Design and implementation of conveyer belt speed control using IOT based VFD.

Variable Frequency Drive is a type of motor controller that drives an electric motor by varying the frequency and voltage supplied to the electric motor.VFD can be used in lots of fields. Variable Frequency Drives are widely used to control the speed of AC motors, like conveyor systems, blower speed

2025-06-28 16:31:42 - Adil Khan

Project Title

Design and implementation of conveyer belt speed control using IOT based VFD.

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

Variable Frequency Drive is a type of motor controller that drives an electric motor by varying the frequency and voltage supplied to the electric motor.VFD can be used in lots of fields. Variable Frequency Drives are widely used to control the speed of AC motors, like conveyor systems, blower speeds, pump speeds, machine tool speeds, & other applications that require variable speed with variable torque. They are basically a green energy savings product that matches the amount of work or load on a motor to the amount of energy it needs to power that amount of work. It allows you to run that motor at the load it needs to be instead of running it at peak load all the time. However, VFDs are very expensive due to which only major industries can afford to utilize them. We will be creating a cost effective 3 phase Variable Frequency Drive as typically 3 phase AC machines are used in the industrial sector. We will be using IGBTs and a Micro controller that can be controlled and monitored wirelessly as it is time consuming and hazardous for technicians to control and monitor VFDs in the field. Using a module we would be able to control and monitor the VFD from a mobile application as well as from a control room which is the competent way for safe and easy operation and monitoring of VFDs. We will be implementing our project on 3 phase induction motor that will be operating an industrial grade conveyer belt.

Project Objectives

Before, many control methods has been employed to enhance flexibility and manufacturing process such as controlling speed of equipment

  1. Changing gear ratios or pulleys
  2. Using hydraulic drives
  3. A valve that limits the flow of fuel
  4. A vane that controls the airflow while speed of motor remains unchanged
  5. Switching it on & off in dual speed motors (inefficient & waste of energy)

Motor drivers are popular because they control the input power and save energy as well as reduce CO2 emission. VSD Technology helps us save losses of mechanical equipment and increases efficiency by allowing motors to run at ideal speed for every load condition.

The main advantage of VFD is that it reduces electricity consumption upto 30% - 60 % as 60% from total city power is given to industries and Improve efficiency of motors which are used in ski lifts, saw mills and hospital ventilation systems especially where flow control is involved

Our VFD will have many key features that make this drive essential in most industrial sectors. First feature will be that VFD will be very affordable as well as reliable. It will also be a key factor in industrial energy saving and will in return also prolong life of mechanical equipment. Most of VFD’s available in the market today are not controlled wirelessly due to which a technician has to been on site to control the speed of motors using VFD; so our VFD will be IOT based which can be controlled from a control centre and also from your cellular device.

Project Implementation Method

The project will be completed using step by step prototyping methodology. This will be separated in blocks and each block will be implemented and tested then made part of the main block. This allows each block to be tested thoroughly before being implemented in the project. This allows better fabrication and implementation of the project.

Benefits of the Project

NO.

Component

Detail

1

Electrical Motors
  • Converts electrical energy to mechanical energy
  • Used in
  1. Transportation
  2. Material handling
  3. Production processes
  • Easy control of motors provides flexibility and precision in meeting user demands
  • Electrical motors use 1/3 of total industrial energy
  • Motors work efficiently when load is at least 75% of rate load (load specified for motor) and it losses PF when decrease 50% of rated load. Huge waste of energy
  • Purchase energy saving motors
  • It has two types AC & DC Motors

1.1

DC Motors
  • Use VSD where good dynamic response and steady state performance is required
  • DC motors are used where momentarily delivery of rated torque is required
  • It  can smoothly go to zero and then accelerate in opposite direction without power circuit switching
  • Speed can be changed by changing voltage
  • DC motor’s speed-torque characteristics can be altered easily than AC motors
  • Advantages
  1. Simple in design
  2. High starting torque
  3. Near linear performance
  4. Ease of controlling speed
  5. Low cost speed drives
  • Disadvantages
  1. Bulky
  2. Expensive

