Frequency Controller

A frequency controller is a common name used for variable frequency drive or VFD. It is also known as adjustable frequency drive, variable-voltage/ variable-frequency drive, variable speed drive, microdrive, frequency inverter drive or AC drive.

This is a particular type of motor drive that is used in electro-mechanical drive systems to control AC motor speed and torque by varying motor input frequency and voltage. These devices are commonly used in applications ranging from small appliances to large compressors and other industrial applications. Systems that use VFDs are more efficient than using throttling control of fluid flow like damper controls in fans. In addition, unlike their ancestors, modern-day VFD devices come at a lesser cost and smaller sizes to fit in any mechanical setting.

Benefits of using VFD drivers or frequency controllers

With bearable cost and smaller size, the VFD controller has become a widely accepted device in an industrial setting. As a result, the potential for retrofits and new project installation is still higher. Moreover, the demand for energy-saving and process control continues to deliver higher growth. These smaller parts are efficiently serving the two main mechanical parts – fans and pumps. However, with current demands of lesser overall demand on power grids, many utility companies are offer rebates and, in many cases, products with virtually no cost to the user. In the meantime, these small devices are successful in offering the following advantage to the users.

Reduces energy consumption

Besides being a cheaper product for your electric system, the VFD is also efficient in delivering higher performance with minimum energy consumption. Also, if you do not want to run your application at full speed, cut down the energy costs by controlling the motor with a VFD. It gives you the flexibility to match the speed of motor-driven equipment to the load requirement. And when we speak of AC, there are no other ways to get the job done. So, if you have an AC based motor, you need to get a suitable VFD for lesser energy consumption and better performance at cheaper rates.

Increased production

These motors offer increased productions with their tighter process controls. And by operating your motor at the most efficient speed of your application, lesser mistakes will occur. As a result, the product level will increase, which will earn your business the highest revenues possible. For instance, if your industrial process includes any size or capacity of belts and conveyors, a VFD will eliminate the jerks on the start-up, allowing a higher and throughput. As a result, you will have better performance and increased productivity in less time.

Equipment like and maintenance

The VFD also has an impact on the lifecycle of the machine and every single of its part. Besides, it also keeps the engine in better working condition; thus, lesser maintenance needed over time. Ensuring optimal motor application speed does all of this. Furthermore, as the VFD offers better control over the voltage and frequency, it will offer protection from issues like phrase protection, electro thermal overloads, over and under-voltage. And at times, it is also an excellent way to decrease or eliminate the water hammer since it offers smooth acceleration and deceleration cycles.

Control over starting current

Generally, when an AC motor starts, it takes up to seven to eight times of motor current to start. This starting current flexes the motor windings, generating heat. Over time this heat reduces the longevity of the motor. But a VFD drive helps the motor to start with zero frequency and voltage. As the voltage and frequency are built, it magnetizes the motor windings that typically take about 50 to 70% of the full-load current. Additional current above this level depends on the connected load and the acceleration speed. In simple words, the entire phenomenon helps in a balanced flow of current hence lesser harm and extended motor life.