is the required stop time under drive and/or system fault
three successive operations from top speed before a cooling peri- conditions? Regen does not occur under these conditions. DB
od is required. Motor and connected load inertia must be used (or may be required whether or not the drive is regenerative.
estimated) in these calculations. Consideration must also be 3. How does the user define "emergency" stopping? Is the
given to equipment near or in the same enclosure with the grids only concern to get the motor disconnected from the power
so that the air temperature does not exceed acceptable limits dur- source (coast or DB) or is the fastest deceleration necessary
ing DB occurrences. (Regen with a coast or DB backup)?
4. How repetitive is the stopping cycle? The more often, the more
6) COST COMPARISONS
heat, and the more likely regen will be advantageous.
General: A regenerative phase controlled drive has twice the
power components and driver circuitry of a non-regen drive and is Exploring these aspects of the application will lead to the right
correspondingly more expensive. Adding DB to a drive requires decision regarding the need for regen, DB, both, or possibly nei-
adding the grids and associated housing. If the drive contains a ther if coasting is always acceptable.

NOTE: This material is not intended to provide operational instructions. Appropriate Reliance
Electric Drives instruction manuals precautions should be studied prior to installation,
operation, or maintenance of equipment.

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Publication D-7733 – March 2000 © 2000 Rockwell International Corporation All Rights Reserved Printed in USA