1.2

AC Motors
  • They work by setting up a magnetic field that rotate with aspect of stator and employ EM forces to entrain the rotor in the rotating of MF
  • Advantages
  1. Simple
  2. Low cost
  3. Reliable
  • Disadvantages
  1. Expensive speed drives
  2. Unable to operate on low speeds

2

Fans
  • It is controlled will on off switch
  • Continuous on and off decrease motor’s life
  • They are main part of ventilating system
  • Varying speed with requirement saves energy and extends motor’s life

3

Pumping Systems
  • 20% OF WORLD ENERGY IS CONSUMED BY ELECTRIC MOTORS
  • VSDs improves
  1. Performance
  2. Reliability
  3. Reduced life cycle loss
  • Most existing systems require flow control of
  1. Bypass lines
  2. Throttling valves
  3. Pump speed adjustments
  • When pump speed is reduced less energy is imparted to the fluid and less energy needs to be throttled or bypassed
  • Speed can be controlled with VSDs
  • Majority of pumps are driven by electric motors

4

Heating, Ventilating & Air Conditioning (HVAC)
  • Ventilation systems are designed to operate at peak load conditions which are experienced only few times a day
  • Inefficient for long period of time
  • The most common method is to modulate the speed is VSD
  • VSD save 15-40% energy in HVAC
  • Speed flow regulate fluid flow (fluid: liquid & gas)
  • In HVAC, VSD characteristics are
  1. Ability to handle higher power levels
  2. Easy programming
  3. Steady response
  4. Increasing reliability
  5. Ruggedness
  6. Decreasing size of units

5

Air compressor system
  • It is a mechanical device
  • The compressed air system utilizes a huge amount of electrical energy
  • The benefits of using VSD in compressors are
  1. Reducing power cost
  2. Decreasing power surge
  3. Delivery of constant pressure
  • Downsides are
  1. Heavy expense
  2. Sensitivity of drives to heat and moisture

NO.

1

1.1

1.2

2

3

4

5

Technical Details of Final Deliverable

Components of VSDs

NO.

Component

Detail

1

Rectifier
  • Used to convert AC to DC
  • Two main topologies are present
  1. Diode Rectifiers
  • Most commonly used
  • Its power circuit consists of 6 power diodes in 3 phase bridge; DC output depends on AC input
  • The diodes are non linear loads so non sinusoidal current is given 
  1. Insulated Gate Bipolar Transistor (IGBT) Rectifiers 

2

Regulator
  • It controls VSD
  • It gathers information and reports faults
  • Enables exchange of data between VSD & Motor

3

Inverter
  • Generate AC by switching DC in alternative directions
  • They have IGBT components
  •  Structure of IGBT results in lack of parasitic diode so IGBT require a free wheel diode to be placed across it
  • PWM control is used to control IGBT switched
  • PWM control consists in rapidly switching on and off the IGBT switches in such a that pulses with variable width constitute a variable waveform

The Project will include

3 Phase Variable Frequency Drive

3 Phase 0.5 HP Gear Motor

Structure of Conveyor Belt

Wireless Module and Digital Application

NO.

1

2

3

3 Phase Variable Frequency Drive

3 Phase 0.5 HP Gear Motor

Structure of Conveyor Belt

Wireless Module and Digital Application

Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther Industries Energy Core Technology Internet of Things (IoT)Other TechnologiesSustainable Development Goals Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

NO.

Component

Detail

1

Rectifier
  • Used to convert AC to DC
  • Two main topologies are present
  1. Diode Rectifiers
  • Most commonly used
  • Its power circuit consists of 6 power diodes in 3 phase bridge; DC output depends on AC input
  • The diodes are non linear loads so non sinusoidal current is given 
  1. Insulated Gate Bipolar Transistor (IGBT) Rectifiers 

2

Regulator
  • It controls VSD
  • It gathers information and reports faults
  • Enables exchange of data between VSD & Motor

3

Inverter
  • Generate AC by switching DC in alternative directions
  • They have IGBT components
  •  Structure of IGBT results in lack of parasitic diode so IGBT require a free wheel diode to be placed across it
  • PWM control is used to control IGBT switched
  • PWM control consists in rapidly switching on and off the IGBT switches in such a that pulses with variable width constitute a variable waveform

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